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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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Step into the realm of proactive machinery care with the #reliabilitygang as we reveal how condition-based maintenance strategies can revolutionise the way you approach maintenance. Unlock the power of letting your equipment's condition prompt maintenance actions, mitigating the risk of 'infant mortality' in new parts and steering clear of the pitfalls inherent in traditional preventative practices. Our conversation is rich with insight on the unpredictable nature of failure modes—bearings being a prime example—showcasing the necessity of vigilant monitoring to ensure longevity and reliability in your machinery.

Will Crane  and Will Ocean talks about the dance of vibration analysis and ultrasound monitoring. We dissect the complexities of machine 'heartbeats,' learning to interpret these vital signs accurately with the different technologies available and how to use them with precision for measuring different parameters . Our discourse isn't complete without delving into the heat of things; thermal imaging stands as a pillar of our discussion, where we unpack the nuances of emissivity values essential for precise temperature assessments. Armed with a multitude of monitoring strategies, from oil sampling to motor current testing, this episode is your guide to a comprehensive approach to fault detection and the maintenance of industrial equipment. Join us for a deep dive into the technologies that maintain the pulse of our machines.

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Hi #reliabilitygang !

Todays podcast we talk about maintenance practices, we talk about the different types and also clear up confusion between Planned maintenance and preventitive maintenance.

We also disscuss why Condition based maintenance is so important to enabling PM Optimization.

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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.

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Hi #relaibilitygang 

This podcast we discuss repair work and why it is so important we do it in the most reliable way. We have some amazing news that we are opening up a repair centre that primarily focusses on reliability and precision maintenance. We talk about how we can close the loop on DETECT, SOLVE and IMPROVE and how having reliable repairs is important to having a reliable plant.

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Hi #Reliabilitygang ! We asked you guys what you wanted to hear from us and you decided that we talk about AI and how it will effect the world of condition monitoring. We talk about the influence of AI on Vibration Analysis and how we believe how the future will look. We also discuss the concerns of machine learning and also the benefits and what it means for the future.

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Hi #reliabilitygang!

We have a special guest on the podcast today, Chris Hullum is often regarded as the GURU of ultrasound. WE talk about Reliability, compressed air leak survey's, Condition Based Lubrication, On Line lubrication systems and the power of Ultrasound.

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Hi #reliabilitygang!

This Podcast we talk about Resonance, this problem when it comes to rotating machinery can cause catastrophic failure and can cause serious damage if not rectified.

We talk about our experience and how we have solved these problems in the past and also how to detect these issues from a maintenance point of view.

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Hi #reliabilitygang !

This weeks podcast we talk about how #reliability should be considered as Insurance for you assets. Manufacturing plant equipment is so valuable when you consider the products that are made, we discuss the reasons why these assets are not being protected and why it is so important they are.

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Hi #reliabilitygang, i hope everyone is having a great week. Welcome the the first podcast of the year and we would like to thank you for all the support last year.

This podcast we reflect on building a successful business and how the challenges and enjoyment for work is so important to sustaining a business in the long term.

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Welcome back to another episode of the reliability gang podcast, this week we talk about reliability and the Roadmap of where to begin and how to actually ensure a effective strategy can make change within an organisation.

We talk about how reliability can be the glue that binds all the departments together for a goal that everyone can benefit from.

We touch on our new accreditation from Mobius Institute and how the ARP courses provide great guidance and knowledge on Reliability and how it can change the Industries and cultures of UK Manufacturing. 

We hope you enjoy this weeks edition, please make sure you subscribe to our podcast on your choice of platform below!

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Good Morning #reliabilitygang, we are back with a very special episode.

Today Chris Hansford Managing Director and Founder of Hansford Sensors joins us in a very down to earth chat about sensors, business and relationships.

We talk about how Hansford sensors started 15 years ago and how Chris's business has scaled through the hard times and how he has managed to run a successful company that has thrived through the last decade.

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  Hi #reliabilitygang, we are back with another podcast, in this episode we talk about observations and why they are so important when taking vibration analysis data.

We talk about reliability and how going back to basics is  the most effective way of getting the results faster.

We hope you find this episode valuable and will see you next week!

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Good morning #reliabilitygang!

This episode we go deep into reliability at Ravago building solutions, James Curson and Nick Thornton discuss how condition monitoring has vastly improved OEE on site and also how its helped them personally with the challenges of running a plant that is constantly running with limited maintenance windows.

We would like to thank Ravago Building Solutions for letting be a part of their reliability Journey.

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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.

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Happy Monday #Reliabilitygang! This weeks podcast we reveal our brand new website. We have also re launched our reliability gang forum. We also go over lots of exciting updates!

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Good Afternoon #reliabilitygang, I hope everyone is having a great start to the week. This weeks discussion we talk about our first impressions of the Wi care Pure analyser.

