AME Milwaukee 2026 International Conference
Tours
Tour
.png)
Johnsonville – Driving equipment reliability through member ownership
OVERVIEW
Welcome to the Reliability Excellence tour, an organizational capability-building journey designed to demonstrate how this approach improves equipment reliability.
The first stop is operator-driven reliability (ODR), where team members transition from operators to equipment owners. Participants will observe how members develop mastery of their machinery through clean, inspect and lubricate (CIL) practices and defect identification to achieve base equipment conditions. ODR guides teams through defined phases, building from foundational behaviors to advanced technical capability and effectiveness.
Next is the planned maintenance (PM) pillar, the backbone of technical capability. This area focuses on developing expertise in precision maintenance, troubleshooting and mechanical adjustments. By leveraging predictive data and technical skills, the PM pillar enables a shift from reactive work to predictable performance, supporting sustained results.The final stop is the focused improvement (FI) pillar, a center of excellence for eliminating losses. This program uses real-time data from tools such as Redzone and Power BI to identify root causes of downtime. FI equips team members with advanced problem-solving skills to address inefficiencies and improve performance.
Together, these three programs support autonomous work groups in achieving a zero-loss mindset and progressing toward 85 percent OEE.
The first stop is operator-driven reliability (ODR), where team members transition from operators to equipment owners. Participants will observe how members develop mastery of their machinery through clean, inspect and lubricate (CIL) practices and defect identification to achieve base equipment conditions. ODR guides teams through defined phases, building from foundational behaviors to advanced technical capability and effectiveness.
Next is the planned maintenance (PM) pillar, the backbone of technical capability. This area focuses on developing expertise in precision maintenance, troubleshooting and mechanical adjustments. By leveraging predictive data and technical skills, the PM pillar enables a shift from reactive work to predictable performance, supporting sustained results.The final stop is the focused improvement (FI) pillar, a center of excellence for eliminating losses. This program uses real-time data from tools such as Redzone and Power BI to identify root causes of downtime. FI equips team members with advanced problem-solving skills to address inefficiencies and improve performance.
Together, these three programs support autonomous work groups in achieving a zero-loss mindset and progressing toward 85 percent OEE.
ABOUT THE COMPANY
In 1945, Ralph F. and Alice Stayer opened a butcher shop, naming the business after their hometown of Johnsonville, Wisconsin. The sausages crafted in the shop were made using a treasured family recipe originating from 19th-century Austria and passed down through generations. Over time, Johnsonville has grown into a global leader in the sausage industry, becoming the No. 1 national sausage brand.
Ralph C. Stayer, the son of Ralph F. and Alice Stayer, has guided the company’s growth since its incorporation in 1968. After decades of leadership as CEO, he transitioned to chairman of the board in 2015. Stayer’s “people-first” approach to business operations has earned widespread recognition, blending teamwork with individual accountability to develop talent across the organization.
Dave Fessenbecker and the reliability team at Johnsonville will share their journey over the past four years as part of the company’s total productive maintenance (TPM) initiative. The team will also highlight progress in planned maintenance and equipment ownership and present its loss analysis process.
https://johnsonville.com
Ralph C. Stayer, the son of Ralph F. and Alice Stayer, has guided the company’s growth since its incorporation in 1968. After decades of leadership as CEO, he transitioned to chairman of the board in 2015. Stayer’s “people-first” approach to business operations has earned widespread recognition, blending teamwork with individual accountability to develop talent across the organization.
Dave Fessenbecker and the reliability team at Johnsonville will share their journey over the past four years as part of the company’s total productive maintenance (TPM) initiative. The team will also highlight progress in planned maintenance and equipment ownership and present its loss analysis process.
https://johnsonville.com
Requirements & Restrictions
Requirements:
Safety glasses (tour site to provide)
Hearing protection (tour site to provide)
Signed non-disclosure agreement (NDA)
Restrictions:
U.S. citizen only
No recording devices
No mobile phones
No competitors
Safety glasses (tour site to provide)
Hearing protection (tour site to provide)
Signed non-disclosure agreement (NDA)
Restrictions:
U.S. citizen only
No recording devices
No mobile phones
No competitors
TAGS
Click on a tag to discover more sessions with that theme, topic or level.
Click on a tag to discover more sessions with that theme, topic or level.
Culture of respect and collaboration
Operations improvement
Level: Intermediate
