Factory Futures

Summary

In 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.

Chapters

00:00 Introduction to Predictive Maintenance

08:33 Understanding the Need for Predictive Maintenance

12:44 Defining Predictive Maintenance and Its Distinctions

19:21 What Predictive Maintenance Is Not

21:52 Addressing Common Objections to Predictive Maintenance

22:37 The Power of AI in Predictive Maintenance

23:58 Overcoming Challenges in Predictive Maintenance

26:21 Setting Goals for Predictive Maintenance

27:13 Addressing Variability in Production Processes

29:14 Understanding Predictive Maintenance: The Five Stages

34:22 The Importance of Feedback in Predictive Maintenance

40:28 What Predictive Maintenance Can and Can't Do

Takeaways

1. Predictive maintenance aims to reduce unplanned downtime costs.
2. It's essential to understand the difference between predictive maintenance and condition-based maintenance.
3. Most failures are not age-related, which is why predictive maintenance is crucial.
4. Data-driven insights can significantly improve maintenance strategies.
5. Human judgment remains vital in interpreting predictive maintenance data.

• Connect with John on Linkedin : https://www.linkedin.com/in/johnsewellreliability/
• Reach out to John's business : https://jsinsightconsulting.com/

Summary

In 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.

Chapters

00:00 Introduction and Professional Journey

06:20 The Importance of Decision-Making in Reliability

08:16 Common Mistakes in Maintenance Organizations

12:48 Understanding Problems vs. Symptoms

15:45 Crafting Effective Problem Statements

19:17 Prioritizing Problems and Solutions

22:03 Common Reliability Issues and Solutions

28:25 Developing a Reliability Strategy

31:34 Building a Business Case for Reliability

37:10 Advice for New Reliability Leaders

Sound 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 Takeaways

• Selecting 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.

Summary

In 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.

Chapters

00:00 Welcome to Season Three!!!

02:37 The New Structure and Focus for the Season Explained

05:31 Engagement and Listener Interaction

Takeaways

• This 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.

• 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/

Summary

In 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.

Chapters

00:00 Introduction to Rob Mora and Cohesive

04:26 Understanding Asset Management and Reliability Challenges

06:53 Common Hurdles in Transitioning to Proactive Management

09:26 Cultural and Organizational Changes Required

11:59 The Importance of ROI in Asset Management

14:42 Real-World Examples of Overcoming Challenges

17:13 Lessons Learned in Asset Management

19:44 Practical Advice for Reliability Engineers

22:36 Avoiding Common Pitfalls in Asset Management

25:09 Why Choose Cohesive for Maximo Integration

27:43 Conclusion and Future Engagements

Takeaways

1. Rob Mora emphasizes the importance and difficulty of transitioning from reactive to proactive asset management.
2. Cohesive focuses on connecting reliability strategy with real-world execution.
3. Data chaos is a common hurdle in asset management that needs addressing.
4. Cultural change is as important as technology in asset management maturity.
5. Leadership buy-in is crucial for successful asset management initiatives.
6. Small wins can build momentum in asset management projects.
7. Measuring success and ROI is essential for long-term buy-in.
8. Companies often treat asset management as a maintenance project rather than a business strategy.
9. Engaging technicians and frontline workers can provide valuable insights.
10. Starting small and scaling up is a practical approach to asset management.

Get Evan's free tools : https://www.evanpowell.com.au/

Connect with him : https://www.linkedin.com/in/evanpowell90/

Summary

In 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.

Chapters

2:00 Introduction to Spares Inventory Management

11:40 Understanding the Challenges of Spares

20:30 Frameworks for Effective Inventory Control

25:03 The Relay Race of Information Transfer

29:45 Demand-Driven Purchasing and Its Impact

30:04 Preventive Maintenance Planning

34:13 Review Cycles for Effective Inventory Management

39:50 Aligning SOP Processes with Spare Parts Strategy

43:32 Advice for Site Leaders on Spare Strategy

45:06 The Future of Spares and AI Integration

Takeaways

1. Spares inventory often has a long tail with 95% of usage coming from 5% of items.
2. Understanding the criticality of parts is essential for effective inventory management.
3. Daily review cycles are crucial for managing replenishment and inventory control.
4. Work orders should drive the demand for purchasing inventory.
5. Visual management of inventory data can facilitate better decision-making.
6. Engaging vendors in the inventory management process can lead to better outcomes.
7. Preventive maintenance should be integrated with inventory management strategies.
8. Regularly reviewing inventory usage helps in optimizing stock levels.
9. AI can enhance predictive maintenance but requires quality data to be effective.
10. Creating a culture of collaboration between engineering and supply chain teams is vital for success.

Keywords

spares management, inventory control, demand-driven purchasing, maintenance strategies, engineering teams, supply chain management, criticality assessment, review cycles, AI in inventory, optimization

Show Links:

• Julien's Linkedin : https://www.linkedin.com/in/julien-maffre-74ba9023/
• Amsyst : https://amsyst.com/

Summary

In 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.

