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Recent episodes
Reliability | Jim Wilson's Guide to Effective Troubleshooting and PM Discipline
Apr 30, 2026
Unknown duration
Loïc Estier - Factories Don’t Have a Data Problem. They Have a Memory Problem.
Apr 14, 2026
Unknown duration
Reliability | Shane Scriven on AI in Manufacturing: What Actually Works
Apr 1, 2026
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Site Leadership | Marcelo Fariello on From Tools to Behaviour: The Real Driver of Reliability
Mar 20, 2026
Unknown duration
PdM Series #2 | Start With the Problem, Not the Sensors
Mar 11, 2026
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| Date | Episode | Description | Length | ||||||
|---|---|---|---|---|---|---|---|---|---|
| 4/30/26 | Reliability | Jim Wilson's Guide to Effective Troubleshooting and PM Discipline | SummaryIn this episode, I sat down with Jim Wilson, Maintenance Manager at Hiland Dairy Foods, Lean Six Sigma Black Belt, and Industrial Electrical Instructor, to talk about what reliability really means inside a modern manufacturing site.We started by reframing reliability as a risk reduction function, not just maintenance. Jim shared why unplanned downtime isn’t just about repair costs, but about product safety, audit exposure, lost production, and even brand damage. We also got into the connection between PM discipline, documentation, and how sites perform under regulatory pressure.From there, we dug into why so many reliability programs fail. We talked about the gap between having a CMMS and actually using it properly, the hidden cost of poor troubleshooting, and what it takes to build real accountability and follow-through inside a maintenance team.We wrapped up with a really practical discussion on developing skilled technicians. Jim explained why troubleshooting is about following a diagnostic sequence rather than memorising fixes, and how training, mentorship, and structured systems can lift both performance and retention.This one is a grounded, practical conversation for anyone leading maintenance or reliability and trying to move from reactive firefighting to a more structured, high-performing operation.Chapters00:00 Introduction to Jim Wilson's Journey07:01 Understanding Reliability as Risk Management11:25 Shifting from Reactive to Structured Reliability Culture17:24 The Importance of PM Discipline and Audit Outcomes21:43 Why Reliability Programs Fail and CMMS Utilization25:02 Effective Parts Control and Inventory Management26:42 Building Relationships in Maintenance Management27:17 Common CMMS Mistakes and Best Practices29:48 The Hidden Costs of Poor Troubleshooting32:48 Understanding the Cost of Downtime34:05 Effective Troubleshooting Techniques37:43 Developing Skilled Technicians44:26 The Importance of Mentorship and CertificationKey TopicsReliability as risk management, not just maintenanceWhy reliability programs fail and how to succeedThe importance of PM discipline and documentationThe role of culture in reliability and safetyTroubleshooting skills and knowledge transferThe impact of unplanned downtime on brand and safetyUsing CMMS effectively for maintenance and auditsDeveloping skilled technicians through mentorship and trainingSound Bites"Unplanned downtime can damage brand reputation.""Know everything about your CMMS and use it fully.""Upskilling technicians creates lasting change."LinksLinkedin : https://www.linkedin.com/in/jimewilson/KeywordsReliability, Maintenance, CMMS, Troubleshooting, Continuous Improvement, Dairy Industry, Risk Management, PM Discipline, Culture Change | — | ||||||
| 4/14/26 | Loïc Estier - Factories Don’t Have a Data Problem. They Have a Memory Problem. | SummaryIn this episode, I sat down with Loïc Estier to talk about a problem almost every factory has, but rarely talks about properly.We explored how so much of the knowledge needed to run a plant at its best is locked in people’s heads, and what happens when that knowledge isn’t available at the moment you need it.Loïc shared some great stories that really bring this to life, and we dug into why traditional approaches like documentation and knowledge bases don’t work the way we think they should.We also talked about what’s changing now with AI, and how capturing real, day-to-day communication might be the key to finally solving this problem.It’s a practical, thought-provoking conversation that I think will make a lot of people reflect on how knowledge actually flows through their site.LinksLinkedin : https://www.linkedin.com/in/loic-e/Website : https://rossops.com/Chapters00:00 Introduction to Knowledge Capture in Manufacturing03:07 Loïc Estier's Journey and Insights05:46 The Human Element in Manufacturing08:39 The Challenge of Data Utilization11:10 The Importance of Experience-Based Knowledge14:04 Real-World Examples of Knowledge Gaps16:26 The Need for Effective Knowledge Management Solutions19:16 Traditional Knowledge Bases vs. Modern Solutions21:59 Leveraging AI for Knowledge Capture24:31 Conclusion and Future Directions24:46 Understanding Structured vs. Unstructured Data30:00 The Future of AI in Manufacturing35:19 Shift Communication and Knowledge Management39:34 Navigating AI's Role in Operational Efficiency42:34 Focusing on Improvement, Not FirefightingSound Bites"Data is just facts without context.""Most knowledge is in people's heads.""Ross is the expert in every factory."KeywordsManufacturing, Knowledge Management, AI, RossOps, Operational Data, Industry 4.0, Digital Transformation, Factory Efficiency, Shift Handover, Data Capture | — | ||||||
