The Maintainers: A Blue Cap Community Podcast

Today on The Maintainers, David & Jake welcome Dave Zapata, the general supervisor of engineering and maintenance at Chicago Heights Steel (CHS). CHS is the largest special-market mill in the United States and has been running the same type of operation since its founding in 1893. 

Dave calls his time with CHS “his longest summer job” as he joined the company straight out of high school in 1994 as a summer laborer. He instead stayed on, working his way through departments and up the ladder from engineering to mechanical to electrical. 

You’ll hear all about CHS’s history and how they’ve evolved their operations over the years. Dave has been instrumental in leading the implementation of new technologies designed to make their processes safer and more efficient as they produce over 14m fence posts each year. He explains how they’ve managed to reduce downtime while maintaining a delicate balance of maintaining current equipment while replacing outdated machinery. In 2019, the company modernized its mill with a new OT network, virtual machines, and HMI systems, dramatically improving productivity. Dave also reveals exciting plans for further advancements, including new robotic lines for fence post production, underscoring CHS's commitment to staying at the forefront of manufacturing technology.

The trio also discuss Dave’s management philosophy, which centers around hands-on leadership and providing his workers with the same opportunities he had coming up at CHS. He stresses the importance of patience and practical learning for those just beginning in their careers and offers his view of the future of the workforce. 

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Guest Bio

Dave Zapata is the General Supervisor of Engineering and Maintenance at Chicago Heights Steel (CHS), the world's largest special market mill in the United States. Dave's journey with CHS began right out of high school in 1994, when he took what was initially intended to be a summer job. Over the next three decades, Dave transitioned through various roles within the company, gaining in-depth knowledge of mechanical and electrical maintenance.

Dave has been instrumental in modernizing CHS operations, focusing on increasing efficiency and safety. Notably, he spearheaded significant equipment upgrades, reducing the need for manual labor and increasing uptime. His leadership style emphasizes hands-on involvement and fostering a strong rapport with his team.

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Guest Quote

"We went from 1959 to 2020 technology. It was a learning process. My approach is: I take the time to learn. Analyze it, make sure l have all the information. And then come up with a solution, and then implement that solution." – Dave Zapata

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Time Stamps 

00:00 Episode Start 

02:00 Opening Icebreaker

03:40 Dave’s Background
04:30 Segment 01: The Maintainer Mashup

05:00 The operation at Chicago Heights Steel

06:40 Finding rail from 1893

08:40 How operations have evolved over the years

10:45 The importance of your team

11:55 Segment 02: What's in Your Toolkit?

12:35 Leading with a learner's mindset

15:15 Modernizing their manufacturing

18:30 Advice on leveling up in your career

19:50 Segment 03: The Future of Factories

20:40 Dave's recommendations for the future

22:25 Solving for a lack of workers

24:20 Ways to upskill your existing maintainers

26:00 Segment 04: Fix It Funnies

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Links

• Connect with Dave Zapata on LinkedIn
• Check out Chicago Heights Steel
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

In this episode of The Maintainers, hosts David Lee and Jake Hall chat with Rafael Padilha Gama, AKA Rafa, the U.S. and Canada Maintenance and Reliability Director at Ingredion. Rafa shares his extensive background in the maintenance and reliability industry, including his roles at InBev and Unilever. He discusses his journey from electrical electronics in Brazil to handling global operations, bringing a wealth of insights into maintenance, reliability, and automation practices across diverse industries and geographies. 

Rafa emphasizes the blend of technical expertise and leadership needed in effective maintenance roles. He believes the critical aspects include having the right people, robust processes, and utilizing appropriate tools. Rafa’s philosophy of focusing on what one can control and improving what they have autonomy over is central to his approach. He provides examples of how successful maintenance programs can enhance operational efficiencies, such as using asset criticality concepts to unlock bottlenecks and employing technology like sensors to improve predictive maintenance. 

