Maintenance & Manufacturing Insights

Martin Engster

Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader at a manufacturing company, this show is for you.

Host Martin Engster sits down for conversations with people who actually work in the trenches of industry, for real talk about what’s working, what’s not, and what they're dealing with day-to-day.

From reducing unplanned downtime and managing MRO inventory to leading maintenance teams and optimizing tool crib workflows, Maintenance and Manufacturing Insights delivers practical, real-world stories you can learn from.

Whether you’re struggling with spare parts chaos, implementing a new CMMS, or just trying to get through the week without a production stop — you’ll find honest insights from peers who’ve been there.

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26 episodes
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Avg 23 min
English

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#26
Yesterday · 33 min
Finding the Real Problem: Mike Escobedo on Data, Maintenance, and Manufacturing
What makes a great manufacturing operator? For Miguel “Mike” Escobedo, it starts with knowing your machine. In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Mike Escobedo, Manufacturing Fabrication Manager at Jackrabbit Manufacturing, to talk about the connection between manufacturing, maintenance, leadership, and problem-solving on the shop floor. Mike has worked in manufacturing since 1999, starting out sweeping floors and eventually moving into leadership. Along the way, he has worked with manufacturing operations including pipe processing, non-destructive testing, hydrostatic testing, chamfering, fabrication, and automated equipment. Mike shares why he believes manufacturing and maintenance have to work hand-in-hand. When operators understand their equipment, they can recognize changes in sounds, performance, quality, and behavior before those changes become bigger problems. One story from Mike’s previous workplace shows why this matters. Operators were initially blamed when a chamfering machine began producing inconsistent bevels. Instead of assuming it was a training problem, Mike collected data and compared results across multiple pieces and materials. That investigation helped the team trace the problem back to a mechanical change: too much tension had been placed on a spring during previous maintenance work. Once the tension was corrected, the machine returned to producing consistent results. Martin and Mike also discuss Industry 4.0, the Internet of Things, preventive maintenance, automation, equipment monitoring, and how technology is changing manufacturing. But technology is only part of the story. Mike believes manufacturing is a team effort. Whether someone is an operator, maintenance technician, manager, or engineer, everyone contributes to getting a quality product out the door. The conversation also gets personal as Mike talks about his love of barbecue, his involvement with his church, and “One Minute with Big Mike,” where he shares scripture and advice on TikTok.
#25
Friday · 19 min
Why the Right Parts Matter in Spindle Repair with Martin Engster
This month, the tables are turned on Maintenance and Manufacturing Insights. Instead of interviewing someone else in the industry, Martin Engster takes the guest seat and gives us a look at what he is seeing in manufacturing and what is happening inside Centreline. Martin shares what he heard while speaking with manufacturers, machine builders, and vendors at recent machine tool shows in Chicago. He also explains why changes in manufacturing do not always show up immediately for a spindle repair facility. New machines often come with warranties, so there can be a delay before repair work begins to follow broader industry activity. We also get a closer look at Centreline’s work. Martin explains the company’s three main areas: spindle repair for CNC machines, precision part manufacturing, and on-site taper grinding. He shares just how tight their tolerances can be, often between 2 and 5 microns. For comparison, Martin says a human hair is about 100 microns. One topic Martin stresses is the importance of OEM parts. He explains how using the wrong parts, installing components incorrectly, or trying to save money with a short-term fix can lead to bigger problems later. Then Martin takes us behind the scenes of a current repair involving a spindle that weighs more than 4,000 pounds. A more typical spindle may weigh around 100 to 200 pounds, making this repair a very different challenge. The team has to manage the bearings, electrical components, cooling systems, alignment, and reassembly while handling a piece of equipment Martin compares to the size of a desk or even working on a car. To close things out, Martin talks about his love of travel and machines. He shares what impressed him at the IMTS show, including a robotic arm moving a full-size car, and tells the stories behind his 1986 Porsche 944 and 1974 Porsche 914.