| 4/1/26 | Reliability | Shane Scriven on AI in Manufacturing: What Actually Works | Follow Shane:Linkedin : https://www.linkedin.com/in/shane-scriven/Website : https://www.sas-am.com/Summary: AI is everywhere right now, but what does it actually look like on the factory floor?In this episode, we unpack three practical areas shaping the next wave of AI in manufacturing. We explore how AI-powered benchmarking can help sites truly understand performance, where low-cost AI can deliver value without massive investment, and what sovereign and edge AI mean in simple terms for real operations.This is a grounded conversation focused on making AI more understandable, more accessible, and ultimately more useful for reliability, maintenance, and site leaders.Chapters00:00 Introduction to AI in Manufacturing06:47 The Second Wave of AI11:26 Understanding AI-Powered Benchmarking16:10 Identifying Gaps with AI20:42 Automating Maintenance Processes24:14 Implementing Low-Cost AI Solutions26:58 Common Pitfalls in AI Projects32:04 Defining Low-Cost AI35:39 Starting with AI as a Reliability Manager37:42 Rapid Fire Round: Insights and MythsSound Bites"AI is not self-aware or conscious""Avoid ignoring data insights""Autonomous assets will make decisions" | — | ||||||
| 3/20/26 | Site Leadership | Marcelo Fariello on From Tools to Behaviour: The Real Driver of Reliability | In this episode, JP sits down with Marcelo Fariello, Plant Manager at Mars, to explore a powerful idea: reliability isn’t just a maintenance function — it’s a leadership system.Marcelo shares lessons from his journey across digital transformation, operational excellence, and plant leadership, including his time at Danone and now leading a major Mars site in Australia.They unpack why many reliability programs stall when they sit solely within maintenance, and what changes when operators take true ownership of their equipment. Marcelo explains how shifting to site-wide accountability can unlock performance gains that tools alone never will.The conversation also dives into the reality of digital reliability tools — why so many initiatives fail, what actually works, and the cultural foundations required before technology can deliver value.Finally, Marcelo breaks down how high-performing sites treat reliability as a leadership discipline, focusing on behaviours, mindset, and breaking down silos between production and maintenance.If you’re a maintenance leader, reliability engineer, or site manager, this episode will challenge how you think about ownership, digital transformation, and what it really takes to build a reliable operation.Chapters00:00 Introduction to Marcelo's Journey02:51 Reframing Reliability and Maintenance03:33 The Importance of Ownership in Operations08:44 Strategies for Cultural Change11:11 Defining Operator Ownership13:11 The Role of KPIs in High-Performance Teams15:26 Effective KPIs for Reliability18:21 The Power of Measurement26:03 Digital Transformation and Its Challenges32:04 Leadership as a System36:09 Hard Truths in Reliability ManagementSound Bites"Silos create a superhero mentality.""Ownership drives pride and performance.""KPIs should motivate, not just measure."Key TopicsHolistic leadership in reliability and operationsOperator ownership and cultural changeRole of KPIs and data in continuous improvement | — | ||||||
| 3/11/26 | PdM Series #2 | Start With the Problem, Not the Sensors | Episode SummaryIn this episode of our predictive maintenance series, we take a step back and tackle something many sites skip: defining the problem before jumping into PdM.Before selecting assets, installing sensors, or launching a pilot, maintenance and reliability teams need to be clear on what they’re actually trying to improve. Is the goal to reduce reactive work? Extend inspection intervals? Increase MTBF on key asset classes? Without alignment on the problem, PdM pilots often drift, expectations collide, and even good results can be misunderstood.We talk through what a strong PdM problem statement looks like, share examples with clear metrics, and discuss how teams can align around success before any technology is introduced. We also address a common concern many sites raise: “We don’t even have good data.” The reality is that every site has signals to start from, even if they’re messy.If you’re considering predictive maintenance or planning a pilot, this episode will help you start in the right place: clarity before technology.Chapters00:00 Introduction to Predictive Maintenance01:57 Defining the Right Problem08:19 Crafting a Clear Problem Statement28:51 Data Challenges in Predictive Maintenance34:09 Conclusion and Next StepsSound Bites"Start with a problem, not just more data.""Measure the impact over a realistic timeframe.""Align your team and get buy-in early."Keywordspredictive maintenance, problem statement, asset management, reliability, maintenance strategy, data quality, pilot projects, business outcomes | — | ||||||
| 3/5/26 | Reliability | Laith Alfaqih on The Organizational Readiness Blueprint for Asset Management | Laith's Linkedin : https://www.linkedin.com/in/laithalfaqih/Connect with Stantec : https://www.stantec.com/enSummaryMany organisations invest in asset management programs, new systems, and predictive tools, yet reliability performance often doesn’t improve as expected. Why? In this episode, JP sits down with Laith Alfaqih, Senior Principal and Asset Management Lead at Stantec, to explore organizational readiness. They discuss why asset management should be treated as a management system, not a toolkit, the most common readiness gaps across industries, and a practical framework leaders can use to assess whether their organisation is truly ready to make asset management stick.Chapters00:30 Introduction and Context Setting04:00 Understanding Organizational Readiness06:40 Defining Asset Management and Its Importance11:23 Challenges in Asset Management Initiatives17:12 Leadership's Role in Asset Management22:41 Reframing Asset Management as a Management System25:12 Holistic Asset Management Approach27:04 Challenges in Data Collection and Management33:25 Organizational Readiness Blueprint42:23 Assessing Organizational Readiness46:12 Leadership Actions for ImprovementSound Bites"Preventing issues starts with good data and standards""Trust your people, empower them, and provide resources""Think with the end in mind for success"Key TopicsOrganizational readiness definition and importanceCommon reasons for asset management project failuresLeadership's role in asset management successData quality and standards in asset managementCreating a culture of continuous improvement | — | ||||||
