Reliability Gang Podcast – Détails, épisodes et analyse

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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:

• <5% – normal
 • 5–8% – defect initiation
 • 8–15% – accelerated damage
 • >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.

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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.

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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.

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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.

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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.

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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. 

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Hi #reliabilitygang !

In this podcast we take you through all the services and offerings SOLVE has to offer, as we start to offer more at Maintain we thought it would be a good idea to take you through all the services that we do in our solve division.

Precision maintenance is the mantra at Maintain and as we start to try and close the loop on our recommendations in the DETECT side of the business we need to ensure that reliability is at the heart of our actions.

We disscuss

1.  The Repair Centre
2. Planned Maintenance on site
3. Engineerings services on site
4. Precision Balancing and Laser Alignment
5. How to correctly install bearings.

We hope you enjoy this episode guys and stay locked in for the next episode.

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Discover the transformative power of precision in motor repair and and the electromechanical industry as we journey through the launch of our new repair centre and take a revealing look at our advanced diagnostic techniques. Our visit to France offers a riveting sneak peek at Acoems innovative vibration analysis tools that promise to be game-changers in maintenance strategies. As we unpack the nuances of electrical equipment and the importance of experience in solving complex problems, we bring you tales from the front lines of reliability, straight from the engineers and technicians who live it daily.

Delve into the heart of motor maintenance with us, where we unveil the role of advanced testing equipment such as the Megger ADX tester in advanced winding testing. From the importance of routine checks to the intricacies of maintaining electrical integrity, we dissect the critical balance between mechanical precision and electrical know-how. With insights into the nitty-gritty details that make a motor tick, we celebrate the finesse required to keep critical machinery at peak performance, ensuring that our clients experience fewer interruptions and smoother operations.

Join our collaborative discourse on precision maintenance and its indelible impact on asset reliability. Learn how a culture of proactive steps and a commitment to excellence can transform the very fabric of repair shop standards. As we discuss the ripple effects of precision work, we underscore the collective efforts that go into advancing our industry, striving not just to be the largest, but the most reliable and top-notch in service quality. With a steadfast ethos of 'detect, solve, and improve', we're paving the way for a future where reliability isn't just an expectation—it's a guarantee.

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Join us #reliabilitygang on a journey to operational excellence with our latest episode, where you'll discover the secrets to forging a robust reliability strategy. We delve into the nuances of gap analysis, the creation of a dynamic reliability roadmap, and the instrumental role of data in pinpointing your organization's needs. We guarantee you'll walk away with a clearer vision and the practical tools needed to elevate your maintenance practices.

This week's discussion isn't just about the what, but the how, as we share invaluable insights into implementing a reliable asset management strategy. Learn to build an effective asset list, appreciate the importance of a standardized coding system, and the transformative power of education in establishing consistency in asset naming. Aligning with ISO standards becomes less intimidating and more accessible as we break down the steps to remove bias from your reliability engineering efforts.

Finally, we unravel the intricacies of maintenance management systems and the criticality assessment of assets, involving every department to reshape your priorities and ensure a holistic approach to plant operations. Discover how to harness the power of FMECA, Pareto analysis, and opportunity rankings to not just revolutionize asset management but to create a maintenance strategy that's as resilient as it is efficient. Join us for this strategic conversation, and understand why our listeners continue to make us a part of their reliability journey.

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Hi #reliabilitygang !

Welcome to a brand new series called the Reliability Roadmap Series, this series focusses on the stages of the roadmap step by step to escape the reactive maintenance cycle.

The first episode is the most important part of any journey, its about getting the buy in from all parties involved that allows the next steps to be effective. This is why the culture is so important as it is the basis of how our mindset and perception needs to change to adopt new techniques that may be very different to what has been done in the past.

This week's candid conversation wades into the intricate dance of change management and communication. We trade insights on how to gradually introduce the concept of reliability to staff, championing incremental change to ensure a solid foundation of support. Dive into our personal takeaways from a DISC workshop, where we learned the art of tailoring dialogue to resonate with every unique communication style—because, at the end of the day, how you convey change can be just as pivotal as the change itself.

We wrap up by highlighting the pivotal role of training and support in cultivating a rock-solid reliability foundation within organisations. Every organization needs its champions, and we stress the value of in-house heroes who can steer the ship away from the stormy seas of reactive maintenance. With a nod to the dedicated reliability engineers and the clear-cut roles they play, we share how to create a robust framework for impactful change. So, as we gear up for our next stage—strategy—we invite you to join us in not just learning but living reliability culture. Here's to a week of taking strides in the right direction!

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