#24
October 1 · 18 min
Simple Fixes, Less Downtime: Maintenance Lessons with Kenneth Welch
What if your maintenance team knew what to do before a machine ever went down? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Kenneth Welch to talk about practical maintenance, manufacturing experience, and the value of preparing for problems before they happen. Kenneth spent 23 years working at Michelin in Ardmore, Oklahoma, before moving into his current role at SendCutSend in Arlington, Texas. His years on the manufacturing floor have taught him that some of the biggest production problems can have surprisingly simple solutions. One idea Kenneth shares is the “pre-mortem.” Instead of waiting for a machine to fail and then figuring out what went wrong, the team looks at the equipment ahead of time and asks: If this machine goes down, what do we do? By identifying the steps before the problem happens, maintenance teams can respond faster and spend less time scrambling for answers. Kenneth also shares a simple lesson from his Michelin days. If a belt was known to break, the team kept a spare belt right where it would be needed. When the belt failed, there was no searching for the correct replacement. The solution was already there. Martin and Kenneth also discuss the importance of listening to the people working on the manufacturing floor. Kenneth believes his floor experience gives him a valuable perspective as a supervisor. The people closest to the equipment often see problems and solutions that may not be obvious from somewhere else in the organization. Kenneth also tells the story of a production problem that had tires stacking up for three days. The solution came from knowing the equipment and recognizing another way to keep production moving. The conversation is a reminder that effective maintenance does not always require a complicated answer. Preparation, communication, experience, and simple solutions can make a major difference.
#23
September 30 · 21 min
Mathew Edwards: Building Maintenance Teams That Keep Manufacturing Moving
What does it take to keep a highly automated manufacturing plant running while working toward production of 21,000 solar panels a day? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Mathew Edwards, Plant Facilities Manager and Maintenance Manager for First Solar in Gaffney, South Carolina. Mathew shares what goes into building and leading a maintenance operation at a new 1.2-million-square-foot manufacturing facility. With highly automated production lines, robots, drives, conveyors, and other equipment, keeping unplanned downtime under control is a major priority. Mathew explains why his team focuses on predictive and preventive maintenance instead of waiting for equipment to fail. Maintenance schedules are driven by equipment usage, run time, cycle counts, inspections, and data. His team also uses information from other facilities to adjust maintenance intervals and make better decisions. But this conversation is about more than machines. Mathew explains why the people maintaining the equipment are just as important as the technology itself. He shares his approach to building a strong maintenance team, giving employees the tools and training they need, and avoiding the common mistake of relying on the same top performers for every difficult job. Martin and Mathew also discuss the value of skilled trades. Mathew encourages people entering the workforce to learn a trade or technical skill and take advantage of every training opportunity their employer provides. The conversation covers preventive and predictive maintenance, reducing unplanned downtime, maintenance planning, spare-parts management, automation, data-driven decision-making, team leadership, employee development, skilled trades, and the importance of networking. About Mathew Edwards Mathew Edwards is the Plant Facilities Manager and Maintenance Manager for First Solar in Gaffney, South Carolina. He leads a maintenance organization supporting a highly automated solar manufacturing facility as it ramps up production. Mathew believes successful maintenance leadership starts with giving people the tools, training, time, and support they need to succeed.
#22
September 24 · 40 min
Varadarajan Balaraman: From Startup Chaos to a Well-Oiled Machine
What does it take to build a manufacturing operation from the ground up while also building the maintenance systems that keep it running? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Varadarajan “V” Balaraman, a site plant manager helping build a startup manufacturing operation within an established company. V shares why starting with new equipment does not mean maintenance can wait. New machines may have fewer breakdowns, but that can also mean the team has fewer chances to learn how the equipment will fail. His approach starts with vendor-recommended preventive maintenance, spare parts, and inspection routines. Then, as real-world failures happen, the team turns those problems into lessons. Martin and V discuss root cause analysis and the importance of looking beyond the immediate machine failure. V explains his approach using five areas: man, machine, method, material, and environment. Instead of simply fixing what broke, the goal is to understand why it happened and use that knowledge to improve the maintenance program. V also shares a real example involving a prop shaft balancing machine. A worn chuck was creating vibration that made good parts appear bad, resulting in scrap and repeated correction attempts. By digging into the measurement system and developing a monthly calibration process, the team was able to identify problems before they created larger production losses. Another example comes from V’s current plant, where glue repeatedly clogged a robotic spray system. After exploring the technical solutions available, V realized technology alone could not eliminate the problem. The answer was a better operating process, including flushing the system before production and whenever the line stopped. The lesson is simple: first determine what technology can solve. When technology reaches its limit, build clear and repeatable work procedures around that reality. The conversation also explores the people side of manufacturing. V explains why operators need a clear way to report what they see and hear on the floor. A small noise noticed by an operator could be the first warning of a larger problem. Building a system where those concerns are captured, reviewed, and resolved helps make maintenance everyone's responsibility. V describes his startup role as being an architect. He is helping turn a “jungle” into an organized value stream by building processes, equipment systems, material flow, quality practices, maintenance routines, and a team culture one problem at a time. Outside of manufacturing, V brings that same builder mindset home. His love of DIY projects has led him to build everything from swing sets to large backyard ziplines for his kids. This episode is for maintenance professionals, plant managers, engineers, manufacturing leaders, and anyone interested in preventive maintenance, root cause analysis, manufacturing startups, reliability, continuous improvement, and building stronger teams.
