Maintenance & Manufacturing Insights

What does it take to keep a manufacturing plant running when some machines date back decades and others are brand new?
In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Tony Ingram, Senior Maintenance Supervisor at Daikin Applied in Faribault, Minnesota.
Tony shares what maintenance really looks like inside a facility producing large air-conditioning systems for data centers, hospitals, factories, and schools. His team works with everything from large punch and shear systems to copper-processing equipment, foam presses, tooling, and machines dating back to the 1950s and earlier.
Martin and Tony discuss the difference between reactive, preventive, and predictive maintenance. Tony explains how his operation is moving further into predictive maintenance by monitoring things such as vibration, temperature, oil levels, and tooling cycles. The goal is simple: spot trouble before a machine stops production.
They also talk about one of the biggest challenges in maintenance—having the right people and the right spare parts when something goes wrong. Tony explains why new equipment should arrive with critical replacement parts already identified and available instead of waiting until the first failure.
Tony also shares one of the most memorable equipment failures of his career: a steel storage system that left roughly two tons of steel about 30 feet in the air after a collision. The recovery took around six hours, with safety taking priority over speed.
The conversation also covers the human side of maintenance, from operator-related problems and staffing challenges to knowing when a repair should be handled internally and when it makes more sense to call an expert.
Outside the plant, Tony brings that same mechanical mindset to motorcycles. He talks about riding and rebuilding his own bike after a third-gear failure turned into a major engine project.
Tony's experience offers a practical look at the people, planning, troubleshooting, parts, and technology required to keep modern manufacturing moving.
 

What does it take to keep more than 280 manufacturing assets running with a small maintenance team?
In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Trevor Kennedy, Plant Manager for Parker Hannifin's HELAC hydraulic actuator operation.
Trevor shares what maintenance looks like inside a busy manufacturing plant producing hydraulic actuators for mining, agriculture, and industrial applications.
The conversation explores Trevor's team's transition toward predictive maintenance. Along with regular preventive maintenance, the team is learning from equipment failures and adding its own inspection points to help identify problems before they become major issues.
Trevor also discusses one of the realities every maintenance team faces: downtime.
When critical equipment goes down, fixing the machine is only part of the challenge. Maintenance leaders must decide whether to repair equipment internally, bring in an OEM or outside specialist, find replacement parts, manage costs, and keep production moving at the same time.
One strategy Trevor's team uses is keeping certain critical replacement components available. For some equipment, having a replacement spindle or other important component ready can help reduce the time production is affected by a failure.
Martin and Trevor also discuss the people behind maintenance. Trevor's operation has more than 280 assets and a maintenance group of seven people, or eight including the manager. When several critical machines need attention at once, manpower can quickly become one of the biggest challenges.
The conversation also shows why modern maintenance is about much more than turning wrenches. Maintenance and plant leaders may be involved in troubleshooting, vendor sourcing, contract and invoice reviews, budgeting, logistics, outsourcing decisions, and operations strategy—all while working against the clock.
Trevor also shares a little about life outside the plant, including his love of sports and live music, playing acoustic guitar, and pursuing his MBA.
If you work in manufacturing, maintenance, operations, or plant leadership, this conversation offers a practical look at what it really takes to keep production moving.