We also discuss new updates on our recent additions to the reliability gang and some more exciting news!

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Good Morning #reliabilitygang, i hope everyone had a great weekend!

This weeks episode we have Ryan Hanney on talking about reliability and how he has implemented a big change at the Francis Crick for CBRE.

We talk about our involvement to helping Ryan with Condition Monitoring and then using them tools to improve reliability.

We hope you enjoy the podcast and have a productive week!

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Hello #reliabilitygang, welcome back to another podcast!

This weeks episode we discuss the Maintain Training Academy and our partnership with Mobius Institute. Maintain has been very passionate about training and we needed an outlet where we can offer approved accredited training courses and training content so we can help people through thew reliability journey.

We hope you enjoy this episode! Make sure you follow us on Linkedin and Instagram @maintainreliability

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Good morning #reliabilitygang, i hope everyone has a great week. This Monday we kick it off with our new slogan DETECT - SOLVE - IMPROVE. In this podcast I explain what the slogan means and how we are approaching reliability in a new strategy in 2022. Have a listen to see the idea behind the new slogan and how we are excited to provide more value for the industry.

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Happy New Year #reliabilitygang, i hope everyone had an incredible Christmas and New Year. We are back with the first Podcast of 2022 with some HUGE announcements. Within this podcast we explain some changes with  Maintain and some incredible partnerships we are forming together.

We hope you enjoy this episode and we are grateful to have you guys a part of the #reiabilitygang.

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Good Morning #reliabilitygang, we are back with another podcast and this week we are talking about our experiences of why asset management is so important for a good robust reliability culture. Organisation is a key factor in understanding what assets you have, what assets are critical in a severity order, what spares are required and how all of these factors are rolled into a system that works to improve reliability. We hope you guys enjoy the podcast and we would love to get some feedback on Linkedin.

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Hello #reliabilitygang, i hope everyone is having a productive week. This weeks Podcast we have a special guest Adam Cutler from Oil Analysis Laboratories on the show. We dive deep into Oil analysis and why it's so important. Maintain have been using OAL since it started and i have been great friends with Adam since my early days at my previous employer. Adam has a big passion for Oil and Bob Cutler the GURU of oil analysis taught me years ago on my lubrication level 1 course. I hope you guys enjoy the podcast and let us know if you require any Oil analysis services as we are a exclusive provider through Adams Lab.

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Good Afternoon #Reliabilitygang We hope everyone has had a great week. This weeks podcast we talk about methods of how to inspire your Engineering teams and how to deal with Non-Believers of Condition Monitoring technology. It can be a difficult task too bring everyone on to the idea of reliability especially if old habits are formed. We also talk about Leadership and teamwork and how it's so important to drive a good working relationship to implement reliability culture.

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Hello  #reliabilitygang i hope everyone is having a great day! Todays podcast is a little different to our usual talking points however i feel everyone listening to this can relate if you are in reliability. I feel that in the reliability community a lot of my connections and listeners care for the culture and practice. I personally wake up every morning with purpose and passion. The reason i can approach my job in this way is because i have a strong WHY and just cause that supports my motivations. We talk about this today and why it is important to have a WHY to our daily practices and how it can change the life you live.

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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.

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Hello #Reliabilitygang i hope everyone is having a productive week! This weeks podcast we talk about how Condition Monitoring can have a big impact on Energy Savings. We talk about our partnership with The Green Team to help Companies achieve better energy usage.  I hope you enjoy this weeks episode!

Also if you are enjoying the podcasts please leave us a review it helps us big time in getting ranked in the podcast world.

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Good Morning my #reliabilitygang, this week we bring you guys an exciting announcement about our partnership with Wi-Care.

Wi-Care is an incredible wireless solution to provide high end quality Vibration analysis. In this episode we talk about Industry4.0 and how we are innovating what we do to provide even more value to our customers.

We would love to get your thoughts on this subject! 

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Good Morning #reliability gang, we are back for the first podcast of 2021!

Toady Will Bower and Will Crane discuss the new One Prod Falcon Vibration Analysers and our new plans and goals for 2021.

I hope everyone enjoys todays podcast update!

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Hello #reliabilitygang I hope you are all having a productive week. This weeks podcast we talk about Lubrication and why it's probably one of the most important reliability tasks we carry out. We talk about the effects of poor practice and how damaging a poor lubrication practice can be. We talk about ways to improve practice and how these methods can increase the life of your machines. We also talk about a recent case study poor practice in lubrication caused a critical failure!

We would love to get your thoughts on this weeks podcast in the forum! You can access it below.

https://conditionmonitoring.co.uk/forums/

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Hello my #reliabilitygang I hope everyone had a great weekend. We are Back with a incredible conversation about Vibration Analysis and why it is a effective tool for Maintenance. This week I am joined by Will Crane.