#21
September 23 · 24 min
Ivan Getov: Maintenance Is More Than Fixing Things
What happens when a company invests in predictive maintenance, AI, and new technology before fixing its basic maintenance processes? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Ivan Getov, Maintenance Excellence Manager at Eastman Chemical Company, about why strong maintenance starts with the fundamentals. Ivan began his career as a chemical engineer and worked in operations before moving into maintenance management. Today, his focus is maintenance excellence and improving the systems that connect work identification, planning, scheduling, execution, and follow-up. Ivan explains why many maintenance teams stay stuck in reactive mode. Fixing a breakdown can feel rewarding because the results are immediate. The maintenance team gets equipment running again and becomes the hero. But Ivan believes organizations need to move away from that hero mentality and build systems that prevent problems before they become emergencies. The conversation also looks at predictive maintenance and AI. Ivan supports these technologies, but he makes an important point: technology cannot fix a broken process. If communication, planning, scheduling, and accountability are weak, adding more technology may simply make those problems happen faster. Ivan shares a real example involving a major river-water line rupture that affected a continuous manufacturing process. During the early response, people were working hard, but crews were losing time because scaffolding, insulation, lockouts, and other requirements were not properly coordinated. The solution wasn't another piece of technology. It was better organization, clear ownership, communication, accountability, escalation procedures, and a detailed plan. Martin and Ivan also discuss the complexity and safety responsibilities behind industrial maintenance, why communication between operations and maintenance matters, and why continuous learning can open unexpected career opportunities. Ivan's advice to younger professionals is simple: keep learning and stay open to opportunities. His own move from chemical engineering and operations into maintenance led him to a career he never originally expected—and one he has grown passionate about. About Ivan Getov Ivan Getov is a Maintenance Excellence Manager at Eastman Chemical Company. With a background in chemical engineering and operations, Ivan has worked as a maintenance manager and now focuses on improving maintenance processes and systems. Ivan also writes about maintenance and leadership on LinkedIn and Substack. He has published a book about leadership and, at the time of this interview, was working on another book focused on maintenance processes and practical playbooks.
