Reliability 4.0

In this episode of Reliability 4.0, we talk with Jerid Jackson, Reliability and Asset Management Senior Manager at PepsiCo - Frito Lay North America, about how he helped roll out a standardized root cause analysis (RCA) program across a complex network of nearly 40 manufacturing sites. Jerid shares the challenges of supporting diverse teams with varying levels of RCA maturity and how EasyRCA became a practical solution for improving follow-through, standardization, and equipment uptime. He also explains how thoughtful change management—starting with pilot sites, hands-on support, and internal collaboration—fueled widespread adoption.

We also dive into how Jerid’s team uses EasyRCA’s AI features to build better executive summaries, guide users to deeper levels of analysis, and increase confidence across all experience levels. Jerid highlights success stories from sites like Aberdeen and Fayetteville, the importance of collaboration via user group calls, and how PROACT training has deepened the organization’s RCA capabilities. Whether you’re supporting a single plant or managing a network, this episode is packed with lessons on building reliability at scale.

In this episode of Reliability 4.0, we speak with Allen Garcia, mechanical engineer at Baker Hughes and PhD candidate at the University of Maryland, where his research centers on AI applications in engineering. Allen shares how he transitioned from traditional mechanical design to AI-powered reliability tools, offering a rare perspective from someone bridging deep technical experience with cutting-edge machine learning. He explains how large language models (LLMs) are helping engineers process work order data, generate knowledge graphs, and accelerate time-consuming tasks like FMEAs and RCAs.We also explore the future of AI-driven maintenance—from dynamic RCAs that update in real-time to domain-specific models built just for reliability and maintenance professionals. Allen weighs in on EasyRCA’s current AI features, the challenge of accuracy in industrial models, and the opportunity to build smarter tools without replacing human insight. Whether you’re an engineer curious about AI or a data scientist entering reliability, this is a grounded and insightful look at where the field is headed.

In this episode of Reliability 4.0, we sit down with Craig Dark, Maintenance Operations Specialist at Drax, to explore how his team rolled out an effective root cause analysis (RCA) program across their U.S. biomass facilities. Craig shares how his career evolved from hands-on millwright work to overseeing process and mechanical reliability and how that practical background shapes his approach to solving problems today. He also walks us through why Drax adopted EasyRCA, what they looked for in a software solution, and how ease of use drove organization-wide adoption.

We also dive into real examples of RCA in action—like how Craig’s team used EasyRCA to resolve a complex quality issue by uncovering not one, but seven interrelated root causes. He explains how they use Power BI for task tracking, how AI helps engineers get “unstuck,” and why executive summaries are key to stakeholder buy-in. Learn how Drax is turning RCA into a repeatable, data-driven tool for both technical and process excellence.

In this episode of Reliability 4.0, we explore the intersection of corrosion science, regulatory compliance, and predictive reliability with Dheerajkumar Narang, a Corrosion and Reliability Engineering Specialist pursuing a PhD at Harrisburg University of Science and Technology. Dheerajkumar unpacks what “Corrosion Management 4.0” really means and how modern plants can use data-driven methods to optimize inspection strategies, reduce operational risk, and maintain compliance with frameworks like API RP 581. He also shares how machine learning models can reduce bias in risk-based inspection (RBI) programs and improve asset integrity planning.

We also discuss how root cause analysis (RCA) integrates with inspection data management systems (IDMS) and why corrosion mechanisms are often the first clue to solving failures in process industries. Dheerajkumar emphasizes the importance of having a corrosion specialist on your reliability team—particularly when working in high-risk environments like oil & gas and chemical plants. He offers a clear, modern framework for improving long-term reliability through better corrosion and risk assessment practices.

In this episode of Reliability 4.0, we sit down with Ali Elsalaymeh, Associate Director of Maintenance Excellence at Bristol-Myers Squibb, to hear his journey from design engineer to seasoned reliability leader. Ali shares how his hands-on experiences in lean manufacturing, TPM, RCM2, and maintenance task analysis have shaped his approach to asset management across pharmaceutical and industrial operations. He emphasizes the critical role of KPIs like MTBF, MTTR, and OEE—and why real success starts with building credibility, measuring honestly, and focusing on fundamentals.

