Maintenance Miracle - An Autonomous Maintenance Kaizen Event

 

Autonomous maintenance is a team-based approach to maintenance activities and part of a total productive maintenance (TPM) process.

 

Course Description

Why do you need TPM? Because...

TPM is the foundation of equipment/process reliability and
Reliability is the enabler to lean

Autonomous Maintenance (AM) is the foundation of TPM and the focus of the Maintenance Miracle event. AM is not really a miracle, but a proven process that partners operators, maintenance technicians, engineers, and leaders in the operation and maintenance of equipment.

In this 3½ day event, participants will gain an understanding of the seven steps of Autonomous Maintenance and the fundamental techniques of 5S and Visual Controls and develop the skills to stabilize equipment performance and stop deterioration by learning to:

  • Construct, Perform, and Adhere to cleaning, inspection and lubrication (CIL) standards
  • Create one-point lessons (OPL)
    • Basic information OPL which ensures adherence to standard work
    • Improvement Bulletin OPL which documents and allows horizontal expansion of new best practices as they are discovered
  • Identify equipment abnormalities
  • Identify and create equipment improvements/contamination Controls

Working in teams alongside associates from the host facility, participants will apply the methods learned to equipment in the workplace which reinforces the learning that has taken place during the classroom sessions through actual application.

At the conclusion of the event, you will understand the techniques and have the skills to begin an autonomous maintenance effort in your facility.

 

Customer Testimonial…

…Walt Miller, Operations Excellence Coach with Cummins Inc. has been a long-time supporter of this program. Here’s how he describes the benefits he and his teams have derived from attending...

"As we continue to struggle in manufacturing to be competitive against challengers from all over the globe it is critical for us as leaders to get every bit of value out of our equipment, our process, and our people.

I have been to six Maintenance Miracles. We have brought with us members of our team that we have identified as key to our implementation of our TPM program. This group of folks range from operators, maintenance support members, senior and mid-level managers, and engineers. With this kind of diversity of people it is critical that the program address each and every one of their needs in supporting and understanding TPM.

I believe your program does this. The combination of half the time in the classroom and half in actual hands-on exercise is key. My team comes away from the event inspired and knowledgeable on how to implement TPM back in the plant." 

To learn more about the benefits of the event, read about one of our previous Maintenance Miracle events here...


 

Learning Ojectives

In this session, participants will learn

    • the role of autonomous maintenance in a total productive maintenance program
    • the value of team-based equipment care
    • the seven steps of Autonomous Maintenance and how to apply them to improve equipment and process reliability
    • to create Provisional Standards – the new equipment care standards
    • how to create One Point Lessons
    • how to make minor improvements to equipment design to make it easier to maintain
    • how identifying and correcting equipment abnormalities will make equipment safer
    • the yellow and blue tag system that perpetuates the process of abnormality identification, correction and low-cost equipment enhancement
    • to successfully transfer the “ownership” of the equipment to the production staff
    • how to build diagnostic and problem-solving skills

 


 

Who Should Attend

Maintenance Managers, Maintenance Technicians, Process Engineers, Supervisors, Team Leaders, Continuous Improvement Managers, Production Managers

 

 


 

Agenda

Tuesday

7:00am

Sign-in at the hotel.

7:15am

Depart for Sauder

8:00am -
12:00pm

Classroom Instruction:
Day one activities include an overview of the TPM strategy and competitive advantage, TPM exercise and discussion on vision and "zero" goals, Autonomous Maintenance Step 1 – Conducting the Initial Cleaning and Inspection, and equipment team assignments.

12:00pm

Luncheon

1:00pm –
4:45pm

On-Site Implementation – Teams monitored by consultant

5:00pm

 

Return to hotel

 

Wednesday

7:30am

Depart for Sauder

8:00am -
12:00pm

Classroom Instruction:
Day two activities include team progress reports, five why analysis, one-point lessons, Autonomous Maintenance Step 2 – Eliminating contamination and inaccessible areas, and Autonomous Maintenance Step 3 – Establishing provisional standards.