The discussion also touches on cultural challenges and communication strategies necessary for managing teams across different countries. Rafa finds value in ensuring that the message delivered is precisely the message received, especially while dealing with diverse cultures from Brazil to Colombia to the United States. His effective communication practices help ensure alignment and consistency across various teams and operations. 

Finally, Rafa talks about the future of factories, highlighting the increasing role of technology and data in maintenance and reliability. He envisions a future where maintenance professionals become data scientists, utilizing AI and smart sensors to foresee and prevent failures. Rafa’s insights serve as useful guidelines for listeners who strive to drive change and adopt innovative technologies in their maintenance practices.

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Guest Bio

Rafael Padilha Gama boasts decades of experience in the maintenance and reliability industry. He currently serves as the U.S. and Canada Maintenance and Reliability Director at Ingredion, a global manufacturer of ingredients and solutions. Rafael has a rich background in electrical electronics and automation, with an impressive career including notable stints at InBev and Unilever, where he honed his expertise in automation, maintenance, and reliability. Rafael is passionate about optimizing maintenance processes and leveraging technology to enhance industrial efficiency. His philosophy centers on continuous improvement, leadership, and leveraging technology to enhance maintenance and reliability processes.

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Guest Quote

“Every time I had a problem, I said, 'What am I going to do to not have this problem again?'  

I hate having the same problems twice or more. So the first [solution] is reliability. Maintenance & reliability is not only technical, it's a lot of leadership. You need to have the right people in the right place” – Rafael Padilha Gama

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Time Stamps 

00:00 Episode Start 

02:30 Opening Icebreaker

03:20 Rafael's Background

04:25 Segment 01: The Maintainer Mashup

04:40 What is Ingredion?

07:05 How Rafael and his team ensure all 40 facilities operate on the same standards

09:30 Setting a high bar for yourself

12:15 Proving the power of maintenance and reliability

15:50 Segment 02: What's in Your Toolkit?

16:25 What sets Rafael apart

20:05 The importance of good communication

23:30 Tips for implementing new initiatives and earning buy-in

27:20 Segment 03: The Future of Factories

28:20 Why Ingredion leverages Tractian

33:50 The evolution of maintenance routes

38:00 Empowering workers with technology

40:30 Segment 04: Fix It Funnies

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Links

• Connect with Rafael Padilha Gama on LinkedIn
• Check out Ingredion
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

In this episode of The Maintainers, hosts David Lee and Jake Hall sit down with Jim Kozel, COO at World Emblem, the largest patch producer in the world, to delve into the intricacies of lean manufacturing and operational excellence. Jim is a seasoned pro when it comes to running high-efficiency manufacturing plants, and he has some stories to share!

Throughout the conversation, Jim highlights how his team embraced lean principles with guidance from the True Lean Toyota-University of Kentucky partnership. By implementing these strategies, his team has achieved substantial productivity gains and on-time performance while sustaining quality in their custom patch manufacturing. They have made major improvements in each of their facilities across North America and Mexico. 

Jim is not stuck in the past, and he shares his thoughts on how competitive manufacturing can be brought back to US soil by leveraging AI, automation, and modern tools. Jim's passion for manufacturing extends to personal anecdotes, including his love for coffee and lifelong learning, making this episode a blend of professional wisdom and personalized storytelling.

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Guest Bio

Jim’s extensive experience in both plant management and the industry World Emblem caters to has propelled Jim from Plant Manager of the Atlanta location to his current title as Vice President of Plant Operations for the United States and Canada. Despite his Six Sigma Black Belt in Lean Manufacturing and his technical training at the Plant Managers Institute, Jim attests to his 20 years of experience in team leadership as the biggest contributing factor to the successes he has attained throughout his career. It is this factor that helps him motivate his current team to achieve success. As World Emblem’s Vice President of Operations, Jim provides for the consistency and predictability of all products to World Emblem customers from 

every production facility throughout the United States and Canada.