| 2/20/26 | Reliability | Simon Murray in 2026 ! The State of Maintenance: 5 Shifts Every Reliability Leader Must Understand | LinksSimon's Linkedin : https://www.linkedin.com/in/yourmaintenancecoach/Simon's Website : https://yourmaintenancecoach.com/Last Year's Episode:https://open.spotify.com/episode/1u6P5ulYwL5Si7VEdLggRj?si=OEk27vxMSaCWXAtwO882jASummaryIn this episode, Simon Murray revisits the evolving trends in maintenance and reliability for 2025, sharing insights from recent conferences, community building, and technological advancements like AI. Discover how organizations are shifting their focus towards system efficiency, store management, and the importance of community networking to stay ahead in maintenance practices.Chapters05:40 Reflections on 2025: Changes and Trends08:12 Community and Networking in Maintenance11:02 Economic Pressures and Budgeting in Maintenance13:44 The Importance of Maintenance Operations Partnership16:31 Justifying Maintenance Needs to Leadership28:05 Building Trust in Maintenance Operations29:21 The Importance of Systems Efficiency32:53 Workshops for Process Improvement35:24 Revamping Stores Management42:34 The Challenge of Preventive Maintenance Reviews46:07 The Impact of AI on Maintenance48:53 Setting Priorities for the Next 90 DaysKey TopicsCommunity and networking in maintenanceRecognition for reliability from leadershipSystems efficiency and digital transformationStores improvement and inventory managementPM review practices and challengesSound Bites"Most maintenance teams have had this awakening""We've almost reached the limit of what we trust Google""AI will have the biggest impact in the next three years"Keywordsmaintenance trends, reliability, AI in maintenance, community networking, asset management, system efficiency, stores improvement, PM review, industry 2025 | — | ||||||
| 1/26/26 | PdM Series #1 | Predictive Maintenance 101: From Data to Action | SummaryIn this first episode of the predictive maintenance series, JP and Tim break PdM down to what actually matters. No theory, no buzzwords, just a clear explanation of what predictive maintenance is, how it works on a real manufacturing site, and why so many people struggle to make sense of it.They start by looking at why predictive maintenance exists in the first place, and where traditional reactive and time-based maintenance start to fall short. The conversation then moves into how PdM really works, from data and baselines through to alerts and action, and why it’s not the same thing as traditional condition monitoring.This episode is all about building a simple mental model for predictive maintenance. If you’ve ever wondered whether PdM is worth exploring, or why it feels confusing or overhyped, this is the place to start.Chapters00:00 Introduction to Predictive Maintenance08:33 Understanding the Need for Predictive Maintenance12:44 Defining Predictive Maintenance and Its Distinctions19:21 What Predictive Maintenance Is Not21:52 Addressing Common Objections to Predictive Maintenance22:37 The Power of AI in Predictive Maintenance23:58 Overcoming Challenges in Predictive Maintenance26:21 Setting Goals for Predictive Maintenance27:13 Addressing Variability in Production Processes29:14 Understanding Predictive Maintenance: The Five Stages34:22 The Importance of Feedback in Predictive Maintenance40:28 What Predictive Maintenance Can and Can't DoTakeawaysPredictive maintenance aims to reduce unplanned downtime costs.It's essential to understand the difference between predictive maintenance and condition-based maintenance.Most failures are not age-related, which is why predictive maintenance is crucial.Data-driven insights can significantly improve maintenance strategies.Human judgment remains vital in interpreting predictive maintenance data. | — | ||||||
| 1/13/26 | Reliability | John Sewell on Fixing the Wrong Things & Making Better Reliability Decisions | Connect with John on Linkedin : https://www.linkedin.com/in/johnsewellreliability/Reach out to John's business : https://jsinsightconsulting.com/SummaryIn this episode, I sit down with John Sewell, maintenance strategy consultant and reliability thinker, to unpack why reliability decisions are often harder than they need to be.We talk about why teams so often work on the wrong problems, how symptoms get mistaken for root causes, and the classic traps maintenance organisations fall into. John shares practical advice on writing better problem statements, prioritising what actually matters, and turning reliability work into something the business truly cares about (hint: money helps).John also shares grounded advice for new reliability leaders. Slow down. Learn the site. Ask better questions. And don’t try to fix everything in your first week.It’s a thoughtful, occasionally surprising conversation about making reliability simpler, smarter, and far more effective.Chapters00:00 Introduction and Professional Journey06:20 The Importance of Decision-Making in Reliability08:16 Common Mistakes in Maintenance Organizations12:48 Understanding Problems vs. Symptoms15:45 