Reliability 4.0

Wastewater plants have gotten away with reactive maintenance for decades. That’s changing. In this episode of Reliability 4.0, Lauren Michael from City of Cedar Rapids shares how her team is building a proactive reliability culture inside a 45-year-old wastewater treatment plant. Lauren explains why executive sponsorship was critical to launching their reliability transformation, and how involving...

Sometimes the perfect RCA becomes the enemy of solving the problem. In this episode of Reliability 4.0, Juan Mendoza from Fresenius Medical Care shares how his team uses Rapid Problem Solving (RPS) to respond to equipment failures faster, reduce repeat downtime, and build stronger problem-solving habits across manufacturing teams. Juan explains why most equipment issues don’t need weeks of investi...

Maintenance isn’t just technical. It’s emotional, political, and people-driven. On this episode of Reliability 4.0, Alejandro Nuñez from  La-Z-Boy shares how his team is building a structured maintenance and reliability system across multiple plants, starting with simple metrics, RCA adoption, and consistent processes. Alejandro explains why reliability programs fail when companies wait for the “p...

The best thing we ever did was just get started. In this episode of Reliability 4.0, Phil White, Chief Maintenance Officer at United Utilities , shares how his team transformed maintenance culture across one of the UK’s largest water and wastewater providers. Over the past six years, United Utilities rebuilt its maintenance strategy from the ground up—reworking hundreds of thousands of PM tasks, i...

“In data centers, you don’t have the luxury of downtime—but you do have redundancy.” In this episode of Reliability 4.0, Lee McClish , Director of Maintenance and Reliability at NTT Global Data Centers , shares how he built a reliability program from scratch for a fast-growing organization with 21 U.S. sites and hundreds of mission-critical assets. Lee discusses how he overcame the challenges of r...

“AI will just get you to the wrong answer faster—if your data isn’t right.” In this episode of Reliability 4.0, Brian Heinsius from Eco Materials shares how they’re building a reliability program from the ground up—starting with data, systems, and remote monitoring across new sites. From setting up Maximo and asset hierarchies to deploying sensors and dashboards, Brian walks through what it takes...

In this episode of Reliability 4.0, Glenn Simmonds from Sabert Corporation shares how they built a reliable culture from the ground up—starting with a reactive culture and transforming it into proactive, sustainable machine reliability. Glenn discusses how Sabert created a roadmap for success, introduced tools, and overcame obstacles in getting leadership and technicians aligned on the importance...

“The best KPI is one that actually achieves a strategy.”In this episode of Reliability 4.0, Kendra Moreno and Matt Vilardebo from JLL share how reliability programs work when metrics, data, and execution are aligned to real business goals. From supporting clients across facilities environments to building standardized reliability practices, they walk through what it takes to make reliability scala...

The best RCAs don’t happen in meetings—they happen at the line. In this episode of Reliability 4.0, KayLeigh Glebe and Corey Tesmer from Haleon share how their Lincoln, Nebraska site made root cause analysis faster, simpler, and technician-owned—without adding more process or overhead. By replacing an aging paper-and-Access workflow, Haleon empowered technicians to capture failures in real time, d...

The hardest part of reliability isn’t collecting data—it’s making decisions you won’t regret later. Ali Walsh , Head of Asset Strategy & Insight at SA Power Networks , shares how her team makes asset decisions that stand the test of time on this episode of Reliability 4.0 . Ali explains how SA Power Networks balances safety, reliability, customer experience, and cost across one of the world’s...

Most reliability improvements don’t come from new tech—they come from fixing what’s already broken. Reuben Walters from Ego Pharmaceuticals shares how focusing on fundamentals helped reduce repeat failures, cut maintenance costs, and build internal capability on this episode of Reliability 4.0 . Reuben walks through real case studies—from recurring spray ball failures to purified water systems—whe...