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Guest Quote

“AI is going to redfine managers’ roles. But you will always need to have the leadership role if you have people in there. The evolution of the personnel and getting people to be able to stay up with technology is key. That’s your biggest hurdle.” – Jim Kozel

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Time Stamps 

00:00 Episode Start 

01:50 Opening Icebreaker

04:00 Jim's Background

07:15 When Jim joined the team at World Emblem

09:05 The definition of lean manufacturing

10:35 Segment 01: The Maintainer Mashup

11:00 Origins of World Emblem

12:45 How Jim succesfully implemented the lean framework

14:35 The University of Kentucky <> Toyota Partnership

17:30 True Lean for Executive Leadership

19:40 Segment 02: What's in Your Toolkit?

20:25 Jim's advice from his own career

21:40 How to hit 100% OEE

24:15 Setting realistic expectations for your team

26:35 The daily impact on workers' lives

30:10 Segment 03: The Future of Factories

30:35 Leveraging automation to nearshore and reshore

33:30 The constant need for labor

34:40 Segment 04: Fix It Funnies

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Links

• Connect with Jim Kozel on LinkedIn
• Check out World Emblem
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

In this episode of The Maintainers, hosts David Lee and Jake Hall dive deep with Sam Hancock, the maintenance manager at Sumitomo Drive Technologies. Sam's journey, spanning decades in the industry, offers a wealth of insights into the world of maintenance and reliability.

The discussion delves into practical advice for developing robust maintenance programs, leveraging advanced CMMS systems, and cultivating a safety-first culture inspired by Sam's time at DuPont. He emphasizes the critical need for proper training, team collaboration, and smart technology integration. He also shares intriguing insights on bridging the gap between engineering design and real-world application, peppered with lighthearted anecdotes about challenges faced and lessons learned. The conversation then shifts to the future of factory maintenance, exploring emerging technologies like robotic thermography and the ongoing evolution of CMMS.

With an optimistic outlook, Sam discusses how his team has embraced digital work orders and other technological advancements to enhance efficiency. The episode concludes with Sam's personal tips for maintaining work-life balance and his curiosity about developments in autonomous vehicles, offering listeners a blend of professional wisdom and relatable experiences.

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Guest Bio

Sam Hancock is an accomplished maintenance manager at Sumitomo Drive Technologies, with over a decade of experience at the company. He began his career at DuPont, where he gained invaluable experience in various roles related to maintenance and reliability. Known for his innovative approach, Sam has worked across different industries, excelling in both engineering and management. Currently, he is deeply involved in advancing maintenance practices at Sumitomo, ensuring that equipment is always operational and effective.

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Guest Quote

"Stay grounded. Machines are still machines and people are still people. That being said, there's a lot of technology that makes things easier. That make the paperwork and administration work so much better. Take advantage of the technologies there.” – Sam Hancock

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Time Stamps 

00:00 Episode Start 

01:40 Opening Icebreaker 

02:15 Sam's Background

08:00 Segment 01: The Maintainer Mashup

08:30 Sam's journey with Sumitomo

10:45  How Sumitomo approaches maintenance

12:50 The push for more customized machinery

14:45 Where you can turn to software for assistance

16:45 Segment 02: What's in Your Toolkit?

17:10 The importance of safety & mentorship

18:40 Advice for those starting out their careers

22:10 Segment 03: The Future of Factories

22:40 Don't forget the human element while adopting new tech

26:40 Dedicating roles for software management

29:20 Segment 04: Fix It Funnies

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Links

• Connect with Sam Hancock on LinkedIn
• Check out Sumitomo Drive Technologies
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

On today’s episode of The Maintainers, hosts David and Jake welcome Jake Hall, the Facilities Maintenance Supervisor at O-I Glass, a prominent global manufacturer of glass containers. Chances are, you’ve enjoyed a drink from one of their bottles at some point in your life.