Crafting Effective Problem Statements19:17 Prioritizing Problems and Solutions22:03 Common Reliability Issues and Solutions28:25 Developing a Reliability Strategy31:34 Building a Business Case for Reliability37:10 Advice for New Reliability LeadersSound Bites"Stop chasing best practices. Just stop.""A good business case is not just a number.""Don't rush in to fix anything quite yet."Key TakeawaysSelecting the right problem matters more than fixing things quickly.Too many organisations optimise for short-term relief, not long-term reliability.If you confuse symptoms with problems, you will fix the wrong thing. Repeatedly.A strong problem statement brings focus and direction.Chasing best practice without a clear strategy rarely delivers results.Better decision-making beats more data every time.Clear communication is critical if you want change to stick.Reliability initiatives land better when they are tied to real business outcomes.New leaders should slow down and understand the site before making changes.Talking to the right stakeholders often reveals what is really going on. | — | ||||||
| 1/9/26 | What’s Coming in Factory Futures 2026 | SummaryIn this episode, I introduce Season Three of the Factory Futures podcast, emphasizing a new structured approach to discussing reliability and operations in manufacturing. The season will feature more episodes, a mix of interviews and focused mini-series, and aims to provide practical insights into predictive maintenance and other relevant topics. Listener engagement is encouraged, with a call for questions and feedback to enhance the conversation.Chapters00:00 Welcome to Season Three!!!02:37 The New Structure and Focus for the Season Explained05:31 Engagement and Listener InteractionTakeawaysThis season is officially the most exciting we've been year ahead.We are changing our approach to provide more structured content.The focus is on real-world manufacturing reliability and operations.Expect more episodes and continuity in our discussions.We aim to bridge the gap between theory and practice in manufacturing.The mini-series will dive deep into specific topics like predictive maintenance.We want to separate reality from hype in predictive maintenance.Listener questions will guide our discussions and guest selections.Feedback is crucial for improving the podcast experience.Thank you for joining us on this journey. | — | ||||||
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| 10/24/25 | Reliability | Rob Mora on Why Smarter Reliability Is Hard, and How to Actually Get There | Speak with Cohesive: https://www.cohesivesolutions.com/Connect with Rob : https://www.linkedin.com/in/rob-mora-bd/Attend Maximo Live : https://theeventgap.eventsair.com/maximo-live/SummaryIn this conversation, Rob Mora, head of global sales for Cohesive, discusses the critical aspects of asset management and reliability engineering. He emphasizes the importance of transitioning from reactive to proactive management, the challenges organizations face in this journey, and the significance of cultural change alongside technological upgrades. Rob shares real-world examples of how companies have overcome data chaos and highlights the need for leadership buy-in and measuring success to ensure long-term commitment to asset management initiatives. He provides practical advice for reliability engineers, stressing the value of starting small and engaging frontline workers to drive improvements in asset management practices.Chapters00:00 Introduction to Rob Mora and Cohesive04:26 Understanding Asset Management and Reliability Challenges06:53 Common Hurdles in Transitioning to Proactive Management09:26 Cultural and Organizational Changes Required11:59 The Importance of ROI in Asset Management14:42 Real-World Examples of Overcoming Challenges17:13 Lessons Learned in Asset Management19:44 Practical Advice for Reliability Engineers22:36 Avoiding Common Pitfalls in Asset Management25:09 Why Choose Cohesive for Maximo Integration27:43 Conclusion and Future EngagementsTakeawaysRob Mora emphasizes the importance and difficulty of transitioning from reactive to proactive asset management.Cohesive focuses on connecting reliability strategy with real-world execution.Data chaos is a common hurdle in asset management that needs addressing.Cultural change is as important as technology in asset management maturity.Leadership buy-in is crucial for successful asset management initiatives.Small wins can build momentum in asset management projects.Measuring success and ROI is essential for long-term buy-in.Companies often treat asset management as a maintenance project rather than a business strategy.Engaging technicians and frontline workers can provide valuable insights.Starting small and scaling up is a practical approach to asset management. | — | ||||||
| 9/18/25 | Reliability | Evan Powell on Smarter Spares: Demand & Driven Inventory for Reliability Leaders | Get Evan's free tools : https://www.evanpowell.com.au/Connect with him : https://www.linkedin.com/in/evanpowell90/SummaryIn this episode, Evan Powell shares his expertise on spares management, discussing the common challenges faced by reliability and maintenance teams. He talks about the importance of understanding the problem with spares, taking control through a structured framework, and implementing demand-driven purchasing strategies. The conversation also covers the significance of review cycles for continuous improvement and the potential future integration of AI in inventory management. Evan provides actionable insights for site leaders to optimise their spares strategy and improve overall operational efficiency.Chapters2:00 Introduction to Spares Inventory Management11:40 Understanding the Challenges of Spares20:30 Frameworks for