Reliability Gang Podcast

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Ever wondered how a “high-efficiency” motor can start wasting energy and damaging bearings before it’s even been switched on?

We did too. So we tested it.

Using offline motor circuit analysis alongside online motor current signature analysis, we inspected brand-new IE4 motors still sitting in their crates. What we found changed the conversation completely. Critical impedance imbalance straight out of the box. One motor already showing early winding defects before it ever saw load.

That’s the moment labels stop mattering and evidence takes over.

This episode walks through why pairing de-energised and energised testing matters.

Offline MCA tells us what’s happening in the windings – contamination, resistive imbalance, insulation condition. Online MCSA, sampled at 44 kHz with serious resolution, shows us what vibration often can’t: rotor bar issues, air-gap problems, electrical harmonics, inverter-driven bearing currents.

In difficult environments – noisy plants, submersible pumps, generators, limited access assets – current signature analysis often gives cleaner, more repeatable insight than vibration alone. We’re seeing faults that used to hide in the noise.

And this isn’t theory. Across 750+ motors tested in the field, we see a clear link between impedance imbalance and winding health:

• <5% – normal
 • 5–8% – defect initiation
 • 8–15% – accelerated damage
 • >15% – critical

That gives teams something powerful: defensible alarm limits and a simple acceptance test that stops bad assets entering the plant.

There’s a practical win too. On one motor we reduced resistive imbalance from over 30% down to around 3.8% just by cleaning and correctly torquing the terminations. Test. Fix. Retest. Immediate improvement.

The real gains come when sites take this seriously:
 Acceptance testing written into purchase orders.
 Evidence required from the factory.
 Faults confirmed using at least two technologies.

That’s how you reduce energy loss, prevent shaft currents from destroying bearings, and turn condition monitoring into real reliability improvements – not reports that sit on a shelf.

If uptime matters.
 If energy efficiency matters.
 If you want better decisions with less noise and less drama.

This episode shows the path: measure what matters, set your own standards, verify the fix, and keep learning.

Enjoy the episode.
 If it helps you rethink your motor strategy, subscribe, share it with a teammate, and drop a quick review with your biggest testing win or surprise.

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Reliability doesn’t fail because the maths is wrong. It fails because of people. That’s where we begin this straight-talking conversation with Steve Morris, the driving force behind Mainstream. For more than 30 years he has been building something different: a movement that puts real maintenance leaders on stage, replaces the hero firefighter with predictable performance, and keeps the community alive all year round so practitioners can share what actually works without the sales pitch.

We look back at where it started, from a handful of TPM calls to what has grown into the biggest reliability conference in the Southern Hemisphere. But what makes it stand out is how it protects the quality of the peer group, only puts customers on stage, and is built on research that identifies the real blockers—communicating risk, finding funding, and leading culture change. Steve lifts the lid on innovation theatres, curated networking, and the free online platform that now connects more than 5,000 professionals across industries. From mining and water to food and oil and gas, the challenges are different but the root causes are the same—people, incentives, language, trust, and habits.

We also look ahead to Mainstream UK. This will be a focused two-day event with five concurrent tracks, global storytellers from Woodside to Mars, and pricing that removes the excuses. If you have ever felt your best preventative work goes unseen while the 2am saviour gets all the recognition, this is your chance to flip the script. It is about rewarding prevention, learning how to sell the value in finance’s language, and being in rooms where practitioners lead the conversation.

The next five years are critical for reliability. Teams are ageing, technology is moving fast, and the skills gap is widening. The advantage will go to those who make the time to think, to share, and to adopt what already works.

If this resonates, subscribe for more conversations with reliability leaders, share the episode with your team, and leave a review so others can find it. Most importantly, connect with the Mainstream community and take one idea back to your site this month.

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When most people think reliability, vibration analysis is the first thing that comes to mind. But what about the electrical side of your motors. That’s where a lot of hidden damage is happening and it’s often ignored.

In this episode we get into shaft current. It’s been around since variable speed drives first hit the scene but it’s still not well understood and definitely not well managed. These stray electrical currents eat away at bearings and windings, quietly cutting motor life down by decades. The scary part is that from what we are seeing around 90 percent of drive installs haven’t been designed properly to deal with it.

I reference the teachings of electrical condition monitoring expert Mark Gurney to break this down. We look at how to actually detect the issue with oscilloscopes, Rogowski coils and the SKF TechEd tool. We explain the difference between common mode and circulating currents and why quick fixes like grounding rings aren’t always the silver bullet people think they are. Done wrong they can even make the problem worse.

We also talk about Motor Current Signature Analysis MCSA. For me this is the future of motor testing. It gives you the ability to pick up not just electrical faults but mechanical ones too. Bearings rotor bars even belt tension can all be identified just from reading the motor’s electrical signal at the MCC. If you’re serious about IoT and advanced monitoring MCSA is a game changer compared to just scattering sensors everywhere.

The bottom line is this. Why are we okay with motors failing after 10 years when they are designed to run 30 or 40. It’s time to move beyond only looking at vibration and start treating electrical testing as a key part of reliability. Our most critical assets deserve that level of care.

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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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