In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Sean Archer, a maintenance manager in the steel manufacturing industry. Sean leads a maintenance team responsible for keeping the equipment, systems, and facility operating safely and reliably.
Sean explains why good maintenance cannot simply be about waiting for something to break. Preventive and predictive maintenance help his team stay ahead of problems. He also shares why root cause analysis can be one of the most valuable tools available to maintenance professionals.
The conversation gets into the real-world challenges of maintaining a facility filled with pumps, drives, tanks, overhead cranes, coil handling equipment, PLCs, and other industrial systems. Sean also shares the story of an equipment failure involving an incinerator that required an evening call to get production running again.
With steel moving through the process at up to 700 feet per minute, downtime can quickly become expensive.
But Sean believes one of the biggest challenges in maintenance isn't a machine. It's making sure maintenance professionals continue learning.
Modern maintenance requires more than screwdrivers and hammers. Technology changes, equipment changes, and maintenance teams have to change with it.
------------------------ Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin sits down with Lucas Richards, Associate Manufacturing Supervisor at Schweitzer Engineering Laboratories, to explore a side of manufacturing that most people never get to see.
Lucas works in an environment where teams assemble the panels and systems used to help monitor, control, and protect critical power infrastructure. These builds can be highly customized, with different devices, wiring, and configurations from one project to the next. That makes skilled, hands-on work an important part of the manufacturing process.
Martin and Lucas discuss why relying on people—not just machines—is so important in this type of operation. Lucas explains how operators are trained and empowered to maintain their own tools and equipment, and why continuous improvement plays such a large role in their approach to maintenance.
They also get into the practical side of improvement. Lucas shares one of his first major projects: finding a safer solution for heat guns after existing tools created concerns around burns and equipment damage. The project required more than simply finding another tool. It meant working across facilities, collaborating with different teams, and finding a solution everyone could support.
The conversation also explores rapid growth, employee development, the challenges of increasing production capacity, and what it means to work for a 100% employee-owned company.
And, of course, Martin and Lucas find some time to talk about welding, LEGO, and why people who work in manufacturing often just enjoy building things.
About Lucas Richards
Lucas Richards is an Associate Manufacturing Supervisor at Schweitzer Engineering Laboratories. His work focuses on manufacturing operations, employee development, continuous improvement, and supporting the hands-on assembly of equipment used in power infrastructure.
To connect with Lucas, search for Lucas Richards on LinkedIn and look for his profile associated with Schweitzer Engineering Laboratories in the Charlotte area.
 
------------------------ Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

From Nuclear Submarines to Napa Valley: Maintenance Leadership, AI, and Continuous Improvement
What does it take to lead maintenance teams in one of the world's most demanding production environments?
In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Joshua Kroll, Facilities Maintenance Supervisor at Trinchero Family Estates, to discuss his journey from serving in the U.S. Marine Corps and Navy's nuclear submarine program to leading maintenance operations in California's wine industry.
Joshua shares how preventive maintenance, structured troubleshooting, skill development, and data-driven decision making help keep thousands of pieces of equipment operating during harvest season—the "Super Bowl" of winemaking. He also explains why challenging assumptions during root cause analysis can dramatically reduce downtime and improve maintenance performance.
The conversation also explores how artificial intelligence is beginning to transform maintenance organizations. Joshua discusses practical ways AI can support maintenance teams, from organizing technical documentation and analyzing equipment data to developing employee training programs and monitoring regulatory updates.
Whether you work in manufacturing, facilities, reliability, or maintenance leadership, this episode offers practical ideas you can apply immediately.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

Building Reliable Maintenance Systems: Gabe Little on Asset Management and Automation
What does it take to keep a large distribution center running while preparing for the future of automation?
In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Gabe Little, a maintenance leader with experience at Jacobson Logistics, Amazon, ThredUP, and Ross Stores. Gabe shares how his career evolved from HVAC technician to leading maintenance teams and transitioning into equipment engineering focused on asset management and lifecycle planning.
The conversation explores the importance of preventive maintenance, CMMS systems, vendor management, documentation, spare parts organization, and maintaining conveyor systems that keep distribution centers operating efficiently. Gabe also shares one of the biggest equipment failures of his career—a catastrophic carousel collapse—and explains how that experience led to better reliability practices and improved drive technology.
Martin and Gabe also discuss how AI is beginning to assist maintenance professionals through analytics and dashboard reporting while emphasizing that experience, reliability, and strong maintenance fundamentals remain the foundation of successful operations.
Whether you're a maintenance technician, supervisor, reliability engineer, or plant leader, this episode offers practical insights into building stronger maintenance programs and preparing facilities for the future.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.
 

