“What happens when your most experienced maintenance technicians retire? And how prepared is your organization to retain the knowledge they take with them?”

In this episode of Reliability 4.0, Casey Pritt from Smurfit WestRock explores one of manufacturing’s biggest challenges: preserving decades of maintenance knowledge while embracing new technology.

Drawing from her IMC presentation, Casey explains how each generation has shaped maintenance practices—and why the future depends on combining hands-on experience with modern digital tools rather than choosing one over the other.

We discuss:

🔸 Why maintenance knowledge is disappearing as experienced workers retire

🔸 How different generations have shaped maintenance strategies

🔸 Why technology should complement—not replace—equipment knowledge

🔸 The challenge of planning large paper mill outages with thousands of contractors

🔸 How AI could help capture expertise before it leaves the workforce

If your organization is preparing for the next generation of maintenance professionals, this episode offers practical insights into protecting knowledge while driving reliability forward.

This episode is available on:

📺 YouTube: https://youtu.be/RDo_8PsbQwY

🎧 Apple Music: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA helps capture and standardize reliability knowledge?👉 https://easyrca.com/engage

#Reliability40 #Maintenance #ReliabilityEngineering #KnowledgeTransfer #AssetManagement #Manufacturing

“Being the best firefighter is not a career strategy.” In this episode of Reliability 4.0, Jeremie Lieb from Worthington Steel shares how his team is transforming maintenance culture by moving away from reactive firefighting and toward proactive reliability practices.

Jeremie explains how Worthington Steel is combining reliability strategy, condition monitoring, AI tools, and frontline engagement to improve maintenance performance across multiple facilities.

We discuss:

🔸 Why reactive maintenance creates long-term safety and reliability risks

🔸 How Worthington Steel is approaching NFPA 70B compliance and electrical reliability

🔸 Why PM follow-up quality matters more than simply completing tasks

🔸 How AI can support planners, maintenance leaders, and RCA thinking

🔸 Why proactive maintenance starts with changing culture—not just adding technology

If your organization is trying to reduce downtime, strengthen reliability culture, or improve maintenance execution, this episode is packed with practical insights.

This episode is available on:

📺 YouTube: https://youtu.be/r89eT9eQohc

🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA can support your reliability program?👉 https://easyrca.com/engage

#Reliability40 #ReliabilityEngineering #Maintenance #RootCauseAnalysis #AssetManagement #Manufacturing

“Dashboards don’t improve reliability. People do.” In this episode of Reliability 4.0, Jordan Gair from Gold Fields shares how his team improved reliability at a large-scale gold mining operation by investing in frontline leaders, coaching, and proactive maintenance culture.

Jordan explains why many reliability transformations fail—not because teams lack data or technology, but because organizations spend too little time supporting the people closest to the work.

We discuss:

🔸 Why frontline coaching matters more than reporting dashboards

🔸 How Gold Fields improved plant reliability through proactive maintenance

🔸 The role of inspections, defect elimination, and quality notifications

🔸 Why sustaining culture change is harder than launching it

🔸 How AI can support maintenance tactics and improve work management

If your organization is trying to improve reliability culture, reduce downtime, or strengthen frontline accountability, this episode is packed with practical insights.

This episode is available on:

📺 YouTube: https://youtu.be/sipbGTXSAns

🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA can support your reliability program?👉 https://easyrca.com/engage

#Reliability40 #Mining #ReliabilityEngineering #Maintenance #AssetManagement #ContinuousImprovement

Wastewater plants have gotten away with reactive maintenance for decades. That’s changing. In this episode of Reliability 4.0, Lauren Michael from City of Cedar Rapids shares how her team is building a proactive reliability culture inside a 45-year-old wastewater treatment plant.

Lauren explains why executive sponsorship was critical to launching their reliability transformation, and how involving leadership from the very beginning helped create buy-in across operations, finance, HR, and city leadership.