We also dive into the power of root cause analysis (RCA) and how small wins, like daily checklists and proper torque practices, can drive millions in savings. Ali offers practical insights on selling new initiatives internally, reducing firefighting culture, and why humility is key for young engineers looking to make an impact. Tune in for a refreshing, no-nonsense conversation on building reliability from the ground up.

In this episode of Reliability 4.0, we talk with Rafael Padilha Gama, Reliability Director for U.S. and Canada at Ingredion, about how he’s driving asset performance and cultural transformation across 19 plants. Rafael shares how a global career—spanning Brazil, Colombia, and now the U.S.—shaped his reliability mindset and why he believes reliability isn’t just about detecting failures—it’s about building a management system grounded in standardization, disciplined routines, and robust KPIs. From asset criticality to work order systems, he explains how standardizing maintenance processes lays the foundation for sustained reliability improvement.

We also dive into the pivotal role of root cause analysis (RCA) and how Ingredion uses 5G-based techniques from TPM and world-class manufacturing to empower technicians and operators. Rafael describes how vibration and temperature sensors backed by AI are transforming early failure detection across more than 1,000 assets in 15 plants—and why the future of reliability engineering lies in data literacy, prioritization, and cross-functional execution. Tune in for a masterclass in practical and strategic reliability leadership, grounded in real-world implementation.

In this episode of Reliability 4.0, we sit down with Todd Heindselman, Supervisor of Customer Support Reliability at Liebherr Mining, to explore how reliability strategies impact ultra-class mining trucks. Todd shares his journey from the U.S. Navy to leading reliability efforts for some of the largest mining equipment in the world, including 400-ton payload trucks. He explains how Weibull studies, component reliability analysis, and condition monitoring help optimize maintenance schedules and prevent costly unplanned downtime in mining operations worldwide.

We also discuss the importance of root cause analysis (RCA) in identifying failure trends and how real-time data insights enhance reliability. Todd shares insights into the tools and technologies that drive his work, from OEM-developed tracking systems to Weibull analysis software that helps forecast optimal component life cycles. He highlights why following the data—rather than making assumptions—is key to uncovering true root causes. He shares how his role bridges the gap between end users and OEMs, ensuring maximum equipment uptime and efficiency.

On this episode of Reliability 4.0, we sit down with John Ramirez, Reliability Manager at Rehrig Pacific, to discuss how he turned around a neglected manufacturing plant by implementing a structured three-stage strategy. John shares his insights on tackling low-hanging fruit, identifying top failure points, and integrating planning and scheduling to significantly reduce downtime. With experience in both maintenance and reliability across multiple industries, he explains how building a proactive culture is key to long-term success.

We also dive into the importance of root cause analysis (RCA) in eliminating recurring failures, how data-driven decision-making supports reliability goals, and why having the right experts and tools—such as CMMS and Power BI—can make all the difference. John reflects on his journey from maintenance to reliability leadership, offering valuable advice for engineers looking to drive impactful change in their organizations.

On this episode of Reliability 4.0, we chat with Rildo Pereira, Maintenance & Reliability Manager at Gestamp, about managing maintenance operations across three Tennessee plants within a global organization spanning 24 countries. Rildo shares how his team leverages SAP, IoT, and predictive maintenance tools to shift from reactive to proactive strategies, improving asset performance and reducing downtime.

We also discuss the importance of root cause analysis (RCA) in preventing recurring failures and how AI-driven insights are shaping the future of reliability. Rildo highlights a key lesson from his career: "Fixing is not the same as solving." Tune in to hear how his team is building a proactive culture and using data-driven strategies to enhance maintenance efficiency.

On this episode of Reliability 4.0, we chat with Justin R. Smith, Senior Manager of Regional Engineering and Maintenance at Americold Logistics, overseeing the North East facilities in America. Justin shares how his team ensures reliability through innovative strategies like onboard vibration monitoring, acoustic diagnostics, and predictive maintenance. He also highlights the role of CMMS tools in streamlining workflows and enhancing technician efficiency.