Effective Inventory Control25:03 The Relay Race of Information Transfer29:45 Demand-Driven Purchasing and Its Impact30:04 Preventive Maintenance Planning34:13 Review Cycles for Effective Inventory Management39:50 Aligning SOP Processes with Spare Parts Strategy43:32 Advice for Site Leaders on Spare Strategy45:06 The Future of Spares and AI IntegrationTakeawaysSpares inventory often has a long tail with 95% of usage coming from 5% of items.Understanding the criticality of parts is essential for effective inventory management.Daily review cycles are crucial for managing replenishment and inventory control.Work orders should drive the demand for purchasing inventory.Visual management of inventory data can facilitate better decision-making.Engaging vendors in the inventory management process can lead to better outcomes.Preventive maintenance should be integrated with inventory management strategies.Regularly reviewing inventory usage helps in optimizing stock levels.AI can enhance predictive maintenance but requires quality data to be effective.Creating a culture of collaboration between engineering and supply chain teams is vital for success.Keywordsspares management, inventory control, demand-driven purchasing, maintenance strategies, engineering teams, supply chain management, criticality assessment, review cycles, AI in inventory, optimization | — | ||||||
| 8/25/25 | Reliability | Julien Maffre on Unlocking Asset Management Strategies | Show Links:Julien's Linkedin : https://www.linkedin.com/in/julien-maffre-74ba9023/Amsyst : https://amsyst.com/SummaryIn this conversation, we sit down with Julien Maffre to talk through the intricacies of asset management, exploring the importance of a structured approach to asset-centric strategies. We discuss the significance of master data, risk assessment, and the role of AI in enhancing asset management practices. Real-world applications and case studies illustrate the challenges and successes in implementing effective asset strategies. The conversation also touches on the cultural aspects of change management and offers advice for young reliability engineers.Chapters00:00 Introduction and Journey Overview04:44 The Evolution of Asset Management07:29 Understanding Asset-Centric Approaches10:17 The Three Pillars of Asset Management12:57 Master Data: The Foundation of Strategy15:51 Challenges in CMMS and Change Management21:27 Transitioning CMMS: Challenges and Opportunities23:50 Understanding Risk Profiles in Asset Management27:20 Three Layers of Decision-Making in Asset Strategy28:50 Asset Strategy: Balancing Maintenance and Investment32:36 Real-World Examples: Transforming Asset Management38:13 The Role of AI in Asset Management43:31 Advice for Young Reliability EngineersTakeawaysAsset management is crucial for operational excellence.Understanding the three pillars of asset management is essential.Master data is foundational for effective asset strategies.Risk assessment helps prioritize maintenance actions.AI can enhance decision-making in asset management.Cultural readiness is vital for successful implementation.Real-world examples illustrate the importance of structured approaches.Young engineers should embrace curiosity and first principles thinking.Effective communication is key in change management.Continuous improvement is necessary for asset management success. | — | ||||||
| 5/26/25 | CI | Damien Lacey - Unlocking Potential in Manufacturing | 📌 Connect with Damien and his team at : https://oepartners.com.au/📌 Connect with Damien on LinkedIn : https://www.linkedin.com/in/laceydamienSummaryIn this episode, Damian Lacey shares his journey from engineering to consulting, emphasizing the importance of continuous improvement in manufacturing. He discusses his experiences at Toyota, highlights case studies demonstrating efficiency improvements, and explores the significance of data in identifying bottlenecks. Damian also addresses the challenges of sustaining improvement programs and the need for effective upskilling of teams. The conversation concludes with insights on underrated tools for continuous improvement and how to connect with him for further discussions.TakeawaysDamian transitioned from engineering to consulting, focusing on operational excellence.Working at Toyota provided a strong foundation in lean manufacturing principles.Identifying bottlenecks is crucial for improving manufacturing efficiency.Engaging frontline workers is key to uncovering improvement opportunities.Data clarity is essential for understanding process performance.Sustaining improvement programs requires ongoing leadership support and engagement.Visual performance management can drive effective problem-solving.Upskilling teams should focus on practical application rather than just theory.Continuous improvement is a collective effort across all levels of an organization.Building a culture of awareness around waste and inefficiency is vital for success.Sound Bites"It's about finding out where the constraints are.""You need to demonstrate that interest."Chapters07:14 - The Toyota Experience13:41 - Identifying Bottlenecks in Manufacturing19:55 - Case Study: Catering Company Improvements23:08 - Engaging Teams for Effective Change25:08 - Balancing Theory and Practice in Continuous Improvement30:20 - Sustaining Change: Making Improvements Stick33:49 - Unlocking Potential through Maintenance and Reliability37:13 - Upskilling Teams for Long-Term Success38:56- Lightning Round: Insights and Reflections | — | ||||||
