The reliability landscape is rapidly transforming, but are organizations truly ready for this evolution? In this thought-provoking episode, we reunite after our individual "side quests" working with different customers to discover we've both encountered the same concerning pattern across manufacturing facilities.

While technology advances at breakneck speed—from pixelated camera phones to sophisticated AI systems in just a few decades—the cultural foundations of reliability and maintenance strategies are evolving at a glacial pace. This creates a dangerous disconnect: companies eagerly investing in IoT sensors, machine learning algorithms, and data historians while neglecting fundamental reliability practices that would make these investments worthwhile.

We share a sobering case study of a critical cooling tower failure that cost over £100,000 in emergency measures, despite previous recommendations for a £2,000 monitoring solution. This exemplifies how organizations often pursue technological silver bullets while overlooking basic maintenance fundamentals. The cooling tower had never received lubrication despite being a lubrication-dependent motor—a simple practice that could have prevented catastrophic failure.

The episode explores why AI and machine learning belong at the top of the reliability maturity assessment, not as shortcuts to excellence. While these technologies show tremendous promise, they require clean historical data, established maintenance practices, and experienced professionals who understand failure modes to interpret their findings. Without these foundations, organizations risk drowning in information while suffocating for wisdom.

Whether you're a maintenance professional navigating digital transformation or a leader making technology investment decisions, this episode offers crucial perspective on balancing innovation with reliability fundamentals. The future belongs to those who master both.

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What does it really take to keep 81 manufacturing sites around the world running at world-class reliability standards?

In this episode, I sat down with Pablo, the Reliability Champion at SKF, the world’s leading bearing manufacturer, to find out. And this chat was packed with gold.

Pablo opened up about how SKF have built something seriously special. Their Maintenance Excellence system brings together the best of Japanese TPM and reliability-centered maintenance to create a global standard that actually works, site to site, culture to culture.

But here’s the standout bit for me. It’s not just about the systems or tools. It’s about the people. SKF have cultivated a real community of over 400 maintenance professionals across the globe. They’re not just clocking in and out. They’re sharing wins, solving problems together, and raising the bar as a unit.

We also talked about their week-long Maintenance Excellence Bootcamps run across three continents, combining deep-dive training with hands-on work to embed excellence into their culture. Add in their push towards smarter CMMS rollouts and the integration of AI for predictive maintenance, and it’s clear these guys aren’t just keeping up. They’re leading the way.

The part that stuck with me most was this quote from Pablo:

"You can have the most perfect system in the world, but if the people aren’t on board, it’s worthless."

That hits home. It’s not the tech. It’s the trust. It’s the culture. It’s the belief that people make reliability real.

Whether you’re running one site or a global operation, there’s something in this conversation for everyone who believes in better maintenance. Tune in and see how SKF keep evolving while staying true to what matters most: people, purpose, and precision.

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In this episode, I sat down with Joseph Anderson from Reliability X for one of the most honest and refreshing conversations I’ve had on reliability. We didn’t just talk tools, data, and KPIs… we talked about what really matters: people.

Joseph shares his own journey, from what he calls being a “defect initiator” (yep, he says he would’ve fired himself back then!) to becoming a leader who changed plant performance by focusing first on the people behind the machines. What really hit me was when he mentioned that maintenance departments have an 80–85% divorce rate. It stopped me in my tracks. That stat alone says it all: reliability is about more than machines. It’s about creating workplaces that don’t destroy home lives.

What I love about Joseph is he breaks down reliability into simple human truths. Relationships between operators and maintenance, leaders who actually listen, collaboration over blame. He even draws lessons from his time running restaurants to show how these principles go beyond manufacturing—they’re about how we treat people, full stop.

We also got real about why companies trip themselves up: blaming individuals instead of fixing broken systems, chasing completion rates instead of real results, buying the latest tech without teaching people how to use it properly, and cutting costs today only to pay big later.

Through it all, Joseph keeps coming back to the same truth: when people know you care, they’ll care for the equipment. It’s that simple.

If you lead a maintenance team, run a plant, or just want to get better at building a strong, reliable culture, this one’s for you. As Joseph says:
 "Maintenance is simple. Don’t overcomplicate it. Don’t make it harder than it needs to be."

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What’s the real value of reliability in your organisation?

It’s a simple question—but one that’s often overlooked before businesses jump into big investments in technology or strategy. And yet, it’s the question that sits at the heart of effective asset management.

Over the years, working closely with a wide range of organisations, we’ve seen a common pattern: many skip the most important first step—getting crystal clear on what reliability actually means for their business. Without that alignment, even the best condition monitoring tools or maintenance strategies can miss the mark.

