Operator Rounds vs. Maintenance Rounds: Understanding the Key Differences

What Are Operator Rounds?

Operator rounds are routine inspections carried out by machine operators or production personnel. Their primary goal is to ensure the safe and stable operation of equipment and to identify potential issues before they escalate.

By adding an extra pair of eyes on the equipment, operator rounds help distribute ownership of reliability across all teams, fostering a culture where everyone plays a role in asset health.

Key Characteristics:

• Performed by machine operators or production personnel.
• Focus on routine checks for operational stability.
• Typical tasks include monitoring pressure, temperature, fluid levels, and performing visual inspections for leaks, unusual noises, or vibrations.
• Immediate corrective actions can sometimes be taken (e.g., adding lubrication, tightening a loose bolt, adjusting process parameters).

What Are Maintenance Rounds?

Maintenance rounds, on the other hand, are conducted by maintenance personnel or reliability technicians. They focus on detecting early signs of equipment failure and planning proactive interventions to prevent breakdowns.

Unlike operator rounds, maintenance rounds are more technical and require specialized knowledge and tools.

Key Characteristics:

• Conducted by maintenance personnel or reliability technicians.
• Designed to detect early signs of failure and deterioration, these techniques are often not always data oriented. While many rely on data (e.g., vibration monitoring or oil analysis), some involve visual inspections or lubrication rounds, though data-driven methods are more common.
• Typical tasks include vibration analysis, thermography, lubrication checks, wear assessments, and oil analysis.
• Often uses predictive maintenance tools such as infrared cameras, ultrasound detectors, and data analytics platforms.
• Findings from maintenance rounds may lead to create work orders, part replacements, or further in-depth inspections.

Key Differences Between Operator Rounds and Maintenance Rounds

While both types of rounds aim to improve asset reliability, they differ in execution, objectives, and impact on maintenance strategy. 

How Operator and Maintenance Rounds Complement Each Other

Rather than being separate processes, operator rounds, and maintenance rounds should work in synergy to enhance maintenance operations.

• Early Detection: Operators act as the first line of defense by identifying abnormalities such as leaks, overheating, or unusual noises. These early warnings allow maintenance teams to conduct deeper investigations and prevent costly failures.
• Data Sharing: Operator logs provide valuable historical data that maintenance teams and reliability team can analyze to identify trends, recurring issues, and potential failure patterns.
• Fostering a Culture of Reliability: Optimized workflows, driven by proper coordination between operators and maintenance teams, help cultivate a culture of reliability within the plant. This approach ensures that minor issues are addressed promptly, preventing them from escalating into catastrophic failures.
• Improved Asset Performance: By leveraging both operator and maintenance rounds, organizations can extend asset life, improve efficiency, and ensure compliance with safety regulations.

Best Practices for Implementing Effective Rounds

To maximize the benefits of both operator and maintenance rounds, organizations should adopt best practices that ensure consistency, efficiency, and actionable insights regarding all types of maintenance.

1. Standardized Procedures

• Implement structured procedure and digital tools to ensure inspections are thorough and consistent leaving no place to human error.
• Use mobile devices to track route completion, log findings, and automate data entry.
• Ensure that both operator and maintenance rounds align with asset criticality and operational priorities.

2. Clear Communication & Escalation Process

• Define clear protocols for operators to report abnormalities to maintenance teams.
• Establish an escalation process to ensure critical issues are prioritized and addressed in a timely manner.
• Encourage cross-departmental collaboration between operations and maintenance teams to improve overall efficiency.

3. Training & Collaboration

• Train operators to recognize early warning signs of equipment failure.
• Educate maintenance personnel on how to interpret operator logs for trend analysis.
• Encourage a culture where reliability is a shared responsibility among all employees.

4. Technology Integration

• Leverage CMMS, APM (Asset Performance Management), and sensors/analyzers to collect, analyze, and act on asset health data.
• Automate alerts and reporting to ensure that critical findings are addressed before they escalate.

5. Ownership of Reliability

• Reliability should not be solely the responsibility of maintenance teams; it must be embraced by operators, production staff, and leadership.
• Establish KPIs (Key Performance Indicators) to measure the effectiveness of both operator and maintenance rounds.
• Recognize and reward proactive behavior in identifying and resolving potential equipment issues.

Conclusion

Operator rounds and maintenance rounds are both essential to an effective asset management strategy. While operator rounds focus on daily operational stability and immediate issue detection, maintenance rounds take a deeper dive into asset health to prevent long-term failures.

Frequently Asked Questions (FAQ)

Why are operator rounds important if we already have maintenance rounds?

Operator rounds provide daily monitoring and allow for early detection of minor issues before they escalate into major failures. They complement maintenance rounds.

Can operator rounds replace maintenance rounds?

No, operator rounds focus on basic inspections and operational stability, while maintenance rounds involve in-depth technical assessments. Both are essential for a comprehensive asset management strategy.

How can we ensure effective collaboration between operators and maintenance teams?

Establish clear reporting procedures, use centralized data-sharing platforms, provide cross-training, and foster a reliability-centered maintenance culture where both teams understand the importance of their roles in asset health.

Raphael Tremblay,
Spartakus Technologies
[email protected]