| 5/5/25 |  CI | Pat Wright - Making CI Stick: Leadership, Teams & Real Change | SummaryIn this episode, Jean-Philippe Picard interviews Pat Wright, an experienced operations leader with over 20 years in manufacturing. They discuss the importance of continuous improvement, the tools and methodologies involved, and how to engage teams effectively. Pat shares insights on leadership, safety, and the challenges of adopting new technologies in manufacturing. The conversation emphasizes the need for genuine leadership support, the role of trust in teams, and the significance of small, incremental improvements for sustainable success.TakeawaysContinuous improvement is a toolbox for problem-solving.Engaging teams is crucial for effective improvements.Leadership support is key to sustaining improvements.It's about overcoming fear of change.A little improvement every day is better than perfection.What’s the problem we’re trying to solve?Trust is built through honest conversations.Technology adoption is about change, not just tools.Safety improvements are essential in manufacturing.Celebrate small wins to keep morale high.TitlesUnlocking Continuous Improvement in ManufacturingThe Power of Team Engagement in OperationsSound Bites"It's about overcoming fear of change.""Celebrate small wins to keep morale high.""What’s the problem we’re trying to solve?"Chapters06:15 -Defining Continuous Improvement: Tools and Approaches09:26 - Practical Applications of Continuous Improvement12:10 - Engaging Teams in Continuous Improvement15:35 - Safety in Manufacturing: A Continuous Improvement Perspective18:17 - Leadership in Continuous Improvement21:24 - Coping with Pressure in Operations Management24:10 - Handling Challenges and Team Engagement31:28 - Data-Driven Problem Solving33:50 - Addressing Underperformance in Teams35:57 - Navigating Technology Adoption Challenges40:01 - Overcoming Fear of Change45:09 - The Importance of Pre-Meeting Discussions46:37 - Learning from Failed Initiatives50:14 - Sustaining Improvements in Operations53:30 - Balancing Ambition and Employee Well-Being55:46 - Recommended Resources and Quotes | — | ||||||
| 4/14/25 |  Reliability | Jeff Shiver - Practical Reliability Principles | Show notes Get the checklist Jeff mentioned : https://info.peopleandprocesses.com/planning-checklist-podcastFollow Jeff on LinkedIn : https://www.linkedin.com/in/jeffshiver/SummaryIn this conversation, Jeff Shiver shares his extensive experience in maintenance and reliability, discussing common mistakes organisations make, effective strategies for improvement, and the importance of planning and scheduling. He emphasises the need for a solid foundation in maintenance practices, the role of kitting and staging in efficiency, and the significance of avoiding delays. Jeff also highlights the importance of understanding criticality in maintenance and how to change relationships with maintenance teams to foster better collaboration and outcomes.Chapters05:46 Jeff Shiver's Journey in Reliability08:35 Impact of Maintenance on Business Viability10:59 Common Reliability Mistakes in Organizations13:55 Understanding Maintenance Strategies16:30 The Importance of Kitting and Staging19:07 Avoidable Delays in Maintenance Execution22:10 The Role of Planning and Scheduling24:28 Precision Maintenance and Avoiding Defects27:26 Building Effective Partnerships with Production30:07 Prioritising Maintenance Work32:15 The Impact of Reactive Work on Planned Maintenance35:00 Evaluating the Value of Preventive Maintenance42:39 Improving PM Programs for Better Efficiency45:45 Criticality and Its Role in Maintenance Strategies50:43 Changing the Relationship with MaintenanceTakeawaysJeff Shiver has over 20 years of experience in maintenance and reliability.Many organizations still make basic reliability mistakes.Effective maintenance strategies require proper planning and scheduling.Kitting and staging are crucial for efficient maintenance execution.Reactive maintenance is more costly and less safe than planned maintenance.PMs should address likely failure modes to add value.Criticality in maintenance should focus on where the organisation is losing money.Inversion thinking can help prevent issues before they arise.Common sense practices are often overlooked in maintenance.Engaging technicians in the PM process leads to better outcomes. | — | ||||||
| 2/17/25 | Reliability | Simon Murray - Making Maintenance Easier | SummaryIn this episode, Simon Murray, a maintenance coach, discusses the three stages of maintenance and reliability, the common challenges faced by organisations, and the importance of leadership investment in reliability. He introduces his training programs designed to help organisations improve their maintenance practices and shares insights on common pitfalls in maintenance management. The conversation emphasises the need for data-driven decision-making and the importance of aligning maintenance goals with overall business objectives.Chapters00:00 Introduction to Simon Murray and His Work04:35 Understanding the Three Stages of Maintenance08:27 Industry Insights and Challenges12:05 Overcoming Leadership Resistance to Reliability Investments20:37 Exploring Simon's Key Programs30:11 Steps to Achieve Maintenance Excellence35:03 The Seven Deadly Sins of CMMS38:59 Advice for Leaders in Maintenance and ReliabilityTakeawaysMaintenance is a journey through three stages: reactive, reliability, and asset management.Leadership often resists investing in reliability due to a lack of understanding of its value.Data is crucial for justifying maintenance investments to leadership.Maintenance teams need to communicate effectively with operations to create joint schedules.Training programs should be tailored to the specific needs of organisations at different stages.Common pitfalls include poor CMMS setup and lack of clear workflows.It's essential to measure and report on the value of maintenance activities.Continuous improvement requires a cultural shift within organisations.Maintenance managers should focus on both technical and leadership skills.Building a community of maintenance managers can provide valuable support and networking opportunities. | — | ||||||
