Reliability 4.0

On this episode of Reliability 4.0, we chat with Ricardo Rojas, Maintenance Manager at Tenaris, a global leader in steel pipe manufacturing for the oil and gas industry. Ricardo shares insights from his extensive international experience, from Venezuela to Saudi Arabia and now the U.S., where he oversees maintenance operations at Tenaris’s heat treatment facility. He discusses how his team focuses on minimizing non-operational interruptions and achieving industrial excellence by aligning safety, quality, and cost.

Ricardo also explores how Tenaris uses tools like IBA software for process control and signal monitoring, as well as AI-powered vibration analysis to identify equipment issues proactively. He emphasizes the importance of communication between maintenance teams and operators to uncover hidden inefficiencies and prevent potential failures. With a passion for continuous improvement, Ricardo offers valuable advice on embracing new technologies and empowering teams to meet modern maintenance challenges. Tune in for a practical discussion on building reliable systems and fostering innovation in industrial operations.

On this episode of Reliability 4.0, we chat with Kyle Grygotis, Hub Maintenance Manager at Imerys, a global leader in specialty minerals. Kyle shares his role overseeing maintenance activities at the Chesapeake, Virginia, plant and his expanded responsibilities supporting additional plants along the East Coast. He explains how his team tracks key performance indicators such as schedule compliance, equipment availability, and preventative maintenance compliance to ensure plant reliability, and how they use monthly downtime reviews to identify quality improvements.

Kyle discusses their use of root cause analysis (RCA) for downtime events lasting more than 8 hours, focusing on quality assurance and preventing rework. He also dives into how emerging technologies like AI and IoT are enhancing equipment monitoring and predictive maintenance, while noting the importance of selecting solutions that fit each plant’s unique needs. Kyle shares practical advice for fellow maintenance managers, emphasizing the value of starting with cost-effective, reliable tools and building from there to create a roadmap for continuous improvement.

On this episode of Reliability 4.0, we chat with Edwin Gutierrez, corporate reliability engineer at Ash Grove Cement. Edwin shares how EasyRCA has transformed their root cause analysis process, replacing an inefficient legacy system and standardizing RCA practices across 12 plants in North America.

He highlights the importance of training and involving team members at all levels to implement corrective actions effectively. Edwin also explains how EasyRCA’s Action Center and dashboard features help track and complete corrective actions, contributing to reduced downtime and improved reliability. With over 140 RCAs completed in just 10 months, Ash Grove Cement is seeing significant cultural and operational improvements.

On this episode of Reliability 4.0, we chat with Derek Wilken, the Maintenance Project Lead at G&W Electric. Derek explains how his team handles preventive maintenance across various facilities and achieves a ~98% completion rate on roughly 600 PM tasks each month.

Derek also talks about the enabling role of technology, such as the eMaint CMMS by Fluke and tablets that allow each member of the maintenance team to move efficiently throughout facilities and increase productivity. Derek is very optimistic about the potential of AI in predictive maintenance, and he also emphasizes the importance of involving machine operators in the decision-making process to ensure the seamless integration of new procedures and enhance reliability.

On this episode of Reliability 4.0, we talk with Matt Sadler, a Global Reliability Engineer at ADM. Matt explains how ADM adopted EasyRCA to simplify their root cause analysis processes, consolidating from six different RCA tools into one. This unification has improved data access and allowed for more informed decision-making throughout their facilities.

Matt points out that EasyRCA’s user-friendly design has empowered a diverse group of ADM employees—from new graduates to experienced professionals—to perform comprehensive RCAs effortlessly. He also mentions some unexpected advantages, such as boosted morale and increased efficiency in ADM’s packaging lines, and stresses the significance of fostering relationships within the organization to improve reliability and enhance processes.

On this episode of Reliability 4.0, we talk with Ernie Newmes, Corporate Maintenance Manager at Enviva. Ernie shares how his team turns wood scraps from sustainable sources into renewable energy by making pellets that help displace coal in power plants.

He dives into his approach to data-driven maintenance using tools like Power BI and the importance of managing key performance indicators (KPIs) to optimize plant performance. Ernie also discusses the challenges of implementing root cause analysis (RCA) and why focusing on simple solutions can often be the most effective.

On this episode of Reliability 4.0, we chat with Debasmita Mukherjee, Senior Manager of Product Reliability at Bloom Energy. Debasmita shares how her team at Bloom ensures clean, reliable power generation solutions using solid oxide fuel cell technology.

She discusses the importance of embedding reliability principles right from the product design phase and explains how balancing key performance metrics with long-term reliability is crucial for success. Debasmita also highlights the challenges of getting cross-functional teams on board with a structured problem-solving approach and shares practical insights on using data-driven strategies to improve product reliability.

On this episode of Reliability 4.0, we talk with Satyaki Ganguly, Senior Reliability Manager at Wolfspeed. Satyaki explains how his team makes sure silicon carbide devices stay reliable even in extreme conditions by using advanced testing and Root Cause Analysis (RCA).

He discusses how RCA helps identify failures, the role of physics in faster testing, and the latest innovations in semiconductor reliability. Satyaki also emphasizes the importance of balancing performance with reliability for long-term success. Tune in if you want practical tips on improving your reliability engineering skills and applying RCA in tough situations.

On this episode of Reliability 4.0, we’re joined by Steve Heavyside, a reliability expert with extensive experience in the steel industry. Steve, who was the Director of Corporate Reliability at Evraz, gives us an inside look at his efforts to move the industry from reactive, fix-it-when-it-breaks maintenance to proactive, forward-thinking strategies using the latest technology.

Steve talks about the challenges of updating old systems, getting frontline workers involved in Root Cause Failure Analysis (RCFA), and how small improvements can lead to big results in reliability. He also discusses the importance of precise maintenance and continuous learning to build a strong reliability culture. Tune in for practical insights on combining traditional methods with modern tools to boost reliability.

On this episode of Reliability 4.0, we chat with Matthew Knuth, Business Development Leader at SPM Instrument. Matthew discusses what he sees as the biggest challenge for the industry at the moment - the pace of technical innovation and top down implementations of condition monitoring (CM) programs without collaboration from the engineers and shop floor operators.

Matthew identifies root cause analysis (RCA) as indispensable for an effective condition monitoring program. He also emphasizes training, cross-team communication, and giving everyone a seat at the table as critical components of change management. If you want to build a CM and RCA program where people “step across the hall” and have cross functional teams and communications that keep operations running smoothly, this episode is for you!