#20
September 15 · 27 min
The Power of Proactive Maintenance with Reinhardt de Jager
What if you could know a machine was going to fail weeks before it actually happened? Instead of scrambling after a breakdown, your team could order the parts, plan the repair, and choose when to take the equipment offline. In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin sits down with Reinhardt de Jager, a Reliability Area Maintenance Manager whose work includes predictive maintenance, reliability-centered maintenance, lubrication programs, shutdowns, and outages. Reinhardt shares his approach to moving maintenance organizations away from reactive repairs and toward proactive reliability. One of the first places to start is with the preventive maintenance plan itself. A work order that simply tells a technician to “check motor” does not provide much value. Reinhardt explains why maintenance tasks should verify specifications, equipment condition, operating processes, and standards while addressing actual failure modes. The conversation then moves into predictive maintenance and condition-based monitoring. By tracking factors such as vibration, temperature, and current draw, maintenance teams can identify developing problems before they become unexpected failures. That changes the entire maintenance equation. Instead of waiting for equipment to break, teams can order parts, prepare the work, coordinate resources, and schedule downtime when it makes the most sense for production. Reinhardt also explains how better maintenance practices connect directly with spare-parts management. Knowing likely failure modes helps organizations decide what should be kept in the storeroom and where strong vendor relationships and fast turnaround times are needed. Martin and Reinhardt also discuss recurring equipment failures and an important question maintenance teams should ask: Why keep getting better at repairing the same problem when you could determine its root cause and eliminate it? Reinhardt shares a real example of condition monitoring detecting a serious problem inside an induction furnace shortly after a new lining was installed. The team trusted the monitoring system, shut down the furnace, investigated the problem, and discovered a potentially dangerous condition before it could develop into something much worse. The discussion ultimately comes back to a lesson Reinhardt received from one of his mentors. His job wasn't simply to fix equipment. His job was to help “move steel through the door.” Reliability is his function for helping make that happen. It is a perspective that connects maintenance with operations, safety, finance, production, inventory, and the larger goals of the business. About Reinhardt de Jager Reinhardt de Jager works in reliability and maintenance management, with responsibilities covering predictive maintenance, reliability-centered maintenance, lubrication, shutdowns, and outages. His career has given him experience in maintenance, reliability, condition-based monitoring, and manufacturing operations. Outside of work, Reinhardt is also continuing his education while raising a growing family.
#19
September 10 · 18 min
Keeping Manufacturing Running: Predictive Maintenance, People & Parts with Tony Ingram
What does it take to keep a manufacturing plant running when some machines date back decades and others are brand new? In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Tony Ingram, Senior Maintenance Supervisor at Daikin Applied in Faribault, Minnesota. Tony shares what maintenance really looks like inside a facility producing large air-conditioning systems for data centers, hospitals, factories, and schools. His team works with everything from large punch and shear systems to copper-processing equipment, foam presses, tooling, and machines dating back to the 1950s and earlier. Martin and Tony discuss the difference between reactive, preventive, and predictive maintenance. Tony explains how his operation is moving further into predictive maintenance by monitoring things such as vibration, temperature, oil levels, and tooling cycles. The goal is simple: spot trouble before a machine stops production. They also talk about one of the biggest challenges in maintenance—having the right people and the right spare parts when something goes wrong. Tony explains why new equipment should arrive with critical replacement parts already identified and available instead of waiting until the first failure. Tony also shares one of the most memorable equipment failures of his career: a steel storage system that left roughly two tons of steel about 30 feet in the air after a collision. The recovery took around six hours, with safety taking priority over speed. The conversation also covers the human side of maintenance, from operator-related problems and staffing challenges to knowing when a repair should be handled internally and when it makes more sense to call an expert. Outside the plant, Tony brings that same mechanical mindset to motorcycles. He talks about riding and rebuilding his own bike after a third-gear failure turned into a major engine project. Tony's experience offers a practical look at the people, planning, troubleshooting, parts, and technology required to keep modern manufacturing moving.
#18
September 8 · 17 min
280 Machines, 8 Maintenance Pros: How Trevor Kennedy Keeps Production Moving
What does it take to keep more than 280 manufacturing assets running with a small maintenance team? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Trevor Kennedy, Plant Manager for Parker Hannifin's HELAC hydraulic actuator operation. Trevor shares what maintenance looks like inside a busy manufacturing plant producing hydraulic actuators for mining, agriculture, and industrial applications. The conversation explores Trevor's team's transition toward predictive maintenance. Along with regular preventive maintenance, the team is learning from equipment failures and adding its own inspection points to help identify problems before they become major issues. Trevor also discusses one of the realities every maintenance team faces: downtime. When critical equipment goes down, fixing the machine is only part of the challenge. Maintenance leaders must decide whether to repair equipment internally, bring in an OEM or outside specialist, find replacement parts, manage costs, and keep production moving at the same time. One strategy Trevor's team uses is keeping certain critical replacement components available. For some equipment, having a replacement spindle or other important component ready can help reduce the time production is affected by a failure. Martin and Trevor also discuss the people behind maintenance. Trevor's operation has more than 280 assets and a maintenance group of seven people, or eight including the manager. When several critical machines need attention at once, manpower can quickly become one of the biggest challenges. The conversation also shows why modern maintenance is about much more than turning wrenches. Maintenance and plant leaders may be involved in troubleshooting, vendor sourcing, contract and invoice reviews, budgeting, logistics, outsourcing decisions, and operations strategy—all while working against the clock. Trevor also shares a little about life outside the plant, including his love of sports and live music, playing acoustic guitar, and pursuing his MBA. If you work in manufacturing, maintenance, operations, or plant leadership, this conversation offers a practical look at what it really takes to keep production moving.
