Advertise on podcast: Reliability Gang Podcast

What if the problem isn’t your data at all but the way you’re trying to use it? Too many plants are stacked with sensors dashboards and alerts yet they are still fighting the same fires every week. I see it constantly. Technology gets layered on top of a weak maintenance strategy and everyone is surprised when nothing really changes. In this conversation I speak openly about an uncomfortable truth. Sensors do not fix broken thinking. Structure does. Planning does. Stopping defects before they ever enter the plant does. We talk honestly about the skills gap and how it quietly drives reactive behaviour. No software will ever replace judgement that is built through training experience and time on the tools. From route based vibration done properly with strong visual observations to acceptance testing that catches motor issues most sites never look for like impedance imbalance these simple disciplines reduce risk and cost when they are done consistently. We also have a real conversation about wireless versus wired monitoring. No hype. Just reality. Load variation mounting quality battery life signal stability over time. The message is simple. The method has to fit the failure mode and the business need not the trend. To help decisions stick I walk through modelling that turns engineering sense into numbers leadership can actually trust. When you map functional failures consequences and detectability you can compare strategies clearly. Run to failure redesign handheld condition monitoring or online systems. You can see the cost the risk and the expected failures over time. What comes through again and again is that reliability improves fastest when we focus on fundamentals. Better design better planning and scheduling precision alignment and strong repair standards. We share real stories including a blower that went red within days despite being monitored to show why reliability has to be built in from the start. If you are tired of dashboards that look good but change nothing and you want to focus on the actions that actually improve outcomes this conversation is for you. Subscribe for more honest conversations about reliability.  Share this with someone who loves tools more than systems.  And leave a review with one change you are committing to this quarter. Support the show

Ever wondered how a “high-efficiency” motor can start wasting energy and damaging bearings before it’s even been switched on? We did too. So we tested it. Using offline motor circuit analysis alongside online motor current signature analysis, we inspected brand-new IE4 motors still sitting in their crates. What we found changed the conversation completely. Critical impedance imbalance straight out of the box. One motor already showing early winding defects before it ever saw load. That’s the moment labels stop mattering and evidence takes over. This episode walks through why pairing de-energised and energised testing matters. Offline MCA tells us what’s happening in the windings – contamination, resistive imbalance, insulation condition. Online MCSA, sampled at 44 kHz with serious resolution, shows us what vibration often can’t: rotor bar issues, air-gap problems, electrical harmonics, inverter-driven bearing currents. In difficult environments – noisy plants, submersible pumps, generators, limited access assets – current signature analysis often gives cleaner, more repeatable insight than vibration alone. We’re seeing faults that used to hide in the noise. And this isn’t theory. Across 750+ motors tested in the field, we see a clear link between impedance imbalance and winding health: • 15% – critical That gives teams something powerful: defensible alarm limits and a simple acceptance test that stops bad assets entering the plant. There’s a practical win too. On one motor we reduced resistive imbalance from over 30% down to around 3.8% just by cleaning and correctly torquing the terminations. Test. Fix. Retest. Immediate improvement. The real gains come when sites take this seriously:  Acceptance testing written into purchase orders.  Evidence required from the factory.  Faults confirmed using at least two technologies. That’s how you reduce energy loss, prevent shaft currents from destroying bearings, and turn condition monitoring into real reliability improvements – not reports that sit on a shelf. If uptime matters.  If energy efficiency matters.  If you want better decisions with less noise and less drama. This episode shows the path: measure what matters, set your own standards, verify the fix, and keep learning. Enjoy the episode.  If it helps you rethink your motor strategy, subscribe, share it with a teammate, and drop a quick review with your biggest testing win or surprise. Support the show