Jake Rice shares a wealth of experiences, from his time as a Navy Interior Communication Specialist to his adventures as a deep-sea diver, ultimately leading him to a fulfilling career in industrial maintenance. Interestingly, before joining O-I Glass, he was unaware that their manufacturing facility was located just around the corner from his home in Toano.

Listeners will gain insights into the challenges of manpower shortages in the post-COVID landscape, as well as the complexities involved in managing continuous and batch processes within glass manufacturing. Throughout the discussion, Rice emphasizes the critical importance of knowledge transfer and his innovative approach to apprenticeship within his team.

The episode also provides an insider’s perspective on maintaining a factory that has been operational for decades, producing thousands of glass bottles every minute. Jake discusses how companies should prepare for the future workforce and advocates for a shift in how maintenance careers are perceived. Whether you’re an industry veteran or just starting out, Jake Rice’s stories and advice are sure to inspire and educate.

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Guest Bio

Jake Rice is 44 years old and has had quite the journey through the maintenance world. Jake joined the navy after high school, worked and received two AS degrees. After the Navy, Jake worked at an R&D company out of the NASA Langley Research Park, worked as an offshore commercial diver, and is now the Facilities Maintenance Supervisor at Owens Illinois (O-I) glass plant in Toano, Virginia. 

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Guest Quote

"When you take manufacturing and you no longer view it as a last resort career opportunity. But as [one] that people should be excited about because [of] the success that it can create in a person's future...I think that's going to make these companies, and really the future of our factories a lot more successful.” – Jake Rice

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Time Stamps 

00:00 Episode Start

01:50 Opening Icebreaker

03:15  Jake's Background

07:30 Segment 01: The Maintainer Mashup

08:10 The journey to O-I Glass

13:05 How O-I Glass Operates

17:00 Maintaining a plant that produces over 1,500 bottles per minute

18:45 Managing a declining workforce post pandemic

23:40 Segment 02: What's in Your Toolkit?

24:00 Where Jake makes his impact

27:15 Segment 03: The Future of Factories

28:20 Shifting the perspective of manufacturing

29:30 Why instant solutions are a challenge for the industry

32:45 Tackling outdated equipment

34:10 Segment 04: Fix It Funnies 

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Links

• Connect with Jake Rice on LinkedIn
• Check out O-I Glass
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

Join hosts David Lee and Jake Hall on this episode of The Maintainers as they have an insightful and inspiring conversation with Vitória Régia Oliveira, Reliability Engineer with Abbott Laboratories and former Maintenance Lead at Magna International.

This episode unravels the compelling story of Vitória's ascent from a favela in Salvador, Brazil, to a leadership role at a Fortune 500 company in Ireland. Discover her relentless pursuit of engineering excellence, driven by curiosity and a refusal to accept 'no' for an answer. Vitória passionately discusses her transition to Ireland, overcoming language barriers, and the cultural advantages of working in a diverse environment. 

You will also hear about Magna International's innovative maintenance strategies, where Vitória's small but specialized team leverages Industry 4.0 and AI to maximize efficiency and output. Listeners will gain valuable insights into managing a multifunctional maintenance team, the importance of continual learning, and the future of factories brimming with digitalization and sustainability initiatives. 

Vitória also highlights the challenges of finding qualified tech professionals and the critical role of partnerships with educational institutions. Her personal touch shines through as she shares the importance of balancing personal and professional life, while not shying away from taking risks to propel one's career. Tune in to be inspired by Vitória's mantra of turning a no into a yes, and learn how you too can harness creativity and resilience to navigate the ever-evolving landscape of maintenance and manufacturing.

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Guest Bio

Born and raised in the neighborhood of Engomadeira in Salvador, the capital of Bahia, Brazil, Vitória Régia Oliveira graduated in Mechatronic Engineering. Despite the challenges of being a black female from a favela, she persevered and secured a position at a tire manufacturing company. Her desire for growth led her to move from Brazil to Ireland, where she not only learned English but also improved her people skills.