| 1/22/25 | Rafe Britton | The Role of Lubrication in Manufacturing Reliability in 2025 | In this episode of the Factory Futures Podcast, I am joined by Rafe Britton to dive deep into the critical role of lubrication in industrial operations, with a special focus on the food and beverage industry. We discuss the common challenges faced in lubrication practices, the importance of condition monitoring, and emerging innovations in lubrication technology. Rafe shares insights into the frequent mistakes made in lubrication management, practical tips for improvement, and the long-term benefits of adopting best practices and proper training. Link to the assessment Rafe refers to : The Lubrication Excellence Framework Quiz : 1. Naviguate to https://lubrication.expert/ --> 2. Right below the header, a click on the button that reads "Start your 5 minute Assessment" 3. Enter your details Some key take-aways Welcome and New Year’s Wishes: Kick off 2025 with a focus on improving reliability through lubrication. Universal Need for Lubrication: If it moves, it likely requires proper lubrication. Contamination Challenges: 80% of machine failures stem from contamination-related issues. Impressive ROI: Investing $1 in lubrication can return up to $40 in value through reduced failures and downtime. Food-Grade Safety: Food-grade lubricants ensure incidental contact is safe and meet regulatory standards. Common Errors: Mixing incompatible lubricants is a frequent and costly mistake. Viscosity Is Key: One of the three most crucial properties of any lubricant. Training Resources: A wealth of online courses and materials are available to improve lubrication knowledge. Chapters & Timestamps 00:00 – Introduction to Lubrication Expertise08:12 – The Importance of Lubrication in Industry12:38 – Challenges in Food and Beverage Lubrication19:01 – Procurement Issues in Lubrication23:01 – Improving Lubrication Practices27:58 – Asset Management and Lubrication Standards30:30 – The Selection Process in Lubrication32:47 – Inspection and Condition Monitoring34:44 – Understanding Lubrication Systems35:41 – Greasing Techniques and Tools39:38 – Auto Lubrication Systems43:16 – Common Mistakes in Lubrication Practices46:50 – Emerging Technologies in Lubrication49:46 – Educational Resources for Lubrication Knowledge Podcast Episode: The Essential Role of Lubrication in IndustrySummaryKey TakeawaysEpisode Chapters | — | ||||||
| 12/12/24 |  Reliability | Cory Pritchard - MD of Predict Australia | Summary In this conversation, I speak with Cory Pritchard, the MD of Predict Australia. Together, we discuss the critical themes of reliability and data in the mining industry. We explore the economics of reliability, the importance of predictive maintenance, and the ongoing data revolution in mining maintenance. Cory shares insights on how existing data can be leveraged to improve operational efficiency and reduce costs, emphasising the need for collaboration with execution teams to enhance data collection processes. We also cover the importance of closing the information loop in maintenance strategies, the challenges associated with CMMS and data quality, and the need to break free from traditional time-based preventive maintenance approaches. We talk about a successful transition to predictive maintenance, emphasising the role of data in improving maintenance strategies. The discussion also touches on innovation and change management within the industry, concluding with insights on the future outlook of the mining sector. Chapters 00:00 Introduction and Background 02:48 Economics of Reliability in Mining 05:57 Business Case for Predictive Maintenance 11:59 The Data Revolution in Mining Maintenance 18:01 Engaging Execution Teams for Data Collection 24:41 Closing the Information Loop 25:34 Challenges with CMMS and Data Quality 29:32 Breaking Free from Time-Based PMs 37:30 Successful Transition to Predictive Maintenance 44:17 Innovation and Change Management 47:14 Future Outlook of the Industry | — | ||||||
| 11/6/24 |  Erik Hupjé | The Road to Reliability Framework Explained | In this episode, we had an insightful conversation with Erik Hupje, founder of Reliability Academy and a widely respected voice in the maintenance and reliability field. With over 50K followers on LinkedIn, Erik is known for consistently sharing high-value content with the industry. The episode is divided into four key parts: Introduction 00:00 - 05:36: Erik’s background and an introduction to the episode. 05:36 - 07:25: Overview of maintenance challenges and the Road to Reliability Framework™. The Road to Reliability Framework™ 7:35 : How the framework came about 11:26: The role of planning and scheduling in effective maintenance. 17:08: Cultural factors influencing maintenance success. 22:31: Continuous improvement in maintenance practices. 27:52: Techniques for capturing and analysing downtime data. Principles of an Effective Maintenance Program 33:06: Key principles for establishing a robust maintenance program. Advice for New Maintenance Managers 44:36: Erik shares valuable advice for those new to maintenance management. We’re confident you'll find value in Erik’s insights. Please share your feedback with us on LinkedIn, including suggestions for future guests you’d like to hear from—perhaps even yourself! | — | ||||||
