Operator Autonomous Maintenance Checklist

Purpose

This checklist helps operators perform short, repeatable care tasks that prevent small failures, improve condition visibility, and make problems visible early. Use it every shift (daily) and complete the weekly items as scheduled. Record results and escalate when criteria indicate a developing fault.

How to use this checklist

1. Complete the header information at the start of each use.
2. Work through the Daily section each shift. Tidy up and note anything outside normal limits.
3. Complete the Weekly section on the assigned day (or as part of the weekly routine).
4. If any item returns an "Issue" or a measurement is outside its acceptance range, follow the Escalation Rules and log the defect in the defect section.
5. Sign and store the completed checklist where the team can review it during huddles and improvement meetings.

Checklist header (fill every time)

• Operator name: ______________________
• Machine / Line ID: ______________________
• Date: ____ / ____ / ______
• Shift: Morning / Afternoon / Night
• Frequency: Daily / Weekly (select)

Daily Tasks (fast routine — aim for 5–15 minutes)

For each task below mark: OK (no action needed), Issue (requires logging/escalation), N/A (not applicable).

• Clean checkpoints

  What to do: Remove debris, wipe sensors & switches, clean vents and cooling paths. Acceptance: Visual cleanliness; no buildup blocking sensors or guards.

  Record: OK / Issue / N/A — Notes: ________________________

• Basic lubrication (task list defined by machine)

  What to do: Apply correct lubricant at labeled points. Use standard lubrication code and amount. Acceptance: Lubricant present, no leaks, moving parts move freely. Record: Performed (Yes/No) — Lubricant code: ______ — Amount/interval: ______ — Notes: ______

• Visual inspection of guards, belts, hoses, fasteners

  Acceptance: No loose guards, no frayed belts, no visible leaks, fasteners secure. Record: OK / Issue / N/A — Notes: ________________________

• Torque checks (critical fasteners identified on machine)

  Acceptance: Torque within documented range or marked as re‑tightened with date/initials. Record: OK / Issue / N/A — Torque value (if measured): ______ Nm — Notes: ______

• Simple measurements (example: temperature, vibration, pressure)

  Examples and acceptance ranges should be posted on the machine. If no range is posted, record the value and flag for review. Record: Measurement type: ______ — Value: ______ — Units: ______ — OK / Out of range

• Check sensors/alarms and indicator lights

  Acceptance: All required indicators return to normal after test; no persistent alarm. Record: OK / Issue / N/A — Notes: ______

• Defect logging

  If you observe any abnormal condition, log it immediately with these minimum data points: short description, severity, exact location, when observed, and a photo reference or folder name if available.

  Record: Defect logged? Yes / No — Defect ID (if available): ______ — Short description: ______________________

Weekly Tasks (slightly deeper — planned weekly work)

• Inspection of wear points and clearances

  Acceptance: Wear within acceptable limits; if approaching limit, enter a maintenance work request with suggested action.

• Functional test of safety devices and interlocks

  Acceptance: Safety devices function reliably; log the test and results.

• Clean or replace filters and strainers where applicable

  Acceptance: Filters clean and free-flow restored; replace if clogged.

• Update local machine log

  Include any recurring trends, near misses, or stabilization after repairs.

Escalation Rules — when to call maintenance now

Escalate immediately and create a maintenance request when any of the following are true:

• Safety hazard exists (exposed live parts, failing guard, unsafe motion).
• Measurement is outside posted safety or process limits (temperature, vibration, pressure).
• Repeated stop or repeated small fault within the same shift (more than 2 occurrences).
• Evidence of imminent part failure (metal flakes, heavy smoke/odor, severe leakage).
• Operator cannot safely complete the task or needs a special tool/skill to continue.

How to escalate: create a maintenance request in the CMMS (or the team’s agreed tool) using this template:

Machine ID: ______ — Symptom: ______ — Severity: Low/Medium/High — Time observed: ______ — Operator: ______ — Immediate action taken: ______

Defect log template (minimum fields)

1. Defect ID / Reference
2. Date / Time
3. Operator name
4. Machine / Location
5. Short description of fault
6. Observed severity (1–5)
7. Immediate workarounds (if any)
8. Photo reference (file name or folder) or sketch
9. Escalated to maintenance? Yes / No — Work order # (if created)

Acceptance criteria examples (post these at the machine)

• Bearing temperature: < 75°C — action if > 75°C.
• Vibration: < 4 mm/s (line amplitude) — action if > 4 mm/s.
• Torque: within ±10% of documented value — recheck if outside range.

Operator responsibilities & good practice

• Perform the checklist consistently and sign it. Consistent short checks prevent accumulated small faults.
• Only perform tasks you are trained and authorized to do. If a task requires lockout or specialized tools, escalate to maintenance.
• Use the defect log to capture context — a short clear description helps maintenance diagnose faster.
• Bring recurring issues to the team huddle so they can be analyzed and solved at the root cause level.

Where to store completed checklists

Place physical checklists in the machine’s log binder or upload the completed form to the team folder/CMMS so maintenance and supervisors can review trends.

Examples (quick reference)

Example entry — Daily: Machine A7 belt tension loose; re-tensioned and marked; torque check rechecked OK; logged as Defect #A7-2026-09-14 and flagged for scheduled replacement next week.

Notes for implementers

Customize the acceptance ranges, lubrication codes, and torque values for each machine. Train operators on the checklist, show examples during shadowing, and review completed checklists weekly during the team huddle to spot trends.