12:00pm

Luncheon

1:00pm –
4:45pm

On-Site Implementation – Teams monitored by consultant

5:00pm

 

Return to hotel

 

Thursday

7:30am

Depart for Sauder

8:00am -
12:00pm

Classroom Instruction:
Day three activities include team progress reports, Autonomous Maintenance Step 4 – General Inspection Development and Training, Autonomous Maintenance Step 5 – Conducting General Inspections, and Autonomous Maintenance Step 6 – Workplace Management and Control

12:00pm

Luncheon

1:00pm –
5:00pm

On-Site Implementation – Teams monitored by consultant

5:30pm –
8:00pm

 

Dinner and Team Presentation Preparation

 

Friday

8:00am -
11:30am

Team Presentations, wrap-up

12:00pm

 

Adjourn - Depart for hotel

 

*Transportation to and from host plant provided by Productivity Inc.

 

 


 

About the host

Sauder Logo

Sauder Woodworking Co. is North America’s leading producer of ready-to-assemble (RTA) furniture and one of the top five residential furniture manufacturers in the United States. An authentic American original, 90 percent of Sauder® furniture is manufactured in Archbold, Ohio — right where they were founded in 1934. Although the town is small (pop. 4,300), their facility is expansive. With some of the most technologically advanced equipment in the world, the facility features nearly 4 million square feet of space, employs about 2,000 workers and houses a wide variety of local and imported materials. Sauder also sources furniture from a network of quality global partners, including a line of office chairs that complement its residential and light commercial office furniture. Sauder is a privately held, third-generation, family run business with several subsidiaries. With its 2,400 employees, the Sauder family of companies generates sales of over $500 million annually.

Sauder started their lean journey in the early 2000’s. Initially 5S and Kaizen improvement systems were developed and deployed. Value stream mapping and kaizen were used to establish focused factories and product flow (based on product features) and ultimately a manufacturing performance system evolved. TPM emerged from the performance system in the spring of 2013 and to-date Sauder has implemented TPM on 21 unique work centers. As a result, they have seen an increase in their Mean Time Between Failure metric that is used to measure equipment reliability. They have also seen improved quality, safer operations, a decrease in emergency breakdowns and a decrease in overall downtime minutes. A stronger relationship between operations and maintenance continues to be forged as they continue on their lean journey.

 


 

What past attendees are saying...

 

 


 

ONLINE REGISTRATION

Price: $2,150.00

Scroll down for online registration form.

EVENT BROCHURE

FAXABLE REGISTRATION

 

Sauder Heritage Inn

Accommodations:

Sauder Heritage Inn
22611 State Rt. 2
Archbold, OH 43502
(419) 445-6408

A block of rooms is being held for Productivity Inc. Maintenance Miracle participants at the Sauder Heritage Inn.

Productivity Inc. attendees receive a reduced rate of $80.00 per night, single or double occupancy. Please call (419) 445-6408 to make your reservations. Tell them you are with the Productivity Inc. “A Maintenance Miracle” group or give them the booking ID # 7278 to receive this special rate.

For more information on the Sauder Heritage Inn, please visit: http://www.saudervillage.org/banquets-meetings/heritage-inn

The hotel is just a few minutes from the Sauder Woodworking facility. Productivity Inc. will provide transportation between Sauder and the hotel.

 



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Registrant Information




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Cancellation policy: Prior to the start of the session, registrations may be transferred to a colleague without charge. To be considered for a refund, we must receive notification of cancellation in writing no later than 21 business days prior to the event. Cancellations received within 21 business days are subject to the full registration fee; money will be held on account for up to one year for use at a future workshop or conference. If no notification of cancellation is provided, registration fees will be forfeited. There is a $200 processing fee for all cancellations. No refunds or credits will be issued once a session is underway. On rare occasions, circumstances may make it necessary to cancel or postpone an event. We encourage attendees to book refundable/reusable airline tickets. We will not be responsible for incidental costs incurred by registrants.

By registering for this event, the registrant hereby acknowledges and agrees that any photographs or videos taken during the event may be used in marketing efforts, including but not limited to news and promotions (web/print) without compensation to the registrant.

Note: All registrant applications will be evaluated for acceptance into the program. Consultants and university faculty may not be permitted to attend this event.

Contact Productivity

Maintenance Miracle

Instructors and attendees comment on the Maintenance Miracle Program.

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