| 9/4/24 |  Tuulia Ijas - Production & Reliability Leadership | Intro & Summary Welcome to our latest podcast episode featuring Tuulia Ijas. At the time of recording this podcast, Tuulia is between roles, having most recently been in Reliability and Maintenance Manager @ Asahi Beverages. In the episode, Tuulia Ijas shares her journey from production to maintenance and the importance of understanding the customer's needs. She emphasises the need for a healthy relationship between production and maintenance, which can be achieved through open communication, collaboration, and shared goals. Tuulia highlights the significance of physical proximity and regular meetings between production and maintenance teams. She discusses the importance of understanding the impact of maintenance on production and vice versa, setting service level agreements, and using continuous improvement tools to improve the relationship. In this conversation, we also touch on the evolution of the role of maintenance and reliability in manufacturing, the challenges of implementing predictive strategies, and engaging the younger generation in manufacturing. Tuulia emphasises the importance of open-source conversations and reassessing agreements in collaborative work. She also highlights the changing role of maintenance and reliability, driven by cost constraints and the availability of data. Tuulia shares her experiences in problem-solving and the need for a poker face in challenging situations. She encourages manufacturing leaders to appreciate the moments of smooth sailing and surround themselves with good people. Chapters Timestamps may not perfectly align with the content, and guest dialogue may have been refined for accuracy. 00:00 Tuulia Ijas' Journey 17:17 Building a Healthy Relationship Between Production and Maintenance 23:00 The Importance of Communication and Collaboration 25:02 Understanding the Impact of Maintenance on Production 27:10 The Evolution of Maintenance and Reliability 29:06 Data-Driven Decision Making in Maintenance 31:13 Utilising Technology for Maintenance Analysis 34:19 Transitioning to a Predictive Strategy 45:23 Problem-Solving and the Poker Face in Manufacturing 47:11 Appreciating the Moments of Smooth Sailing | — | ||||||
| 7/23/24 |  John Broadbent - 50 Years in Manufacturing | Intro It's been such a pleasure to have John Broadbent on the podcast. It's been such a pleasure to have John Broadbent on the podcast. John is a one-of-a-kind veteran in the industry with nearly 50 years of experience (even if he doesn't look a day over 40!). With a career that spans from his early days as a mechanical engineering cadet at CSR to founding multiple successful businesses and becoming a renowned expert in digital transformation, John's journey is a testament to the evolution and potential of modern manufacturing. Throughout the conversation, John shares invaluable insights drawn from his extensive career, highlighting the challenges and opportunities within the Australian manufacturing landscape. He discusses the importance of smart manufacturing, the role of automation in addressing labor shortages, and the critical need for real-time data integration. Whether you're a site leader grappling with operational inefficiencies or an executive considering the digital transformation journey, John's practical advice and proven strategies offer a roadmap to achieving manufacturing excellence in the 21st century. John shares so many gems in this podcast, some of our favourite parts where; - 00:01:35 - The Beginning of John's Journey John Broadbent shares his early career experiences, starting as a mechanical engineering cadet at CSR in 1975, setting the stage for his extensive journey in the manufacturing industry. - 00:04:13 - Insights into Smart Manufacturing John discusses his pivotal role in building factories in China and Thailand, providing a firsthand account of the early implementations of smart manufacturing practices and their long-term benefits. - 00:10:35 - The Challenges of Today's Manufacturing Leaders , and the Lego Meme - 00:14:18 - Real-Time Data and Operational Improvement & Why OEE is becoming a Fad John emphasises the importance of real-time data integration and its impact on operational efficiency, offering practical advice on how manufacturing leaders can streamline their processes. - 00:16:18 - Driving around town with no dashboard and no windows, and the MD in the passenger seat - 00:19:53 - Addressing Labor Shortages with Automation John explores how automation can help mitigate labor shortages, using examples from successful companies like GPC Electronics and Coca-Cola to illustrate the benefits of investing in smart manufacturing technologies. - 00:30:24 - The Necessity of Leadership Commitment John highlights the critical role of leadership in committing to digital transformation, outlining the steps organisations need to take to align their strategy and achieve sustainable growth in the manufacturing sector. | — | ||||||
| 7/2/24 |  Michael Riches - Leading People & Leveraging Technology | It's been such a pleasure to have Michael Riches on the podcast. Mike is passionate people leader, with an impressive logical, analytical mind. Throughout the episode, it's clear that he always puts people first, and that would be a larger part of his success. He explains the challenges and long-term benefits of implementing new technology, sharing some success stories and mistakes and previous sites he's led. He mentions practices like asset care software and autonomous maintenance. Mike stresses the need for preparation and sticking to long-term goals, even when immediate results aren't visible. They also discuss how crucial employee engagement is for success. Michael shares how focusing on engagement led to improvements in safety, quality, efficiency, and financial performance. The conversation wraps up with insights on leadership, making better daily decisions, and dealing with imposter syndrome. | — | ||||||
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