Justin offers practical advice on reliability metrics, technician development, and fostering cross-functional collaboration. He emphasizes the importance of clear communication, continuous training, and leveraging data-driven insights to improve operational performance. Whether you’re a seasoned professional or new to reliability, this episode delivers actionable strategies to help you succeed.

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!

On this episode of Reliability 4.0, we’re thrilled to chat with Rhasean "Sean" Taylor, the Reliability and Mechanical Integrity Manager at Honeywell. Sean shares how his team uses innovative technology to maintain and improve asset reliability in the chemical industry.

He discusses the importance of Root Cause Analysis (RCA) in their workflow, utilizing Logic TreeS and the 5 Whys method to identify and address root causes effectively. Sean also highlights the challenges of finding skilled labor, the benefits of AI in data management, and the crucial role of continuous learning and safety in reliability engineering.

On this episode of Reliability 4.0, we’re thrilled to have a chat with Scott Wiebold, the Root Cause Failure Analysis Expert at International Paper. Scott shares how his team uses EasyRCA software to improve reliability and solve problems efficiently.

He discusses how they identify root causes using the Logic Tree method, the benefits of EasyRCA in streamlining analyses, and the importance of training and continuous improvement. If you want to learn how to enhance your RCA process and keep your operations running smoothly, this episode is for you!

Join us on Reliability 4.0 as we chat with Michelle Legge from the AES Corporation. Michelle shares her incredible journey from completely starting over as a mother of three kids to becoming a senior reliability engineer. Learn more about how AES uses cutting-edge tech like AI and machine learning to keep their energy systems running smoothly.

Michelle also talks about the importance of Root Cause Analysis (RCA) in preventing and solving problems. Whether you're new to reliability or a seasoned pro, you'll find valuable insights and inspiration in Michelle's story. Tune in to learn practical tips for improving reliability and making your operations more efficient.

On this episode of Reliability 4.0, we talk with Yuri Grinshteyn, a Senior Site Reliability Engineer (SRE) at Google. Yuri explains how Google's team helps keep their systems running smoothly for customers. 

He talks about finding and fixing problems quickly, using data and automation to make things work better, and why it's important to focus on what customers need. If you want to learn how to keep your systems reliable and your customers happy, this episode is for you!

In this episode of Reliability 4.0, we speak with Kim Stalder, Asset Reliability Team Leader at Schreiber Foods, the largest privately-owned dairy company in the world! 

Kim shares her journey from quality technician to reliability leader and discusses Schreiber Foods' focus on Total Productive Maintenance (TPM) and the importance of foundational skills in maintaining equipment.

Kim highlights the challenges of accurate downtime costing, and the innovative use of continuous monitoring for critical assets. She also provides insights on partnering with operations leaders and the significance of ongoing education in reliability engineering.

In this milestone 10th episode of the Reliability 4.0 Podcast, we welcome Dave Fessenbecker, the Director of Reliability at Johnsonville, one of the top sausage brands in the U.S. and around the world. With over 16 years at Johnsonville, Dave brings a wealth of experience to the discussion.

Dave dives into Johnsonville’s commitment to Total Productive Maintenance (TPM), the key performance indicators driving their success, and the indispensable tools they use, including the Red Zone intelligent manufacturing platform. Dave also shares insights on the importance of creating operator skills and the critical role of root cause analysis (RCA) in maintaining plant reliability.

In this episode of Reliability 4.0, we dive into the crucial work of environmental cleanup and waste management with Sean Walker from Washington River Protection Solutions. Sean's role at WRPS centers around overseeing the safe and reliable management of nuclear and chemical waste at the Hanford site, a key part of America's nuclear history. Sean explains the innovative processes involved in converting hazardous tank waste into stable glass forms, a method known as vitrification, which prevents environmental contamination. This complex operation not only underscores the importance of reliability in waste management systems but also highlights the critical nature of environmental protection measures. Join us to understand more about the intersection of technology, safety, and environmental stewardship from a reliability engineering perspective in one of the most challenging and vital areas of industrial operations. Click here to learn more about the Hanford Site: https://www.youtube.com/watch?v=ykiktmfzIHg

Join us in this episode with Doug Garrison, Director of Technical Services at Zimmer Biomet. Located in Indiana, Zimmer Biomet stands as a global leader in orthopedic manufacturing. Doug shares insights into his rise from a reliability manager to overseeing technical services, emphasizing the unique challenges of medical device manufacturing under rigorous regulatory standards. Our discussion highlights the critical role of reliability in medical manufacturing, the integration of advanced technologies, and the cultural importance of trust and collaboration across departments. Doug’s expertise delves into maintaining high standards and operational efficiency in a complex global environment. Tune in to learn how Doug is navigating the intricate landscape of medical device production with innovative reliability and maintenance strategies.

