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    Maintenance Miracle an Autonomous Maintenance Kaizen Event
    Autonomous Maintenance
    Manufacturing industry Public Educational Events

    Maintenance Miracle - An Autonomous Maintenance Kaizen Event - Fall 2021 - Archbold, Ohio

    October 5-8 - a 3 ½ day hands on learning event

    This event teaches the 7-steps of Autonomous Maintenance and demonstrates the process for conducting AM steps 1-3 in your facility. Designed for production, maintenance and engineering managers, supervisors, team leaders and process owners interested in improving equipment and process reliability and safety.

    Register Now Brochure Faxable registration

    Why do you need TPM?

    TPM is the foundation of equipment/process reliability and reliability is the enabler to Lean.
    TPM/AM Goals

    • Zero accidents
    • Zero unplanned downtime
    • Zero speed losses
    • Zero defects
    • Minimum life cycle costs

    PM/AM raises APQ (availability, performance, quality).

    • 67% reduction in unplanned downtime
    • 67% increase in equipment/process performance efficiency (that’s free capacity!)
    • 70% reduction in maintenance (fix/repair) costs

    Your safety is our priority! We are following evolving best practices and CDC guidelines for physical gatherings including: meeting in larger rooms, limiting attendance to each event, setting physical distance in all meeting rooms, providing contactless food service, cleaning meeting facilities throughout the day, and following all facility protocols. We will update as necessary to ensure the safety of all. These will be outlined in your registration confirmation packet.


    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.


    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.


    Created to teach the 7-steps of Autonomous Maintenance and demonstrate a process for conducting AM Steps 1-3 in your facility.


    Host Plant: Sauder Woodworking – Archbold, Ohio


    Day 1 activities include:

    Classroom Instruction

    • 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
    • Equipment Team assignments.

    Hands on Activity

    • Shop-Floor Implementation of Autonomous Maintenance Step 1

    Day 2 activities include:

    Classroom Instruction

    • Team progress reports
    • Five why analysis
    • One point lessons
    • Autonomous Maintenance Step 2: Eliminating Contamination and Inaccessible Areas
    • Autonomous Maintenance Step 3: Establishing Provisional Standards

    Hands on Activity

    • Shop-Floor Implementation – continue Step 1, apply Steps 2 and 3

    Day 3 activities include:

    Classroom Instruction

    • Team progress reports
    • Autonomous Maintenance Step 4: General Inspection Development and Training, Step 5: Conducting General Inspections, and Step 6: Workplace Management and Control
    • Discussion of Step 7: Advanced Improvement Activities

    Hands on Activity

    • Shop-Floor Implementation – continue Steps 1-3

    Dinner and Team Presentation Preparation
    Team Presentations
    12:00pm Workshop adjourns

    Full curriculum is available in the event brochure.*


    Walt Miller, former 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.”


    “Very instructive and well-run event. Having the ability to implement the tools we were
    learning created an ideal platform to learn the principle to applying TPM in our own facility.”
    Monte Goins – TPM Coordinator – Crown Equipment

    “I’ve learned it is way cheaper to be proactive.”
    Jeff Pleinis – Turning Center Lead – Goodrich

    “In the 40 years of maintenance this was the one to attend. Excellent job by the instructor.
    The host plant was great.”
    John Akins – Maintenance Team Manager – Sun Products Corp.

    “Very good in applying principles of TPM and emulating the process in a manufacturing environment—hands on.  Re-emphasizes the importance of the “human factor” in attaining reliability.”
    Tim Davis – Engineering Manager—Continuous Improvement – Ventura Foods


    Sauder Woodworking Co.

    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 U.S. An authentic American original, 90% of Sauder® furniture is manufactured in Archbold, Ohio — right where they were founded in 1934. 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 is a privately held, third-generation, family run business with several subsidiaries. With its three-shift operation, 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 87 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 their lean journey.

    To learn more about Sauder Woodworking Company, visit

    Consultants and competitors of Sauder Woodworking are not eligible to attend.



    Productivity Inc. is a leading consulting and training firm that helps organizations build new capabilities, save money, and grow. We focus on three progressive strategies: Operational Excellence, Innovation Systems and Leadership Development.

    Working together, these strategies provide the means to continually refresh a company’s value proposition while making the organizational changes needed for daily improvement and sustainable growth.

    We pioneered the implementation of Lean and TPM methodologies in manufacturing in the late 1970s. Since then, we have extended these methodologies across a wide range of industries, including healthcare, finance, and other service industries.

    Today, our time-tested management system, motion™ provides organizations with:

    • a uniquely comprehensive approach to implementing Lean across an entire enterprise, incorporating assessment, leadership, and business renewal.
    • a robust process for innovation to develop an organization-wide capability to create new forms of value – reliably, predictably, repeatedly.

    More than simply a Lean consulting firm, Productivity Inc. can provide you with a variety of methodologies to keep your enterprise in motion™.


    Hampton Inn by Hilton
    1037 Hotel Drive, Defiance, OH, 43512, (419) 784-1515

    A block of rooms is being held for Productivity Inc. Maintenance Miracle participants at the Hampton Inn in Defiance, Ohio. Maintenance Miracle attendees receive a reduced rate of $125 per night, single or double occupancy (The group code is PTB). Reservations must be made by September 20th to receive this special rate. When you call to make your reservation, tell them you are with the Productivity Inc., Maintenance Miracle group to receive this special rate. The Hampton Inn is a 50 minute drive from the Toledo, OH airport and one hour drive from the Ft. Wayne, IN airport. Productivity Inc. will provide daily transportation between the Hampton Inn and Sauder Woodworking site.

    Book your room.


    Event brochure

    Maintenance Miracle – Archbold, Ohio
    2021 Fall Session – Oct 5-8 – a 3 ½ day hands on learning event

    Download brochure

    Faxable registration

    Printed Registration form
    Fax: 1-203-225-0771
    Call us: 1-800-966-5423 or 203-225-0451

    Download registration

    Cancellation Policy

    Prior to the start of the program, registrations may be transferred to another colleague without charge. To be considered for a refund, we must receive notification of cancellation in writing no later than 30 days prior to the event. Cancellations received within 30 days of the start of the program are subject to the full registration fee and this money will be held on account for up to one year for use at a future workshop or conference. Cancellations received within 10 business days of the start of a program will be assessed a fee equal to 20% of the registration fee; the remainder of the fee 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 $200.00 processing fee for all cancellations. No refunds or credits will be issued once a program is underway.

    On rare occasions circumstances may make it necessary to cancel or postpone an event. We encourage attendees too book refundable/reusable airline tickets. We are not responsible for incidental costs incurred by registrants. Any individual attending this program hereby acknowledges and agrees that any photographs or videos taken during the event may be used in marketing efforts (web/print) including, but not limited to news and promotion without compensation to the participant.

    Consultants and competitors of Sauder Woodworking Company are not eligible to attend.