In Ireland, she continued to advance her technical knowledge by completing a Higher Diploma in Science in Computing while working in the healthcare sector. After securing a work visa, she pursued further studies, completing CPDs in Energy Sustainability, Project Management, and Sustainability & ESG. This enabled her to work effectively with Industry 4.0, automation, and sustainability.

With eight years of experience in the automotive industry, she is now challenging herself in the medical device and life sciences industry, focusing on Industry 4.0, digital transformation, and machinery reliability.

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Guest Quote

"My mantra is: 'Everybody can say no, but we always go for a yes. Why not still ask? Why not still try?' So everything that I did in my life was always using this mantra. I came to Ireland without any English, and I learned English from nearly [ground] zero. Sometimes the risks are going to change your life forever for the better." – Vitória Régia Oliveira

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Time Stamps 

00:00 Episode Start

01:45 Opening Icebreaker

02:20 Vitória's Background

04:15 Segment 01: The Maintainer Mashup

05:00 What is Magna International?

07:35 Doing more with less

12:15 The software powering Magna International

14:00 Segment 02: What's in Your Toolkit?

16:25 Don't be afraid of the word "no"

23:15 Advice for others looking for change

26:05 Segment 03: The Future of Factories

28:50 The workforce challenge

30:55 The most exciting parts of the future

33:00 Segment 04: Fix It Funnies 

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Links

• Connect with Vitória Régia Oliveira on LinkedIn
• Check out Abbott
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

Join David Lee and Jake Hall on this episode of The Maintainers as they speak with Larry Branch, a seasoned paint technologist at Nissan. Larry has been with Nissan for over twenty years and today you’ll hear how he leads within the organization, where his journey has taken him, and why he gives so much back to his local community. 

Larry began with Nissan from a college job fair and has continuously advanced his career , holding various roles from line technician to certified master trainer, and helping launch new facilities globally, including stints in Mexico and Japan. His story is enriched by the mentorship of his father who sparked his passion for automobiles at an early age.

The trio also discuss the importance of standardizing training across facilities and the balance between embracing new technologies while maintaining fundamental skills. Larry’s insights reveal the intricate dance of integrating AI and manual expertise to ensure high-quality production. Plus, his dedication to community service will inspire you; from mentoring young men in Mississippi to participating in Habitat for Humanity projects, his commitment to giving back is unwavering. 

For those passionate about personal and professional development, Larry's take on lifelong learning and the significance of certificates over traditional degrees in the manufacturing world is eye-opening. Tune in to learn how to merge professional growth with personal fulfillment in the realm of manufacturing.

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Guest Bio

Larry C Branch has been a resident of Brandon, MS since 2013. He has two children (son-Kentrell Branch (14) and daughter-Tysheana Lucas (22). Larry attended Jackson State University where he received his BS Degree in 2020. 

Larry has been part of Nissan North America for over 21 years and has held various roles in his tenure. He is currently a Technologist and Master Trainer within the Paint/Plastics Department in Canton, MS. Within his current title, he is responsible for Training and New Model Launch Activities. 

Larry travels around the globe visiting other facilities for training and benchmark activities and has had the luxury to live in Aguascalientes, Mexico as well as Utsunomiya, Japan. He was voted 1 of 8 members of the 2021 Southern Automotive Conferences “Stars of Manufacturing”. 

Outside of Nissan, Larry enjoys traveling to sporting events and seeing other cultures. When he’s not traveling or working, he dwells in my passion of volunteering. He is a part of a male mentoring program (CHAMPS) and helps at the John & Vera Mae Perkins Foundation in Jackson, MS.

