DIY Maintenance in Industry

Introduction

    In the modern industrial environment, efficiency and cost-effectiveness play a crucial role in corporate operations. One of the key tools for achieving these goals is DIY (Do It Yourself) maintenance, where minor maintenance tasks are performed not by dedicated maintenance personnel but by operators and machine handlers. In Hungary, this practice is often referred to as autonomous maintenance. This approach not only reduces costs but also contributes to increased production efficiency and minimizes downtime.

What is DIY Maintenance in Industry?

DIY maintenance refers to basic, simple maintenance activities that do not necessarily require skilled maintenance personnel. These tasks typically include:

·       Daily inspections: Cleaning machines, visual inspections, lubrication.

·       Simple repairs: Tightening loose screws, replacing clogged filters.

·       Preventive maintenance: Periodic inspections, replacing wear parts at predetermined intervals.

·       Cleaning and inspecting sensors and measuring instruments.

These types of tasks can be safely carried out by machine operators with proper training and protocols. The biggest challenge in this system is defining the boundary: how far does the responsibility of operators extend, and where do maintenance tasks begin that should be performed exclusively by qualified maintenance technicians or engineers?

Implementing DIY Maintenance in Industry

A successful implementation requires a well-structured strategy consisting of the following steps:

1.     Identifying tasks – Determining which maintenance tasks can be assigned to operators.

2.     Training and education – Operators must receive appropriate theoretical and practical training to ensure safe and effective execution.

3.     Documentation and guidelines – Detailed work instructions and visual aids should be created for maintenance steps.

4.     Providing tools and materials – Operators must have access to the necessary tools and materials.

5.     Defining responsibilities – It must be clearly stated which tasks operators can perform and which require a specialist.

6.     Monitoring system – Continuous monitoring and feedback should be implemented to improve efficiency.

The Role of Machine Setters and TPM Coordinators

    For more complex production lines and automated cells, it may be advisable to introduce a machine setter role. Some companies have successfully implemented this model, where selected operators receive specialized training and acquire deeper technical knowledge, allowing them to perform more complex adjustments and fine-tuning without the need for maintenance personnel.

Additionally, some companies have TPM (Total Productive Maintenance) coordinator roles, assigned to selected operators to support and enhance autonomous maintenance processes. TPM coordinators:

·       Are responsible for daily maintenance and inspection processes.

·       Focus on maintaining optimal machine conditions.

·       Act as a bridge between operators and maintenance teams.

·       Regularly report identified issues and suggest improvements.

These roles help ensure that operators perform assigned maintenance tasks more professionally and prevent errors or accidents caused by untrained interventions.

Defining Boundaries: What Can Operators Do and What Can They Not?

    In industrial applications of DIY maintenance, it is essential to define which types of tasks non-skilled operators can perform and which must be reserved for maintenance technicians or engineers. Some maintenance tasks, such as electrical system repairs, are strictly regulated and can only be performed by professionals with the appropriate qualifications.

Tasks That Operators Can Perform:

·       Lubrication and cleaning.

·       Checking mechanical fasteners, tightening loose screws.

·       Cleaning sensors and optical detectors.

·       Basic inspection of pneumatic and hydraulic systems (checking for leaks).

Tasks That Must Be Performed by Maintenance Technicians or Engineers:

·       Inspecting and repairing electrical systems.

·       More complex hydraulic and pneumatic system repairs.

·       Mechanical repairs on critical machinery.

·       Operations involving hazardous or high-energy interventions.

To properly define these boundaries, clear internal regulations must be established, specifying which tasks are allowed for operators and which require maintenance personnel intervention.

Preventing Accidents: Protecting Safety Systems

    In industrial settings, enthusiastic operators have attempted to fix machine downtimes themselves, sometimes unintentionally interfering with safety systems, leading to serious accidents. To prevent such incidents, the following measures should be implemented:

·       Strict enforcement of LOTO (Lockout-Tagout) procedures – Operators must not open machines for interventions without proper lockout procedures, ensuring full de-energization before any maintenance.

·       Clearly marked and color-coded restricted areas – It must be explicitly defined which areas operators can access and which are exclusive to maintenance personnel.

·       Regular safety training sessions – Operators must be continuously educated on the importance of safety systems and restricted interventions.

·   Automated warning and shutdown systems – Machines should have immediate alerts or shutdown mechanisms triggered when safety systems are breached.

·  Defining a responsibility matrix – Clear rules should be established regarding which interventions are permitted and the consequences of rule violations.

Conclusion

    DIY maintenance is an effective method for industrial companies to reduce maintenance costs and increase operational efficiency. However, it cannot be implemented without proper training, safety regulations, and monitoring mechanisms. In more advanced industrial environments, introducing machine setter and TPM coordinator roles can help make maintenance more efficient and safer, while minimizing unexpected downtimes and increasing operator accountability. This system can contribute to making manufacturing processes smoother and more reliable.

 

Best regards: LBMM Team


Location: Miskolc, Magyarország

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