In this episode, we talk about how to build a strong business case for reliability—one that really connects with leadership and drives decisions. We also unpack why Overall Equipment Effectiveness (OEE) is such a powerful metric. It gives a full-picture view by balancing availability, performance, and quality—essential ingredients for any reliability programme. Measuring these before you start sets the stage to show true financial impact down the line.

Here’s a stat worth paying attention to: about 80% of equipment failures are preventable. But prevention doesn’t start with gadgets—it starts with understanding. Too often, companies rush into solutions without first figuring out why their assets are failing in the first place. We share a real-life example of a site that almost spent a fortune on sensors that would’ve only covered 20% of their critical equipment. A solid assessment saved them from a costly misstep.

The real game-changer? It’s not tech—it’s people. Awareness and training spark the kind of cultural shift that keeps reliability efforts alive and thriving. When everyone—from the shop floor to the boardroom—understands their role in keeping things running, that’s when real transformation happens.

Whether you’re just getting started or trying to breathe new life into an existing programme, this episode lays out a roadmap to make reliability a true business driver—not just a technical checkbox.

Tune in now and learn how to ignite your organisation’s reliability journey.

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What if the key to making electric motors more reliable isn’t a complex new technology but a better understanding of the fundamentals of electrical engineering?

In this episode, we sit down with Mark Gurney, a reliability and electrical engineering expert, to hear his journey from troubleshooting issues at biogas plants to leading a full-scale reliability program at an Australian dairy company. Mark takes us behind the scenes of a commonly overlooked problem, electrical fluting in bearings. He breaks down why strong motor management and condition monitoring practices are essential for long-term reliability.

We also dive into the broader impact of electric motors in industrial settings and the small yet powerful maintenance habits that make a difference, like using silica gel packs to keep humidity in check. Mark shares his insights on the importance of cleanliness, professionalism, and passing on knowledge to the next generation of engineers.

You'll hear real-world lessons from his time on biogas sites, including how proper earthing and a structured troubleshooting approach can prevent serious issues like bearing currents. He also highlights the value of hands-on training programs that bridge the gap between theory and practice.

As we wrap up, we touch on upcoming discussions around shaft current problems and thank Mark for sharing his knowledge. We can’t wait to have him back for more.

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Curious about where condition monitoring is headed and how it’s changing the way we approach maintenance? In this episode, we dive into the strategic decisions shaping our industry and explore how adapting to new technologies can elevate operations. Broadcasting from our brand-new podcast studio, we’ll talk about how spontaneous conversations often lead to our best ideas—and how systems like Acoem are driving efficiency in exciting ways. We’ll also discuss the increasing demand for asset reliability training and how it’s reshaping the way clients think about maintenance.

How do you find the balance between spontaneity and strategy in content creation? We’ll share our approach to planning podcasts and videos to deliver high-quality content, including ideas for listener polls and covering multiple topics in a single episode. You’ll also hear about our new office in Wakefield, a key part of our UK expansion, and the importance of hands-on data collection in today’s world of AI and wireless sensors. Plus, we’ll give you a glimpse into how our video strategy is fueling growth and amplifying our message.

This episode is packed with innovative ideas around condition monitoring and the rise of the “hybrid engineer.” We’ll talk about why engineers remain critical in this tech-driven revolution, highlighting the balance between cutting-edge systems and human expertise. Companies like Acoem are leading the way with solutions that improve plant reliability, while data analysis turns raw numbers into actionable steps to optimize operations. Join us as we explore the game-changing impact of embracing new technologies, with insights on accountability, reliability, and the exciting products and workflows that are redefining the future.

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Step into a world where agriculture meets precision engineering with our special guest host, Harry Crane, affectionately known as "Mr. Solve." This episode promises to transform your understanding of maintenance practices as we uncover how Harry transitioned from the fields to become a pivotal part of our business’s Solve division. His role has been crucial in the establishment of our state-of-the-art repair center, a testament to his dedication and innovative spirit. You'll learn how early experiences with steam engines and a passion for mechanics laid the groundwork for a precision-driven approach to solving complex mechanical issues.

Join us as we unravel the parallels between agricultural and industrial maintenance, highlighting the vital role of proactive strategies in minimizing downtime. Through an insightful case study on biogas motors and compressors, we demonstrate the advantages of conducting repairs in a fully equipped center versus on-site fixes. Harry shares his journey of mastering complex repairs after completing an EX course, emphasizing the foresight needed in selecting the right tools and resources. This episode underscores the importance of fostering a culture change—moving from reactive to proactive maintenance—and educating clients on the long-term benefits of reliability engineering.