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Guest Quote

"When you're dealing with things that have high-cost value, high-safety value and high-quality value such as automobiles, it's very important that you define standards and you have a way to track and keep those standards. If there's a standard, differences will stand out and come to you rather than you having to go find those differences." – Larry Branch

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Time Stamps 

00:00 Episode Start

01:25  Opening Icebreaker

02:30 Larry's Background

05:55 Segment 01: The Maintainer Mashup

07:50 How Nissan invests in their employees

11:15 Ensuring trainings keep up with technologies

14:30 Where Larry has traveled as part of the New Model Launch (NML) Team

18:20 The need for standardizations across organizations

20:00 Segment 02: What's in Your Toolkit?

22:35 All the ways Larry gives back to his community

28:10 Should you stay at one company or hop around?

30:00 Segment 03: The Future of Factories

33:45 Challenges and opportunities

37:05 Segment 04: Fix It Funnies 

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Links

• Connect with Larry Branch on LinkedIn
• Check out Nissan
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

On today’s episode of "The Maintainers," David and Jake sit down with the ever-insightful Ron Moore, managing partner at RM Group Inc., who shares his riveting journey from working on nuclear submarines to becoming a globetrotting consultant in reliability. 

Right off the bat, Ron shares stories about sky-high standards in nuclear sub maintenance, offering listeners a treasure trove of lessons about the importance of upstream defect management. Throughout the conversation, Ron dives into his master strategies for creating a seamless maintenance environment. He champions the significance of executive sponsorship, collaboration across departments, and genuine shop floor engagement. 

Ron’s specific approach makes complex ideas accessible, stressing that effective training, the right tools, and strong leadership are the backbone of any successful maintenance program. As the chat transitions to the future of manufacturing, Ron offers his thoughts on AI and the critical role of a strong manufacturing base for national security. His candid views on these topics are both eye-opening and practical, making for a holistic discussion that addresses current challenges and future opportunities. With his knack for storytelling and an uncanny ability to simplify intricate concepts, Ron Moore provides a masterclass in reliability and operational excellence that will leave listeners both informed and inspired.

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Guest Bio

Ron Moore is Managing Partner of The RM Group, Inc., and an internationally recognized authority on strategies and practices for operational and manufacturing excellence. He travels worldwide working with manufacturing companies in North and South America, Europe, Australia, Africa, and Asia.

Ron is also the author of “Making Common Sense Common Practice: Models for Operational Excellence,” of “What Tool? When? A Management Guide for Selecting the Right Improvement Tools,” of “Where Do We Start Our Improvement Program, of Business Fables & Foibles,” of “A Common Sense Approach to Defect Elimination,” and of “Our Transplant Journey: A Caregiver’s Story,” as well as author of over 80 journal articles. Ron has applied the principles described in these books worldwide to help companies to improve productivity and global competitive position. 

Ron is a member of the Society of Maintenance and Reliability Professionals, a Certified Maintenance and Reliability Professional, and Fellow with the Electric Power Reliability Alliance. Prior to this, he was also a Senior Fellow with the University of Dayton's Center for Competitive Change, Chairman of its Manufacturing Series Advisory Board; a former advisory board member for the Instrumentation and Control Division of Lockheed Martin Energy Systems. 

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Guest Quote

“If you don't have good leadership alignment, teamwork, and so on, it doesn't matter what tool you use. It's not going to work. So the key to any effective organization is executive sponsorship, the sense of working collectively to a common purpose, the alignment, the culture, and so on.  It's those kinds of things that really matter the most.” – Ron Moore

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Time Stamps 

00:00 Episode Start

01:35 Opening Icebreaker

03:20 Ron's Background

07:40 Surprising insights from nuclear sub maintenance

09:20 Segment 01: The Maintainer Mashup

10:00 Ron's perspective on maintenance and reliability practices

13:25 How Ron guides his clients in the right direction

17:55 Building strong partnerships for operational excellance

21:55 Segment 02: What's in Your Toolkit?