In this episode of Reliability 4.0, we welcome Chris Barkow, Reliability Solutions Manager at Regal Rexnord. Chris shares his journey from pharmaceuticals to steel mill maintenance, emphasizing the need to shift from reactive to proactive maintenance. 

Chris highlights the importance of torque monitoring and technology in predicting equipment failures and reducing unplanned downtime. He also discusses the challenges of justifying reliability investments and the balance between technology and human expertise in predictive maintenance. 

Tune in to learn more about driving efficiency and reliability across industries!

We have Sujay Soman with us on our newest episode of Reliability 4.0! Sujay is a Senior Reliability Engineer at Samsung Austin Semiconductor, a leading semiconductor manufacturer known for its commitment to reliability and innovation in the industry.

He highlights the significance of involving maintenance and reliability engineers during the design phase of projects to ensure equipment reliability, availability, and maintainability. By leveraging reliability data and collaborating with design engineers early on, organizations can make informed decisions and avoid costly maintenance issues down the line.

Additionally, Sujay talks about the importance of KPI selection and business case ROI development for effective reliability engineering, illustrating how these aspects enable organizations to measure the success and impact of reliability initiatives more comprehensively.

Watch the full episode and gain insights into how his team is shaping the future of reliability engineering at Samsung Austin Semiconductor and beyond!

Welcome back to another Reliability 4.0 episode! I had the chance to speak with Henry Chiang from Sodexo, who serves as the North American technical lead. Sodexo is a global company that provides facilities management and food services.

Henry shares insights into his role, covering the complexities of managing technical facilities and emphasizing the need for robust reliability programs. He highlights the importance of integrated approaches to maintenance, engineering, and sustainability.

Henry also explores the potential of AI in analyzing maintenance plans and the importance of dynamic scheduling tools in fostering a culture of reliability. 

Listen to the full episode as we discover how organizations can enhance operational efficiency and drive reliability in the ever-evolving landscape of facility management!

Bringing you another Reliability 4.0 episode featuring Justin Thomas, Director of Corporate Engineering at Premier! Premier is an award-winning company specializing in project management for hospitality, multifamily, and student housing sectors.

Justin talks about Premier's multifaceted approach to project management, emphasizing the critical role of reliability in ensuring the success of their projects. Justin shares how Premier was able to enhance operational efficiency and prolong asset lifespan by being intentional with reliability and proactively addressing issues.

Tune in to learn how Justin makes the world a more reliable place with Premier's commitment to excellence in project management and reliability.

This week, I got to to speak with Charles Mborah from Heidelberg Materials, one of the world's largest integrated manufacturers of building materials.

Our conversation focused on the challenges of implementing new technologies and changes in the workplace, the difficulty of attracting qualified personnel to the industry, and the importance of certain tools like oil analysis and condition-based monitoring in reliability engineering.

Charles also highlighted the importance of mean time between failures (MTBF) as a key performance indicator and how demonstrating the cost benefits of new approaches can help overcome resistance to change. Finally, we touched upon the need for a maintenance culture that involves everyone on the team.

I hope you find this interview as helpful as I did. Please tune in to future episodes as we continue to make the world a more reliable place!

In our latest Reliability 4.0 podcast episode, I had the opportunity to speak with Chris Phillips from Southwire, one of North America's leading wire and cable manufacturers.

We discussed the aspects of keeping operations reliable in a large manufacturing environment, the difficulties of managing facilities and using technology to improve production. Chris highlights the need to pay attention not only to production assets but also to the importance of facility and infrastructure assets, which are often overlooked.

Tune in to gain insights on navigating through the complexities of modern manufacturing environments.