#17
September 2 · 13 min
Sean Archer: Why Today’s Maintenance Techs Have to Keep Learning
In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Sean Archer, a maintenance manager in the steel manufacturing industry. Sean leads a maintenance team responsible for keeping the equipment, systems, and facility operating safely and reliably. Sean explains why good maintenance cannot simply be about waiting for something to break. Preventive and predictive maintenance help his team stay ahead of problems. He also shares why root cause analysis can be one of the most valuable tools available to maintenance professionals. The conversation gets into the real-world challenges of maintaining a facility filled with pumps, drives, tanks, overhead cranes, coil handling equipment, PLCs, and other industrial systems. Sean also shares the story of an equipment failure involving an incinerator that required an evening call to get production running again. With steel moving through the process at up to 700 feet per minute, downtime can quickly become expensive. But Sean believes one of the biggest challenges in maintenance isn't a machine. It's making sure maintenance professionals continue learning. Modern maintenance requires more than screwdrivers and hammers. Technology changes, equipment changes, and maintenance teams have to change with it. ------------------------ Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#16
August 26 · 23 min
Building Better by Hand: Lucas Richards on Manufacturing and Continuous Improvement
In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin sits down with Lucas Richards, Associate Manufacturing Supervisor at Schweitzer Engineering Laboratories, to explore a side of manufacturing that most people never get to see. Lucas works in an environment where teams assemble the panels and systems used to help monitor, control, and protect critical power infrastructure. These builds can be highly customized, with different devices, wiring, and configurations from one project to the next. That makes skilled, hands-on work an important part of the manufacturing process. Martin and Lucas discuss why relying on people—not just machines—is so important in this type of operation. Lucas explains how operators are trained and empowered to maintain their own tools and equipment, and why continuous improvement plays such a large role in their approach to maintenance. They also get into the practical side of improvement. Lucas shares one of his first major projects: finding a safer solution for heat guns after existing tools created concerns around burns and equipment damage. The project required more than simply finding another tool. It meant working across facilities, collaborating with different teams, and finding a solution everyone could support. The conversation also explores rapid growth, employee development, the challenges of increasing production capacity, and what it means to work for a 100% employee-owned company. And, of course, Martin and Lucas find some time to talk about welding, LEGO, and why people who work in manufacturing often just enjoy building things. About Lucas Richards Lucas Richards is an Associate Manufacturing Supervisor at Schweitzer Engineering Laboratories. His work focuses on manufacturing operations, employee development, continuous improvement, and supporting the hands-on assembly of equipment used in power infrastructure. To connect with Lucas, search for Lucas Richards on LinkedIn and look for his profile associated with Schweitzer Engineering Laboratories in the Charlotte area. ------------------------ Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#15
August 19 · 28 min
Joshua Kroll: Maintenance Leadership, AI, and Continuous Improvement
From Nuclear Submarines to Napa Valley: Maintenance Leadership, AI, and Continuous Improvement What does it take to lead maintenance teams in one of the world's most demanding production environments? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Joshua Kroll, Facilities Maintenance Supervisor at Trinchero Family Estates, to discuss his journey from serving in the U.S. Marine Corps and Navy's nuclear submarine program to leading maintenance operations in California's wine industry. Joshua shares how preventive maintenance, structured troubleshooting, skill development, and data-driven decision making help keep thousands of pieces of equipment operating during harvest season—the "Super Bowl" of winemaking. He also explains why challenging assumptions during root cause analysis can dramatically reduce downtime and improve maintenance performance. The conversation also explores how artificial intelligence is beginning to transform maintenance organizations. Joshua discusses practical ways AI can support maintenance teams, from organizing technical documentation and analyzing equipment data to developing employee training programs and monitoring regulatory updates. Whether you work in manufacturing, facilities, reliability, or maintenance leadership, this episode offers practical ideas you can apply immediately. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#14
August 11 · 22 min
Building Reliable Maintenance Systems: Gabe Little on Asset Management and Automation
