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

Maintenance Miracle - An Autonomous Maintenance Kaizen Event - Fall 2019 - Longview TX

2019 Fall Session – October 29 - November 1 – Longview, TX – a 3 ½ day certificate program

This certificate program 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

TPM/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


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: Komatsu – Longview, TX


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



The Komatsu Mining Corporation is part of the global Komatsu family of companies; indispensable partners to the mining, forestry, industrial and construction industries. Komatsu Mining provides essential equipment, systems and solutions used by companies worldwide to extract fundamental minerals for developing modern infrastructure, technology and consumer products. They help customers safely and sustainably optimize their operations across the globe. They have a long and illustrious history in the mining industry. With service centers and manufacturing facilities across the globe, they aim to be near areas of major mining activity to support our customers directly and collaborate regularly.

Komatsu’s products and related services are used extensively for the mining of coal, copper, iron ore, oil sands, gold and other mineral resources. They pride themselves on providing a full range of value-added aftermarket services and are committed to assisting their customer’s mine ores and minerals at the lowest possible cost. They continually implement programs and initiatives that will make them a more efficient and effective business. These are not just programs but are part of their core values and therefore represent their focus on things that matter.

Komatsu’s Longview Operations began their lean journey in 2010 with the implementation of a mixed-model assembly line for their Wheel Loader products. The mixed-model assembly line consists of cellular designed sub-assembly cells feeding a main line through systematic pull signals. Since the completion of the assembly line a value stream approach has been taken to improve all feeding work centers. As a result of all these plant-wide continuous improvement efforts, they have seen a 40% reduction in total lead time for Wheel Loader products. The core competencies of the Longview facility consist of Heavy Fabrication, Machining, and Assembly. Komatsu Mining Longview Operations has previously hosted the Maintenance Miracle in 2014, 2015, and 2016

For more information on Komatsu Mining Corporation, visit their website at

Consultants and competitors of Komatsu 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 & Suites Longview

North 3044 Eastman Road, Longview, TX 75605 Phone: (903) 663-8670

A block of sleeping rooms has been held at the Hampton Inn & Suites in Longview. Make your hotel room reservations under the Productivity Inc. / Maintenance Miracle room block. The discounted rate is $99 per night plus tax. This rate is available until October 14, 2019. Please make your reservations before this date to ensure availability. After this date, it cannot be guaranteed. The Hampton Inn & Suites Longview North is located near I-20 in the northern area of town, less than three miles from the Gregg County Airport and within walking distance of restaurants in the area.

Hampton Inn & Suites Longview


Event brochure

Maintenance Miracle – An Autonomous Maintenance Kaizen Event – Salem, Ohio

2019 Fall Session – October 29 – November 1 – a 3 ½ day certificate program

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. By registering for this meeting, the registrant hereby acknowledges and agrees that any photographs or videos taken during the event may be used for our purposes, including but not limited to news and promotion without compensation to me.

Consultants and competitors of Komatsu are not eligible to attend.