Chapters

00:00 Introduction and Journey Overview

04:44 The Evolution of Asset Management

07:29 Understanding Asset-Centric Approaches

10:17 The Three Pillars of Asset Management

12:57 Master Data: The Foundation of Strategy

15:51 Challenges in CMMS and Change Management

21:27 Transitioning CMMS: Challenges and Opportunities

23:50 Understanding Risk Profiles in Asset Management

27:20 Three Layers of Decision-Making in Asset Strategy

28:50 Asset Strategy: Balancing Maintenance and Investment

32:36 Real-World Examples: Transforming Asset Management

38:13 The Role of AI in Asset Management

43:31 Advice for Young Reliability Engineers

Takeaways

• Asset 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.

📌 Connect with Damien and his team at : https://oepartners.com.au/

📌 Connect with Damien on LinkedIn : https://www.linkedin.com/in/laceydamien

Summary

In 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.

Takeaways

• Damian 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."

Chapters

07:14 - The Toyota Experience

13:41 - Identifying Bottlenecks in Manufacturing

19:55 - Case Study: Catering Company Improvements

23:08 - Engaging Teams for Effective Change

25:08 - Balancing Theory and Practice in Continuous Improvement

30:20 - Sustaining Change: Making Improvements Stick

33:49 - Unlocking Potential through Maintenance and Reliability

37:13 - Upskilling Teams for Long-Term Success

38:56- Lightning Round: Insights and Reflections

Summary

In 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.

Takeaways

• Continuous 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.

Titles

• Unlocking Continuous Improvement in Manufacturing
• The Power of Team Engagement in Operations

Sound Bites

• "It's about overcoming fear of change."
• "Celebrate small wins to keep morale high."
• "What’s the problem we’re trying to solve?"

Chapters

06:15 -Defining Continuous Improvement: Tools and Approaches

09:26 - Practical Applications of Continuous Improvement

12:10 - Engaging Teams in Continuous Improvement

15:35 - Safety in Manufacturing: A Continuous Improvement Perspective

18:17 - Leadership in Continuous Improvement

21:24 - Coping with Pressure in Operations Management

24:10 - Handling Challenges and Team Engagement

31:28 - Data-Driven Problem Solving

33:50 - Addressing Underperformance in Teams

35:57 - Navigating Technology Adoption Challenges

40:01 - Overcoming Fear of Change

45:09 - The Importance of Pre-Meeting Discussions

46:37 - Learning from Failed Initiatives

50:14 - Sustaining Improvements in Operations

53:30 - Balancing Ambition and Employee Well-Being

55:46 - Recommended Resources and Quotes

Show notes 

Get the checklist Jeff mentioned : https://info.peopleandprocesses.com/planning-checklist-podcast

Follow Jeff on LinkedIn : https://www.linkedin.com/in/jeffshiver/

Summary

In 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.

Chapters

05:46 Jeff Shiver's Journey in Reliability

08:35 Impact of Maintenance on Business Viability

10:59 Common Reliability Mistakes in Organizations

13:55 Understanding Maintenance Strategies

16:30 The Importance of Kitting and Staging

19:07 Avoidable Delays in Maintenance Execution

22:10 The Role of Planning and Scheduling

24:28 Precision Maintenance and Avoiding Defects

27:26 Building Effective Partnerships with Production

30:07 Prioritising Maintenance Work

32:15 The Impact of Reactive Work on Planned Maintenance

35:00 Evaluating the Value of Preventive Maintenance

42:39 Improving PM Programs for Better Efficiency

45:45 Criticality and Its Role in Maintenance Strategies

50:43 Changing the Relationship with Maintenance

Takeaways

1. Jeff Shiver has over 20 years of experience in maintenance and reliability.
2. Many organizations still make basic reliability mistakes.
3. Effective maintenance strategies require proper planning and scheduling.
4. Kitting and staging are crucial for efficient maintenance execution.
5. Reactive maintenance is more costly and less safe than planned maintenance.
6. PMs should address likely failure modes to add value.
7. Criticality in maintenance should focus on where the organisation is losing money.
8. Inversion thinking can help prevent issues before they arise.
9. Common sense practices are often overlooked in maintenance.
10. Engaging technicians in the PM process leads to better outcomes.

Summary

In 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.

Chapters

00:00 Introduction to Simon Murray and His Work

04:35 Understanding the Three Stages of Maintenance

08:27 Industry Insights and Challenges

12:05 Overcoming Leadership Resistance to Reliability Investments

20:37 Exploring Simon's Key Programs

30:11 Steps to Achieve Maintenance Excellence

35:03 The Seven Deadly Sins of CMMS

38:59 Advice for Leaders in Maintenance and Reliability

Takeaways

Maintenance 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.