Reliability doesn’t fail because the maths is wrong. It fails because of people. That’s where we begin this straight-talking conversation with Steve Morris, the driving force behind Mainstream. For more than 30 years he has been building something different: a movement that puts real maintenance leaders on stage, replaces the hero firefighter with predictable performance, and keeps the community alive all year round so practitioners can share what actually works without the sales pitch. We look back at where it started, from a handful of TPM calls to what has grown into the biggest reliability conference in the Southern Hemisphere. But what makes it stand out is how it protects the quality of the peer group, only puts customers on stage, and is built on research that identifies the real blockers—communicating risk, finding funding, and leading culture change. Steve lifts the lid on innovation theatres, curated networking, and the free online platform that now connects more than 5,000 professionals across industries. From mining and water to food and oil and gas, the challenges are different but the root causes are the same—people, incentives, language, trust, and habits. We also look ahead to Mainstream UK. This will be a focused two-day event with five concurrent tracks, global storytellers from Woodside to Mars, and pricing that removes the excuses. If you have ever felt your best preventative work goes unseen while the 2am saviour gets all the recognition, this is your chance to flip the script. It is about rewarding prevention, learning how to sell the value in finance’s language, and being in rooms where practitioners lead the conversation. The next five years are critical for reliability. Teams are ageing, technology is moving fast, and the skills gap is widening. The advantage will go to those who make the time to think, to share, and to adopt what already works. If this resonates, subscribe for more conversations with reliability leaders, share the episode with your team, and leave a review so others can find it. Most importantly, connect with the Mainstream community and take one idea back to your site this month. Support the show

When most people think reliability, vibration analysis is the first thing that comes to mind. But what about the electrical side of your motors. That’s where a lot of hidden damage is happening and it’s often ignored. In this episode we get into shaft current. It’s been around since variable speed drives first hit the scene but it’s still not well understood and definitely not well managed. These stray electrical currents eat away at bearings and windings, quietly cutting motor life down by decades. The scary part is that from what we are seeing around 90 percent of drive installs haven’t been designed properly to deal with it. I reference the teachings of electrical condition monitoring expert Mark Gurney to break this down. We look at how to actually detect the issue with oscilloscopes, Rogowski coils and the SKF TechEd tool. We explain the difference between common mode and circulating currents and why quick fixes like grounding rings aren’t always the silver bullet people think they are. Done wrong they can even make the problem worse. We also talk about Motor Current Signature Analysis MCSA. For me this is the future of motor testing. It gives you the ability to pick up not just electrical faults but mechanical ones too. Bearings rotor bars even belt tension can all be identified just from reading the motor’s electrical signal at the MCC. If you’re serious about IoT and advanced monitoring MCSA is a game changer compared to just scattering sensors everywhere. The bottom line is this. Why are we okay with motors failing after 10 years when they are designed to run 30 or 40. It’s time to move beyond only looking at vibration and start treating electrical testing as a key part of reliability. Our most critical assets deserve that level of care. Support the show

The reliability landscape is rapidly transforming, but are organizations truly ready for this evolution? In this thought-provoking episode, we reunite after our individual "side quests" working with different customers to discover we've both encountered the same concerning pattern across manufacturing facilities. While technology advances at breakneck speed—from pixelated camera phones to sophisticated AI systems in just a few decades—the cultural foundations of reliability and maintenance strategies are evolving at a glacial pace. This creates a dangerous disconnect: companies eagerly investing in IoT sensors, machine learning algorithms, and data historians while neglecting fundamental reliability practices that would make these investments worthwhile. We share a sobering case study of a critical cooling tower failure that cost over £100,000 in emergency measures, despite previous recommendations for a £2,000 monitoring solution. This exemplifies how organizations often pursue technological silver bullets while overlooking basic maintenance fundamentals. The cooling tower had never received lubrication despite being a lubrication-dependent motor—a simple practice that could have prevented catastrophic failure. The episode explores why AI and machine learning belong at the top of the reliability maturity assessment, not as shortcuts to excellence. While these technologies show tremendous promise, they require clean historical data, established maintenance practices, and experienced professionals who understand failure modes to interpret their findings. Without these foundations, organizations risk drowning in information while suffocating for wisdom. Whether you're a maintenance professional navigating digital transformation or a leader making technology investment decisions, this episode offers crucial perspective on balancing innovation with reliability fundamentals. The future belongs to those who master both. Support the show