Building Reliable Maintenance Systems: Gabe Little on Asset Management and Automation What does it take to keep a large distribution center running while preparing for the future of automation? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Gabe Little, a maintenance leader with experience at Jacobson Logistics, Amazon, ThredUP, and Ross Stores. Gabe shares how his career evolved from HVAC technician to leading maintenance teams and transitioning into equipment engineering focused on asset management and lifecycle planning. The conversation explores the importance of preventive maintenance, CMMS systems, vendor management, documentation, spare parts organization, and maintaining conveyor systems that keep distribution centers operating efficiently. Gabe also shares one of the biggest equipment failures of his career—a catastrophic carousel collapse—and explains how that experience led to better reliability practices and improved drive technology. Martin and Gabe also discuss how AI is beginning to assist maintenance professionals through analytics and dashboard reporting while emphasizing that experience, reliability, and strong maintenance fundamentals remain the foundation of successful operations. Whether you're a maintenance technician, supervisor, reliability engineer, or plant leader, this episode offers practical insights into building stronger maintenance programs and preparing facilities for the future. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#13
August 5 · 12 min
Inside Manufacturing Facilities with Nathan Santiago
Every minute of downtime matters in manufacturing. In this episode, Martin Engster sits down with Nathan Santiago, Facilities Engineer at C&H/New Holland, to discuss what it really takes to keep a large manufacturing campus operating efficiently. Nathan shares how preventive maintenance goes far beyond simply following OEM schedules. He explains how maintenance teams adapt service intervals for equipment that runs around the clock, organize specialized tools and spare parts at critical machines, and work closely with production teams to minimize downtime. The conversation also explores the growing role of predictive maintenance. Nathan discusses how sensors and cycle-count monitoring are helping manufacturers identify failing components before they create costly production interruptions. Beyond equipment maintenance, Nathan shares real-world examples of solving operational challenges. From eliminating hundreds of hours of laser downtime through a simple logistics improvement to responding quickly after severe roof leaks threatened production, he demonstrates how thoughtful problem-solving and teamwork can dramatically improve manufacturing performance. Whether you're involved in maintenance, facilities engineering, operations, or manufacturing leadership, this episode offers practical insights into reducing downtime, improving reliability, and supporting production through better planning. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#12
July 30 · 36 min
Helmuth Lara: Maintenance Excellence in the World's Largest Machines
What does it really take to keep the lights on for thousands of people? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Helmuth Lara, an experienced mechanical engineer and plant manager whose career has spanned nearly three decades in oil & gas, gas turbines, rotating equipment, and power generation. From his early days working in South American refineries to managing power generation for the U.S. Virgin Islands, Helmuth shares what it takes to maintain some of the world's largest and most complex machines. The conversation explores the importance of preventive maintenance, how major overhauls are planned, and why successful maintenance is about far more than fixing broken equipment. Helmuth explains how coordination, planning, logistics, and teamwork all play critical roles in keeping critical infrastructure operating safely and reliably. He also shares one of the most dramatic equipment failures he has ever experienced—a gas turbine explosion caused by an undetected gas leak—and explains how careful investigation and engineering allowed the team to safely restore the plant. Martin and Helmuth also discuss today's biggest maintenance challenges, including long supply-chain lead times, predictive maintenance technologies, equipment reliability, and the changing landscape of power generation. They even dive into electric vehicles, energy efficiency, and why understanding where electricity actually comes from is more important than ever. Whether you work in maintenance, manufacturing, reliability, or simply enjoy learning how massive industrial systems operate, this episode provides valuable real-world insight from someone who has spent his career keeping critical equipment running. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#11
July 28 · 27 min
The Hidden Side of Medical Manufacturing with Cory James
Most people never stop to think about where the medical tubing inside catheters, stents, and other life-saving devices actually comes from. In this episode, Martin Engster sits down with Cory James, Plant Manager at Zeus Industrial Products, to pull back the curtain on one of the most important—but least visible—parts of medical manufacturing. Cory shares how Zeus Industrial Products manufactures precision medical-grade tubing used by many of the world's leading medical device companies. The conversation explores the challenges of balancing preventive maintenance with increasing production demands, the importance of investing in people, and why in-house engineering has become a competitive advantage. Drawing from his military background and leadership experience, Cory also discusses how discipline, teamwork, and continuous improvement help drive manufacturing excellence while navigating the growing pains that come with rapid business growth. Whether you're in maintenance, manufacturing leadership, engineering, or simply curious about how everyday products are made, this episode offers an inside look at an industry that quietly impacts millions of lives every day. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#10