We discuss:

🔸 Why many wastewater plants are still operating reactively

🔸 How Cedar Rapids launched “Program Phoenix” to improve reliability

🔸 Why executive sponsorship must start at kickoff—not after the fact

🔸 How RCA helped shift the culture away from blame

🔸 Why wastewater operators need reliability more than ever as infrastructure ages

If your organization is trying to improve asset performance while working with aging infrastructure and limited resources, this episode is full of practical lessons.

This episode is available on:

📺 YouTube: https://youtu.be/65UtsavmfJg

🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA can support your reliability journey?👉 https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #Wastewater #AssetManagement #ReliabilityEngineering #Maintenance

Sometimes the perfect RCA becomes the enemy of solving the problem. In this episode of Reliability 4.0, Juan Mendoza from Fresenius Medical Care shares how his team uses Rapid Problem Solving (RPS) to respond to equipment failures faster, reduce repeat downtime, and build stronger problem-solving habits across manufacturing teams.

Juan explains why most equipment issues don’t need weeks of investigation—and how setting clear rules around speed, ownership, and execution helps teams stay focused on solving problems instead of endlessly analyzing them.

We discuss:

🔸 Why every unplanned downtime over 45 minutes triggers an RPS.

🔸 How “containment first” keeps production moving before investigation starts.

🔸 Why rapid investigations must be completed within five days.

🔸 The difference between rapid problem solving and deep RCA investigations.

🔸 Why most reliability improvements still come from mastering the basics.

If your organization struggles with recurring downtime or slow investigations, this episode offers a practical framework for building a faster reliability culture.

This episode is available on:

📺 YouTube: https://youtu.be/9CeZ3wcFjAU

🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA can help your team solve problems faster?👉 https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #Manufacturing #Maintenance #ContinuousImprovement #ReliabilityEngineering

Maintenance isn’t just technical. It’s emotional, political, and people-driven. On this episode of Reliability 4.0, Alejandro Nuñez from La-Z-Boy shares how his team is building a structured maintenance and reliability system across multiple plants, starting with simple metrics, RCA adoption, and consistent processes.

Alejandro explains why reliability programs fail when companies wait for the “perfect system” instead of building consistency with the people and processes they already have.

We dig into:

🔸 Why structure improves reliability without killing creativity

🔸 How La-Z-Boy rolled out RCA across plants

🔸 Why maintenance transformation is a people challenge first

🔸 The importance of starting small with metrics and processes

🔸 Why inconsistency—not complexity—is what breaks reliability programs

If your organization is trying to move beyond reactive maintenance, this episode is packed with practical lessons on building systems that actually stick.

This episode is available on:

📺 YouTube: https://youtu.be/HW5_j_4Y6hQ

🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699

Or wherever you get your podcasts!

Want to explore how EasyRCA can support your RCA program? Start here: https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #Maintenance #AssetManagement #ReliabilityEngineering

The best thing we ever did was just get started. In this episode of Reliability 4.0, Phil White, Chief Maintenance Officer at United Utilities, shares how his team transformed maintenance culture across one of the UK’s largest water and wastewater providers.

Over the past six years, United Utilities rebuilt its maintenance strategy from the ground up—reworking hundreds of thousands of PM tasks, investing in technician capability, and creating a culture focused on continuous improvement instead of reactive work.

We dig into:

🔸 Why maintenance excellence is more about people and culture than tools

🔸 How United Utilities rebuilt its entire PM workbank using reliability principles

🔸 The role of PM compliance and PM yield in driving accountability

🔸 How “bad actor” dashboards help identify long-term reliability problems

🔸 Why Phil believes the hardest part of transformation is simply getting started

If your organization is trying to move from reactive maintenance to a proactive reliability culture, this episode offers practical lessons from a large-scale transformation journey.

This episode is available on:

📺 YouTube

🎧 Apple Music

Or wherever you get your podcasts!