What does it really take to keep 81 manufacturing sites around the world running at world-class reliability standards? In this episode, I sat down with Pablo, the Reliability Champion at SKF, the world’s leading bearing manufacturer, to find out. And this chat was packed with gold. Pablo opened up about how SKF have built something seriously special. Their Maintenance Excellence system brings together the best of Japanese TPM and reliability-centered maintenance to create a global standard that actually works, site to site, culture to culture. But here’s the standout bit for me. It’s not just about the systems or tools. It’s about the people. SKF have cultivated a real community of over 400 maintenance professionals across the globe. They’re not just clocking in and out. They’re sharing wins, solving problems together, and raising the bar as a unit. We also talked about their week-long Maintenance Excellence Bootcamps run across three continents, combining deep-dive training with hands-on work to embed excellence into their culture. Add in their push towards smarter CMMS rollouts and the integration of AI for predictive maintenance, and it’s clear these guys aren’t just keeping up. They’re leading the way. The part that stuck with me most was this quote from Pablo: "You can have the most perfect system in the world, but if the people aren’t on board, it’s worthless." That hits home. It’s not the tech. It’s the trust. It’s the culture. It’s the belief that people make reliability real. Whether you’re running one site or a global operation, there’s something in this conversation for everyone who believes in better maintenance. Tune in and see how SKF keep evolving while staying true to what matters most: people, purpose, and precision. Support the show

In this episode, I sat down with Joseph Anderson from Reliability X for one of the most honest and refreshing conversations I’ve had on reliability. We didn’t just talk tools, data, and KPIs… we talked about what really matters: people. Joseph shares his own journey, from what he calls being a “defect initiator” (yep, he says he would’ve fired himself back then!) to becoming a leader who changed plant performance by focusing first on the people behind the machines. What really hit me was when he mentioned that maintenance departments have an 80–85% divorce rate. It stopped me in my tracks. That stat alone says it all: reliability is about more than machines. It’s about creating workplaces that don’t destroy home lives. What I love about Joseph is he breaks down reliability into simple human truths. Relationships between operators and maintenance, leaders who actually listen, collaboration over blame. He even draws lessons from his time running restaurants to show how these principles go beyond manufacturing—they’re about how we treat people, full stop. We also got real about why companies trip themselves up: blaming individuals instead of fixing broken systems, chasing completion rates instead of real results, buying the latest tech without teaching people how to use it properly, and cutting costs today only to pay big later. Through it all, Joseph keeps coming back to the same truth: when people know you care, they’ll care for the equipment. It’s that simple. If you lead a maintenance team, run a plant, or just want to get better at building a strong, reliable culture, this one’s for you. As Joseph says:  "Maintenance is simple. Don’t overcomplicate it. Don’t make it harder than it needs to be." Support the show

What’s the real value of reliability in your organisation? It’s a simple question—but one that’s often overlooked before businesses jump into big investments in technology or strategy. And yet, it’s the question that sits at the heart of effective asset management. Over the years, working closely with a wide range of organisations, we’ve seen a common pattern: many skip the most important first step—getting crystal clear on what reliability actually means for their business. Without that alignment, even the best condition monitoring tools or maintenance strategies can miss the mark. In this episode, we talk about how to build a strong business case for reliability—one that really connects with leadership and drives decisions. We also unpack why Overall Equipment Effectiveness (OEE) is such a powerful metric. It gives a full-picture view by balancing availability, performance, and quality—essential ingredients for any reliability programme. Measuring these before you start sets the stage to show true financial impact down the line. Here’s a stat worth paying attention to: about 80% of equipment failures are preventable. But prevention doesn’t start with gadgets—it starts with understanding. Too often, companies rush into solutions without first figuring out why their assets are failing in the first place. We share a real-life example of a site that almost spent a fortune on sensors that would’ve only covered 20% of their critical equipment. A solid assessment saved them from a costly misstep. The real game-changer? It’s not tech—it’s people. Awareness and training spark the kind of cultural shift that keeps reliability efforts alive and thriving. When everyone—from the shop floor to the boardroom—understands their role in keeping things running, that’s when real transformation happens. Whether you’re just getting started or trying to breathe new life into an existing programme, this episode lays out a roadmap to make reliability a true business driver—not just a technical checkbox. Tune in now and learn how to ignite your organisation’s reliability journey. Support the show