July 24 · 22 min
Keeping Glass Production Running: Maintenance Lessons with Josiah Peterson
Every building, office, and home depends on glass, but few people ever stop to think about the complex manufacturing process behind it. In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Josiah Peterson, Maintenance Manager at Oldcastle Building Envelope, to discuss what it takes to keep a modern glass manufacturing facility operating efficiently. Josiah shares his unique career journey—from growing up on a dairy farm and working in logging communities to maintaining high-speed manufacturing equipment in industries ranging from Amazon and food production to energy drinks and now architectural glass manufacturing. The conversation explores the challenges of maintaining specialized equipment, sourcing obsolete replacement parts, balancing production demands with preventive maintenance, and introducing predictive maintenance technologies like vibration analysis and infrared inspections. Josiah also explains how glass is cut, tempered, polished, and prepared for residential and commercial projects, including supplying glass for Allegiant Stadium in Las Vegas. If you're interested in maintenance leadership, reliability, manufacturing careers, CMMS implementation, predictive maintenance, or industrial problem-solving, this episode offers practical insights from someone who has worked across multiple manufacturing industries. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#9
June 25 · 39 min
Small Problems, Big Profits: Lessons in Maintenance and Leadership with James Harris
Small problems often create the biggest losses. In this episode, James Harris shares how focusing on defects, root causes, and reliability transformed struggling operations and delivered major improvements. Martin Engster sits down with James Harris, a U.S. Army Reserve officer and experienced maintenance and engineering professional. James discusses his journey through manufacturing, process improvement, and military leadership. During the conversation, James explains how maintenance teams can move beyond reactive repairs and create lasting reliability. He shares stories from high-speed beverage production lines, discusses the importance of defect elimination, and explains why troubleshooting skills are more valuable than simply being the hero who fixes equipment after it breaks. James also reveals how one project produced a 60% increase in profit by focusing on the small issues that others overlooked. He discusses root cause analysis, preventive maintenance, reliability-centered maintenance, and why quality should sometimes outweigh the lowest price. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#8
June 23 · 28 min
Todd Gibbs: How Small Changes Create Big Reliability Gains
What does it take to keep thousands of automotive glass components moving through production every day? In this episode, Martin Engster sits down with Todd Gibbs, Maintenance Manager at Carlex Glass, to discuss more than four decades of maintenance experience and the importance of building reliability into manufacturing operations. Todd shares how his time serving in the U.S. Navy's nuclear submarine program helped shape his approach to maintenance and reliability. From vibration analysis and thermography to root cause analysis and planned shutdowns, he explains why reliability-centered maintenance delivers greater value than simply completing preventive maintenance tasks. Listeners will hear real-world examples of maintenance successes, including how upgrading conveyor chains eliminated costly downtime and how creative repairs helped avoid catastrophic failures while replacement parts were being scheduled. Todd also offers insights into automotive glass manufacturing, manpower challenges in the trades, spare parts strategies, and the role of new technologies like AI and 3D printing. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
#7
June 19 · 23 min
Korey Mertz: The Hidden Costs of Ignoring Machine Maintenance
In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Korey Mertz of Advanced Machine Engineering to discuss why preventive maintenance is often overlooked and how manufacturers can move from reactive repairs toward a more proactive approach. The show notes follow recommended practices for strong podcast descriptions and listener engagement. Korey shares his journey from studying mechanical engineering to leading business development within the Tool Clamping Systems Division at Advanced Machine Engineering. Drawing on years of experience working with drawbar systems and spindle components, he explains why monitoring pull force and understanding wear trends are essential to maintaining part quality and avoiding costly downtime. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

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