What if uptime isn’t enough? But more about usable capacity. Drew Hellyer from Aurizon explains how his team uses usable capacity to drive reliability across their 2700 km railway network on this episode of Reliability 4.0. Drew dives into how Root Cause Analysis (RCA) and predictive tools help keep the trains running smoothly. We dig into: 🔸 Why usable capacity is the real metric for success 🔸...

What happens when you need to shift from coal to biomass—and your condition monitoring system can’t keep up? Richard Barber from Drax Group shares how his team used Maximo to manage maintenance, navigate system upgrades, and transition from coal to biomass power on this episode of Reliability 4.0. We dig into: 🔸 Why transitioning from reactive to condition-based maintenance takes more than just a...

Imagine managing reliability for 28 plants—except they’re all moving, and you can’t call a vendor when something breaks. Esther van der Voort from Anthony Veder shares how her team handles maintenance, spare parts, and root cause analysis across a global fleet of gas ships on this episode of Reliability 4.0 . We dig into: 🔸 How to model spare parts strategy for mobile assets 🔸 What happens when...

Ever tried rolling out digital tools across multiple plants—only to find culture is the real challenge? Marian Samaan from Diageo shares how she’s navigating digital transformation across 12 sites, building asset care programs, and using RCA and condition monitoring to drive real business impact on this episode of Reliability 4.0 . We dig into: 🔸 Why cultural transformation is the real challenge...

Ever launched a pilot that never went anywhere? Leo Castillo from ICU Medical unpacks the costly trap of “pilot purgatory”—when promising tech never scales past testing. With nearly two decades of experience spanning supply chain, IT, and operations, Leo shares practical strategies for turning pilots into long-term wins on this episode of Reliability 4.0. We dig into: 🔸 What pilot purgatory is an...

What if your best employee could train an AI system, so no knowledge is lost when they retire? In this episode of Reliability 4.0 , we sit down with Ron Norris , former Director of Innovation at Georgia-Pacific and now founder of Advanced Innovation Management (AIM), to unpack how he used causal AI to capture decades of expert knowledge and improve operational decision-making across supply chain,...

What do wearables, IIoT, and root cause analysis have in common? In this episode of Reliability 4.0 , we sit down with Drew Allen , CEO of Grace Technologies , to talk about the future of maintenance safety, innovation, and culture. From condition monitoring to electrical safety tools to a new wearable that literally vibrates when you’re approaching danger—Drew shares how his team is pushing relia...

What does it take to scale an RCA program across a massive manufacturing network? In this episode of Reliability 4.0, we sit down with Greg Evans and Brandy Heath from CMC to unpack how they rolled out EasyRCA across 40+ sites, onboarded over 400 users, and gained traction in places they didn’t expect—like IT and safety teams. We dig into: • Why CMC needed a standard RCA tool in the first place •...

What happens when AI gets trained like a doctor—only for your mining equipment? In this episode of Reliability 4.0 , we sit down with Michael Zolotov , Co-Founder and CTO of Razor Labs , to explore how his team is using AI sensor fusion to detect failures weeks before traditional systems sound the alarm. Michael shares how they built an “automated doctor” for fixed and mobile assets, and how it’s...

What really makes or breaks a CMMS rollout? In this episode of Reliability 4.0, we sit down with Greg Christensen, host of CMMSradio, to unpack the lessons he’s learned personally and from hundreds of conversations with maintenance and operations pros navigating the world of CMMS and asset management. We dig into: 🔸 Why CMMS projects fail (hint: it’s not the software) 🔸 How to build a business c...

In this highlight from the Reliability 4.0 Podcast, Jerid Jackson shares how he implemented EasyRCA across nearly 40 PepsiCo (Frito-Lay North America) sites. He explains the real-world challenges of standardizing failure analysis, the value of AI in creating executive summaries and corrective actions, and how EasyRCA makes it possible to replicate solutions across identical equipment—all while imp...

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 becam...

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...

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...