Reliability 4.0

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...

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 o...

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 op...

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...

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...

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 i...

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 reducin...

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...

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 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,...

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 corre...

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...

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-friendl...

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) t...

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 m...

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 r...

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...

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 ana...

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...

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 trai...