Concluding with a heartfelt appreciation for our listeners, we reflect on the challenges of implementing cultural shifts in maintenance practices. Harry's journey from agriculture to precision engineering showcases how the right tools and training can elevate work standards and engineer satisfaction. As we continue to champion reliability and precision, we express our excitement about launching a new podcast studio, promising to enhance content production and deliver even more insightful episodes. We thank you for your support and look forward to sharing more stories of innovation and dedication in our upcoming episodes.

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What if cutting-edge maintenance technology could revolutionise the biogas industry? Discover the transformative impact of condition-based monitoring as we take you through our collaboration with Future Biogas. Our journey celebrates a surge in listener engagement and introduces exciting future plans, including our move to a new studio at Maintain HQ. This transition will enable us to create even more high-quality content, such as webinars and product demonstrations, while enhancing our focus on the unique challenges and opportunities presented by the biogas sector.

As we explore the evolving landscape of biogas, tune in to learn about the advancements in maintenance technologies, like vibration analysis, infrared thermography and optical gas imaging, that are making significant strides. We highlight the game-changing Opgal EyeCgas camera and its role in providing affordable, comprehensive monitoring solutions. By advocating for more frequent inspections beyond the annual norm, we aim to enhance insurance and risk assessment processes, ensuring that biogas sites operate efficiently and reliably. Our discussion extends to the importance of integrating online monitoring systems, like the MVX, to mitigate risks associated with equipment.

Experience the sustainable benefits of biogas production as we delve into the process from feedstock acquisition to renewable energy generation. With a focus on maintaining optimal conditions, our insights cover everything from vibration analysis to the critical role of CHP plants. The collaboration with Future Biogas empowers operators with a holistic maintenance package, supporting local communities and stabilising energy costs. Join us as we share the expertise required for handling ATEX motors, maintaining accurate audit trails, and ensuring seamless operations across multiple sites, emphasising how advanced technology and strategic planning are reshaping the biogas industry.

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Join us for an enlightening conversation with Bertrand from Acoem, who expains how the Falcon Vibration analyser uses Accurex technology. Imagine diagnosing machine defects without needing historical data—this is what Accurex achieves through its innovative use of AI and vibration measurements. Broadcasting straight from France, Bertrand offers an insider's look at how Accurex transforms vibration data collection, especially when historical data trends are unavailable, captivating us with its ability to identify a bearing defects and fault conditions from one reading with advanced diagnostics.

We also explore the fusion of human expertise and AI in the realm of vibration diagnostics. With a robust database of over 50,000 expert-verified diagnostic advice from real use experts in the field this database has been fused into the falcon. We dive into the deployment of these powerful capabilities in Edge devices, ensuring machine diagnostics are both immediate and independent of cloud services. This segment also raises thought-provoking questions about the future of machine diagnostics and the dynamic interplay between advancing AI technologies and essential human insight.

Our discussion takes an exciting turn as we examine the broader implications of Accurex technology. Envision a future where even non-experts can make informed maintenance decisions with confidence, particularly for simpler machinery like pumps and fans. While Accurex is already reshaping industrial maintenance, Bertrand shares insights into the challenges and future prospects of tackling more complex machines. We wrap things up by highlighting how Nest Vision aimed at simplifying access to critical industrial health data, and reflect on the invaluable role of user feedback in our ongoing quest for improvement. This episode is a must-listen for anyone interested in the future of AI-driven reliability management.

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Back to basics with VA Best Practice by understanding the strategic placement of sensors and the critical role of industry standards like ISO standards. We promise you'll walk away with insights into how to avoid the pitfalls of slipping standards and cost-cutting measures that could lead to missed defects and lost customer trust.

Our discussion takes a deep dive into the understanding of effective vibration analysis strategies, emphasising the importance of repeatable processes and strategic investments in technology. Discover the truth behind common misconceptions around digital solutions and the risks tied to minimising sensor usage. We share our passion for upholding high standards and our dedication to educating both engineers and clients on proper data collection techniques, ensuring that reliability and efficiency are always at the forefront.

In an industry where reliability can make or break success, we challenge the status quo by exploring the broader context of plant operations and the need for robust maintenance frameworks. Addressing faulty strategies head-on, we highlight how technology must complement, not complicate, existing processes. Join us for an engaging conversation that not only questions current practices but also inspires action toward a holistic approach to maintenance and reliability.

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