We dive deep in conversation about our experiences in vibration Analysis and why we think it is so important for industry.

We cover

• What is Vibration analysis 
• Where it is most effectively used
• Bearing failure case study
• Wireless Solutions
• The future of Condition Monitoring

We would love your feedback on our forum on todays podcast, please see the link below two get involved in the discussion.

 

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Good Morning my #reliabilitygang! Welcome back to episode 2 of Maintain reliable talk. Today we have some BIG announcements. I take you through some exciting new ventures and building a reliability community. I also talk in the second half about types of maintenance and why each one may be used depending on the plant or process. I hope enjoy it and I hope you all have a productive week.

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Hello Everyone! This is the Reliable Talk first episode and I am so happy to have you with me on my my new podcast. Todays episode is an introduction to where I started in engineering and my story of my reliability journey.

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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."

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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.

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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.

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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.

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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.

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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.

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Mentorship beats tools. Full stop.

I’ve been on the road with Maintain Reliability across food factories, metal plants and logistics sites, and the pattern is the same everywhere. Companies invest in systems before they invest in judgement. They gather more data before they build the confidence to act on what they already know. Then they wonder why the breakdowns keep coming.

The issue is rarely a lack of information. It’s a lack of guided decision making.

Training gives knowledge. Mentoring builds judgement. There’s a big difference. In a classroom everything makes sense. On a live plant with production breathing down your neck and budgets under pressure, it’s a different game. That’s where experience matters. Someone standing next to the engineer saying, focus here, not there. Fix this first. Leave that for now. Sequence it properly.

Order is everything in reliability.

Before we talk about monitoring strategies, we ask simple questions. Is planning and scheduling tight. Are critical assets clearly defined. Is lubrication consistent. Are work orders closed properly. Do people understand their roles. If those foundations are weak, adding more layers just increases confusion and backlog.

When the basics are strong, performance compounds.

A proper reliability audit is usually the turning point. Not a tick box exercise. A real look at how the plant operates. It exposes gaps in communication, spares, lubrication standards, ownership and accountability. More importantly, it gives leadership clarity. It turns reliability from a cost into a structured improvement plan.

Technology has its place. We use condition monitoring every day. But the team must own the data. They must understand what a trend means, what the risk is, and what action follows. Without that, nothing changes.

I’ve seen engineers with almost no budget transform a site because they closed the loop fast and acted decisively. I’ve also seen sites with serious investment still stuck reactive because culture didn’t support action.

Reliability works when people take ownership. When KPIs drive behaviour. When leaders back decisions. And when mentors hold the rope when pressure hits.

If you want results that last, start with an honest audit. Build a roadmap you can defend. Strengthen the people. Then layer in the systems.

That’s how we do it at Maintain Reliability.

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You can have all the data in the world coming out of your condition monitoring programme… vibration data, OGI surveys, thermography images, air leak reports… and still not improve reliability.

And it usually comes down to one simple thing.

No one can actually see what’s going on end to end.

In this episode, we talk properly about that. The gap between finding issues and actually fixing them. Because too often the insight is there, but it’s sat in emails, reports, or spreadsheets and nothing really moves forward.

We get into the systems we’re building to solve that. Things like customer portals where everything sits in one place. Recommendations, evidence, current status, deadlines. So actions don’t just disappear or get forgotten about. Everyone can see what needs doing and where things are at.

We also break down what should sit where, because this is where a lot of people get it wrong.

Your CMMS is there to manage work. History, failure codes, maintenance actions. That’s its job. But it’s not built to visualise vibration data or leak images. Trying to force it into that role just creates friction.

That’s why we’re pushing towards more of a reliability hub approach. Something that sits alongside your CMMS and, where possible, links into it. So when you raise a recommendation, it can turn straight into a work order with proper traceability.

And where integration isn’t possible because of security or system limitations, we still need that feedback loop. So we talk about simple, practical ways to capture comments, updates, and closures without slowing engineers down or adding more admin.

We also get into the value of closing the loop properly on repairs.

When you can link the fix back to the original condition monitoring finding, everything becomes clearer. Photos, verification, root cause… it all starts to tell a story. People understand what those “high readings” actually meant. And more importantly, what needs to change to stop it happening again.

There’s also a lot of money being left on the table in areas people overlook. Air leaks are a big one. They just sit there costing thousands until someone actually takes ownership and fixes them.

And we touch on RCM and FMECA as well. How to keep them simple and useful, rather than turning them into massive Excel exercises that no one wants to touch.

If you’re serious about predictive maintenance, defect elimination, and building systems that actually work for engineers, this one will land.

If it does, share it with someone you work with, subscribe to the podcast, and leave a review so we can get it out to more people.

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