What if the key to making electric motors more reliable isn’t a complex new technology but a better understanding of the fundamentals of electrical engineering? In this episode, we sit down with Mark Gurney, a reliability and electrical engineering expert, to hear his journey from troubleshooting issues at biogas plants to leading a full-scale reliability program at an Australian dairy company. Mark takes us behind the scenes of a commonly overlooked problem, electrical fluting in bearings. He breaks down why strong motor management and condition monitoring practices are essential for long-term reliability. We also dive into the broader impact of electric motors in industrial settings and the small yet powerful maintenance habits that make a difference, like using silica gel packs to keep humidity in check. Mark shares his insights on the importance of cleanliness, professionalism, and passing on knowledge to the next generation of engineers. You'll hear real-world lessons from his time on biogas sites, including how proper earthing and a structured troubleshooting approach can prevent serious issues like bearing currents. He also highlights the value of hands-on training programs that bridge the gap between theory and practice. As we wrap up, we touch on upcoming discussions around shaft current problems and thank Mark for sharing his knowledge. We can’t wait to have him back for more. Support the show

Curious about where condition monitoring is headed and how it’s changing the way we approach maintenance? In this episode, we dive into the strategic decisions shaping our industry and explore how adapting to new technologies can elevate operations. Broadcasting from our brand-new podcast studio, we’ll talk about how spontaneous conversations often lead to our best ideas—and how systems like Acoem are driving efficiency in exciting ways. We’ll also discuss the increasing demand for asset reliability training and how it’s reshaping the way clients think about maintenance. How do you find the balance between spontaneity and strategy in content creation? We’ll share our approach to planning podcasts and videos to deliver high-quality content, including ideas for listener polls and covering multiple topics in a single episode. You’ll also hear about our new office in Wakefield, a key part of our UK expansion, and the importance of hands-on data collection in today’s world of AI and wireless sensors. Plus, we’ll give you a glimpse into how our video strategy is fueling growth and amplifying our message. This episode is packed with innovative ideas around condition monitoring and the rise of the “hybrid engineer.” We’ll talk about why engineers remain critical in this tech-driven revolution, highlighting the balance between cutting-edge systems and human expertise. Companies like Acoem are leading the way with solutions that improve plant reliability, while data analysis turns raw numbers into actionable steps to optimize operations. Join us as we explore the game-changing impact of embracing new technologies, with insights on accountability, reliability, and the exciting products and workflows that are redefining the future. Support the show

Step into a world where agriculture meets precision engineering with our special guest host, Harry Crane, affectionately known as "Mr. Solve." This episode promises to transform your understanding of maintenance practices as we uncover how Harry transitioned from the fields to become a pivotal part of our business’s Solve division. His role has been crucial in the establishment of our state-of-the-art repair center, a testament to his dedication and innovative spirit. You'll learn how early experiences with steam engines and a passion for mechanics laid the groundwork for a precision-driven approach to solving complex mechanical issues. Join us as we unravel the parallels between agricultural and industrial maintenance, highlighting the vital role of proactive strategies in minimizing downtime. Through an insightful case study on biogas motors and compressors, we demonstrate the advantages of conducting repairs in a fully equipped center versus on-site fixes. Harry shares his journey of mastering complex repairs after completing an EX course, emphasizing the foresight needed in selecting the right tools and resources. This episode underscores the importance of fostering a culture change—moving from reactive to proactive maintenance—and educating clients on the long-term benefits of reliability engineering. Concluding with a heartfelt appreciation for our listeners, we reflect on the challenges of implementing cultural shifts in maintenance practices. Harry's journey from agriculture to precision engineering showcases how the right tools and training can elevate work standards and engineer satisfaction. As we continue to champion reliability and precision, we express our excitement about launching a new podcast studio, promising to enhance content production and deliver even more insightful episodes. We thank you for your support and look forward to sharing more stories of innovation and dedication in our upcoming episodes. Support the show

What if cutting-edge maintenance technology could revolutionise the biogas industry? Discover the transformative impact of condition-based monitoring as we take you through our collaboration with Future Biogas. Our journey celebrates a surge in listener engagement and introduces exciting future plans, including our move to a new studio at Maintain HQ. This transition will enable us to create even more high-quality content, such as webinars and product demonstrations, while enhancing our focus on the unique challenges and opportunities presented by the biogas sector. As we explore the evolving landscape of biogas, tune in to learn about the advancements in maintenance technologies, like vibration analysis, infrared thermography and optical gas imaging, that are making significant strides. We highlight the game-changing Opgal EyeCgas camera and its role in providing affordable, comprehensive monitoring solutions. By advocating for more frequent inspections beyond the annual norm, we aim to enhance insurance and risk assessment processes, ensuring that biogas sites operate efficiently and reliably. Our discussion extends to the importance of integrating online monitoring systems, like the MVX, to mitigate risks associated with equipment. Experience the sustainable benefits of biogas production as we delve into the process from feedstock acquisition to renewable energy generation. With a focus on maintaining optimal conditions, our insights cover everything from vibration analysis to the critical role of CHP plants. The collaboration with Future Biogas empowers operators with a holistic maintenance package, supporting local communities and stabilising energy costs. Join us as we share the expertise required for handling ATEX motors, maintaining accurate audit trails, and ensuring seamless operations across multiple sites, emphasising how advanced technology and strategic planning are reshaping the biogas industry. Support the show

