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 and how to avoid it
🔸Why appetite, adoption, and alignment matter more than features
🔸 How to track the right KPIs (think: OEE, throughput, scrap rate)
🔸 Why setting expectations and exit strategies is non-negotiable
🔸 Where root cause analysis fits into a scalable digital transformation
If you're running pilots—or stuck in one—this episode will help you rethink how to get out of test mode and into results.
This episode is available on:
📺 YouTube
Or wherever you get your podcasts!
Interested in running a successful pilot of our RCA software, EasyRCA? We've helped teams across the globe pilot and roll out EasyRCA across entire enterprises. Want to learn more? https://easyrca.com/engage
#PilotPurgatory #DigitalTransformation #RootCauseAnalysis #Reliability #Maintenance #Reliability40
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, procurement, and more.
We dig into:
🔸 What causal AI is, and why it’s different from traditional AI
🔸 How it helped increase touchless order processing from “a single digit to 90%”
🔸 Why knowledge + data > data alone
🔸 How to use AI for hypothesis testing and explainable decisions
🔸 What this means for the next generation of RCA and reliability tools
If you’re facing a wave of retirements, struggling with knowledge transfer, or curious about the role of AI in root cause analysis, this episode will spark new ideas.
This episode is available on:
📺 YouTube:
Or wherever you get your podcasts!
Looking to make RCA faster, smarter, and easier to scale? Get in touch with our team at https://easyrca.com/engage
#Reliability40 #CausalAI #RootCauseAnalysis #KnowledgeCapture #DigitalTransformation #ManufacturingInnovation
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 reliability forward.
We dig into:
🔸 Why culture matters more than strategy when rolling out tech
🔸 How to identify the right assets for condition monitoring
🔸 What their “Proxy” wearable does, and how it saved lives
🔸 How Grace built a culture of risk-taking with reliability baked in
🔸 Why RCA is key to turning sensor data into smarter decisions
If you lead reliability, safety, or maintenance teams—or just want to learn how to deliver quick wins while building a long-term plan—this one’s for you.
This episode is available on:
📺 YouTube
Or wherever you get your podcasts!
Want to explore how sensor data and RCA can work together to reduce downtime and improve safety? Reach out to our team at https://easyrca.com/engage
#Reliability #Maintenance #RootCauseAnalysis #ConditionMonitoring #WearableTech #Reliability40
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
• How they evaluated and trialed EasyRCA to see if it fit their needs
• What made EasyRCA stand out (hint: visual workflows and ease of use)
• How their power user strategy fueled faster adoption
• The unexpected use cases that are helping drive cross-functional reliability
If you're deploying software across multiple locations—or trying to get better follow-through on RCAs—this episode is full of real-world strategies and insights from a team that’s making it happen.
This episode is available on:
📺 YouTube
Or wherever you get your podcasts!
Looking to improve your RCA process, unify your team’s approach, or explore EasyRCA? Message us directly or reach out here: https://easyrca.com/engage
#RootCauseAnalysis #Reliability #Maintenance #ContinuousImprovement #Reliability40 #DigitalTransformation
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 already helping clients like Glencore save millions.
We dig into:
🔸 Why most legacy AI models fail in mining—and what to do instead
🔸 How Razor Labs reduced failure detection time by 3–5 weeks
🔸 The two ROI stories that win over execs: less downtime, lower maintenance cost
🔸 How their platform integrates with SCADA, SAP, oil analysis & more
🔸 Where RCA software fits in for long-term strategy
If you're curious about how AI can solve real equipment issues—not just produce pretty dashboards—this episode delivers.
This episode is available on:
📺 YouTube
Or wherever you get your podcasts!
Want to explore how AI and RCA can work hand-in-hand to solve your toughest reliability challenges? Message us or connect at: https://easyrca.com/engage
#Reliability40 #AIinMining #RootCauseAnalysis #PredictiveMaintenance #MiningInnovation #DigitalTransformation
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 case for switching systems
🔸 What separates shiny tech from real process improvement
🔸 The role of leadership, training, and user buy-in
🔸 Where RCA fits into the big picture of long-term success
If you’re evaluating vendors, leading a digital transformation, or just trying to make your plant more reliable — this episode is full of real talk and hard-won insights.
This episode is available on:
📺 YouTube
Or wherever you get your podcasts!
If you’re looking for practical ways to strengthen your reliability program, tie your CMMS data to real problem-solving, or make RCA easier for your team, let us know! You can message us directly or get in touch with our team here: https://easyrca.com/engage.
#CMMS #Maintenance #Reliability #RootCauseAnalysis #Reliability40 #DigitalTransformation
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 improving follow-through and collaboration.
📌 Watch the full episode: https://www.youtube.com/watch?v=fzN7qj8sbHo
🔔 Subscribe for more Reliability 4.0 insights!
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.