Every minute of downtime matters in manufacturing. In this episode, Martin Engster sits down with Nathan Santiago, Facilities Engineer at C&H/New Holland, to discuss what it really takes to keep a large manufacturing campus operating efficiently.
Nathan shares how preventive maintenance goes far beyond simply following OEM schedules. He explains how maintenance teams adapt service intervals for equipment that runs around the clock, organize specialized tools and spare parts at critical machines, and work closely with production teams to minimize downtime.
The conversation also explores the growing role of predictive maintenance. Nathan discusses how sensors and cycle-count monitoring are helping manufacturers identify failing components before they create costly production interruptions.
Beyond equipment maintenance, Nathan shares real-world examples of solving operational challenges. From eliminating hundreds of hours of laser downtime through a simple logistics improvement to responding quickly after severe roof leaks threatened production, he demonstrates how thoughtful problem-solving and teamwork can dramatically improve manufacturing performance.
Whether you're involved in maintenance, facilities engineering, operations, or manufacturing leadership, this episode offers practical insights into reducing downtime, improving reliability, and supporting production through better planning.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

What does it really take to keep the lights on for thousands of people?
In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Helmuth Lara, an experienced mechanical engineer and plant manager whose career has spanned nearly three decades in oil & gas, gas turbines, rotating equipment, and power generation. From his early days working in South American refineries to managing power generation for the U.S. Virgin Islands, Helmuth shares what it takes to maintain some of the world's largest and most complex machines.
The conversation explores the importance of preventive maintenance, how major overhauls are planned, and why successful maintenance is about far more than fixing broken equipment. Helmuth explains how coordination, planning, logistics, and teamwork all play critical roles in keeping critical infrastructure operating safely and reliably.
He also shares one of the most dramatic equipment failures he has ever experienced—a gas turbine explosion caused by an undetected gas leak—and explains how careful investigation and engineering allowed the team to safely restore the plant.
Martin and Helmuth also discuss today's biggest maintenance challenges, including long supply-chain lead times, predictive maintenance technologies, equipment reliability, and the changing landscape of power generation. They even dive into electric vehicles, energy efficiency, and why understanding where electricity actually comes from is more important than ever.
Whether you work in maintenance, manufacturing, reliability, or simply enjoy learning how massive industrial systems operate, this episode provides valuable real-world insight from someone who has spent his career keeping critical equipment running.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

Most people never stop to think about where the medical tubing inside catheters, stents, and other life-saving devices actually comes from. In this episode, Martin Engster sits down with Cory James, Plant Manager at Zeus Industrial Products, to pull back the curtain on one of the most important—but least visible—parts of medical manufacturing.
Cory shares how Zeus Industrial Products manufactures precision medical-grade tubing used by many of the world's leading medical device companies. The conversation explores the challenges of balancing preventive maintenance with increasing production demands, the importance of investing in people, and why in-house engineering has become a competitive advantage.
Drawing from his military background and leadership experience, Cory also discusses how discipline, teamwork, and continuous improvement help drive manufacturing excellence while navigating the growing pains that come with rapid business growth.
Whether you're in maintenance, manufacturing leadership, engineering, or simply curious about how everyday products are made, this episode offers an inside look at an industry that quietly impacts millions of lives every day.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

Every building, office, and home depends on glass, but few people ever stop to think about the complex manufacturing process behind it.
In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Josiah Peterson, Maintenance Manager at Oldcastle Building Envelope, to discuss what it takes to keep a modern glass manufacturing facility operating efficiently. Josiah shares his unique career journey—from growing up on a dairy farm and working in logging communities to maintaining high-speed manufacturing equipment in industries ranging from Amazon and food production to energy drinks and now architectural glass manufacturing.
The conversation explores the challenges of maintaining specialized equipment, sourcing obsolete replacement parts, balancing production demands with preventive maintenance, and introducing predictive maintenance technologies like vibration analysis and infrared inspections. Josiah also explains how glass is cut, tempered, polished, and prepared for residential and commercial projects, including supplying glass for Allegiant Stadium in Las Vegas.
If you're interested in maintenance leadership, reliability, manufacturing careers, CMMS implementation, predictive maintenance, or industrial problem-solving, this episode offers practical insights from someone who has worked across multiple manufacturing industries.
 
------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.