22:30 Discussing Ron's published works and lessons in operational excellance

29:48 Uncovering operational complexities in manufacturing

33:58 Segment 03: The Future of Factories

34:40 The future of manufacturing with new technology

44:05 Segment 04: Fix It Funnies 

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Links

• Find Ron Moore's books on Amazon 
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

Welcome back to The Maintainers with Jake Hall and David Lee. In our Season 02 premiere, listen as Paul Flitcraft, the man who once maintained fighter jets and now ensures your cabinets are flawlessly made, shares his captivating journey from Navy hangars to factory floors. As the Director of Corporate Maintenance for American Woodmark Corporation, Paul has been with the company for nearly a decade.

Throughout the interview, Paul brings powerful lessons about data-driven maintenance — utilizing advanced tech to prevent equipment failures and drastically cut downtime. If you’re serious about leveling up your maintenance game, you don’t want to miss his insights on predictive maintenance and AI tools.

Paul dives into the importance of creating a cohesive, collaborative team environment. Drawing parallels from his military days, he highlights how breaking down silos between departments can skyrocket efficiency. His philosophy? Real leadership is about empowering and educating your team, which he lives out by mentoring future leaders to eventually surpass him.

Additionally, Paul shares eye-opening stories about overcoming obstacles and driving cultural change in organizations. He offers Jake and David practical advice on integrating modern tools and fostering a proactive maintenance culture to revolutionize operations. Tune in for a blend of military discipline, modern tech, and heartfelt mentorship — all aimed at making your facility as reliable as a well-oiled machine.

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Guest Bio

Paul Flitcraft is the Director of Corporate Maintenance at American Woodmark Corporation, one of the nation’s largest cabinet manufacturers with over 19 facilities and 10,000 team members.

With a distinguished background in military service, where he worked on fighter jets, Paul applies his extensive knowledge of maintenance and reliability to manage large-scale operations. He is known for promoting a data-driven approach to maintenance and fostering a culture of continuous learning and improvement across the organization. 

Paul's unique journey from military service to corporate leadership showcases his dedication to maintaining operational excellence and supporting his team to achieve remarkable results.

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Guest Quote

"I always liked taking older things and watching them turn into something new or better. I have a

53 Chevy that I would match up against anything that you put out on the market today. I joined the military to work on fighter jets, got out and started in a manufacturing company making cabinets. And you know what? I'm still that way today. I'm a maintainer. I love watching equipment work. Somebody told me once that a successful company is only good as the maintenance department and I believe that.” – Paul Flitcraft

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Time Stamps 

00:00 Episode Start

03:05 Paul’s Background

04:41 Segment 01: The Maintainer Mashup

05:10 How AWC thinks about reliability 

9:29 Lessons Paul takes from his time in the Navy

12:26 Segment 02: What's in Your Toolkit?

13:08 Creating standards in both your personal and professional shop floors

15:38 The importance of training the next in line

21:06 Standing up for your convictions

23:18 Segment 03: The Future of Factories

24:21 Implementing automation succesfully

28:27 Working to prevent downtime across the business

32:29 Hurdling corporate obstacles when implementing new technology

34:40 Segment 04: Fix It Funnies 

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Links

• Connect with Paul Flitcraft on LinkedIn
• Learn more about American Woodmark Corporation
• Connect with David Lee on LinkedIn
• Connect with Jake Hall on LinkedIn
• Learn more about Tractian

Last year, we launched The Maintainers: A Blue Cap Community Podcast. We sought out to connect with the maintenance professionals who ensure their entire organizations stay up and running, and to arm you with the resources you need to level up your career. After ten amazing episodes with guests from companies such as Boston Dynamics, American Wood Fibers, and CP Kelco, the response has been amazing. Thank you to the thousands of viewers who tuned in, and to the incredible guests who joined us for Season One. One clear takeaway we had from every story was that the world of manufacturing and maintenance is undergoing a huge evolution. That is why we are excited to announce Season Two. Over the next ten episodes, we’ll hear from another incredible roster of maintenance leaders. Keep an eye out for Season Two of The Maintainers wherever you enjoy your podcasts.