Want to improve your RCA and maintenance processes? 👉 https://easyrca.com/engage

#Reliability40 #MaintenanceExcellence #RootCauseAnalysis #AssetManagement #PreventiveMaintenance #ContinuousImprovement

“In data centers, you don’t have the luxury of downtime—but you do have redundancy.” In this episode of Reliability 4.0, Lee McClish, Director of Maintenance and Reliability at NTT Global Data Centers , shares how he built a reliability program from scratch for a fast-growing organization with 21 U.S. sites and hundreds of mission-critical assets.

Lee discusses how he overcame the challenges of redundancy-driven complacency, built a proactive culture, and created measurable results by focusing on preventive maintenance (PMs), KPIs, and effective communication.

We dig into:

🔸 How NTT's data centers balance redundancy with reliability

🔸 Why reliability and culture are the hardest aspects to change

🔸 How Lee built PMs and KPIs from scratch to track progress

🔸 The importance of educating operators and “preaching” proactive maintenance

🔸 How Lee uses scorecards to hold teams accountable and drive continuous improvement

If you’re building a reliability program in a growing, complex environment—or struggling with culture change—this episode has the lessons learned you can implement today.

This episode is available on

📺 YouTube

🎧 Apple Music

Or wherever you get your podcasts!

Want to improve your reliability culture and program? 👉 https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #DataCenters #PreventiveMaintenance #ReliabilityEngineering #ContinuousImprovement

“AI will just get you to the wrong answer faster—if your data isn’t right.” In this episode of Reliability 4.0, Brian Heinsius from Eco Materials shares how they’re building a reliability program from the ground up—starting with data, systems, and remote monitoring across new sites. From setting up Maximo and asset hierarchies to deploying sensors and dashboards, Brian walks through what it takes to create a scalable reliability foundation before layering on advanced analytics.

We dig into:

🔹Why building a clean, accurate data foundation comes before AI

🔹How remote monitoring enables small teams to manage multiple sites

🔹How AI can help analyze data—but still requires careful validation

🔹Why starting with simple RCA (like 5 Whys) is often enough early on

🔹How to use condition-based signals to trigger maintenance actions

If you’re trying to scale reliability across sites—or exploring AI in maintenance—this episode is a practical look at what to build first.

This episode is available on:

📺 YouTube

🎧 Apple Music

Or wherever you get your podcasts!

Want to strengthen your RCA foundation? 👉 https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #AssetManagement #PredictiveMaintenance #AI #ReliabilityEngineering #DigitalTransformation

In this episode of Reliability 4.0, Glenn Simmonds from Sabert Corporation shares how they built a reliable culture from the ground up—starting with a reactive culture and transforming it into proactive, sustainable machine reliability.

Glenn discusses how Sabert created a roadmap for success, introduced tools, and overcame obstacles in getting leadership and technicians aligned on the importance of machine reliability and root cause analysis.

We dig into:

🔸 The steps Sabert took to build a machine reliability program from scratch

🔸 How Sabert faced resistance and used change management to turn culture around

🔸 The role of documentation and institutionalizing processes for sustainability

🔸 Why Root Cause Analysis (RCA) and preventive maintenance matter more than reactive repairs

🔸 The key lessons Glenn learned about proceduralizing change in a growing organization

If you’re struggling with change management or trying to build a reliability culture, this episode offers a clear blueprint for success.

This episode is available on:

📺 YouTube: https://youtu.be/MnK3LHfYhBU

🎧 Apple Music: https://podcastsconnect.apple.com/my-podcasts/show/reliability-4-0/6223fe96-8647-4a4e-856f-635785c0426c/episodes

Or wherever you get your podcasts!

Want to see how EasyRCA can help institutionalize reliability?👉 https://easyrca.com/engage

#Reliability40 #RootCauseAnalysis #MachineReliability #ChangeManagement #Maintenance #ContinuousImprovement #ReliabilityCulture