Join us for an enlightening conversation with Bertrand from Acoem, who expains how the Falcon Vibration analyser uses Accurex technology. Imagine diagnosing machine defects without needing historical data—this is what Accurex achieves through its innovative use of AI and vibration measurements. Broadcasting straight from France, Bertrand offers an insider's look at how Accurex transforms vibration data collection, especially when historical data trends are unavailable, captivating us with its ability to identify a bearing defects and fault conditions from one reading with advanced diagnostics. We also explore the fusion of human expertise and AI in the realm of vibration diagnostics. With a robust database of over 50,000 expert-verified diagnostic advice from real use experts in the field this database has been fused into the falcon. We dive into the deployment of these powerful capabilities in Edge devices, ensuring machine diagnostics are both immediate and independent of cloud services. This segment also raises thought-provoking questions about the future of machine diagnostics and the dynamic interplay between advancing AI technologies and essential human insight. Our discussion takes an exciting turn as we examine the broader implications of Accurex technology. Envision a future where even non-experts can make informed maintenance decisions with confidence, particularly for simpler machinery like pumps and fans. While Accurex is already reshaping industrial maintenance, Bertrand shares insights into the challenges and future prospects of tackling more complex machines. We wrap things up by highlighting how Nest Vision aimed at simplifying access to critical industrial health data, and reflect on the invaluable role of user feedback in our ongoing quest for improvement. This episode is a must-listen for anyone interested in the future of AI-driven reliability management. Support the show

Back to basics with VA Best Practice by understanding the strategic placement of sensors and the critical role of industry standards like ISO standards. We promise you'll walk away with insights into how to avoid the pitfalls of slipping standards and cost-cutting measures that could lead to missed defects and lost customer trust. Our discussion takes a deep dive into the understanding of effective vibration analysis strategies, emphasising the importance of repeatable processes and strategic investments in technology. Discover the truth behind common misconceptions around digital solutions and the risks tied to minimising sensor usage. We share our passion for upholding high standards and our dedication to educating both engineers and clients on proper data collection techniques, ensuring that reliability and efficiency are always at the forefront. In an industry where reliability can make or break success, we challenge the status quo by exploring the broader context of plant operations and the need for robust maintenance frameworks. Addressing faulty strategies head-on, we highlight how technology must complement, not complicate, existing processes. Join us for an engaging conversation that not only questions current practices but also inspires action toward a holistic approach to maintenance and reliability. Support the show

How can you transform your plant maintenance strategy with the latest in vibration analysis and condition monitoring? Join us as we uncover the secrets behind leveraging wireless sensors to revolutionize maintenance practices. We’ll explore criticality assessments and failure mode analysis to ensure you choose the right technologies for your needs. Plus, meet Will, our new Technical Director, who’s on a mission to balance cutting-edge innovations with cost-effective solutions for clients new to the world of condition monitoring. We'll also dissect the potential pitfalls of a one-size-fits-all approach to wireless sensor installation. Learn from real-world examples where traditional vibration analysis falls short and discover the importance of meticulous evaluation and planning. We highlight the key differences between the Sparrow and Eagle sensors, discussing their unique advantages and applications in industrial settings. From hazardous environments to the biogas industry, find out which sensor is right for your specific needs. Finally, we delve into setting the correct frequency for data collection and the move towards proactive maintenance strategies. Understand the benefits of continuous monitoring systems like MVX and how they support plant digitalization. We emphasize the need for cultural and operational shifts to keep pace with technological advancements and preview exciting upcoming projects. Tune in and get inspired by pioneering maintenance strategies and the future of digitalization in industrial plants.  Support the show