Reliability 4.0

Hosted by Sebastian Traeger, CEO of Reliability.com

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Nov 2026

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This podcast is your premier destination to unravel how cutting-edge technologies like AI, IoT, and Big Data are revolutionizing the way we approach reliability and maintenance in various industries. Our host, the CEO of Reliability.com, Sebastian Traeger, uses his extensive experience to illuminate the most pressing topics in the reliability engineering field today. The Reliability 4.0 Podcast is here to keep you informed and inspired, bringing you insightful discussions, interviews with leading experts, and real-world case studies. Subscribe now to never miss an episode!

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60 recent

November 3, 202621 min

E64: Getting Preventive Maintenance Just Right: Failure Modes, Criticality & RCA with Thomas Povanda

The goal isn’t to do more preventive maintenance. It’s to do the right maintenance, on the right assets, at the right time. In this episode of Reliability 4.0, Thomas Povanda from Sanofi explore about building maintenance strategies around failure modes, asset criticality, and risk. Tom explains his “Goldilocks” approach to preventive maintenance. As Tom puts it: “We don’t want to over-PM. We don’t want to under-PM. We want to PM just right.” That starts with understanding the dominant failure modes of critical equipment and investing the right level of maintenance and condition monitoring based on risk. He also shares how Sanofi connects reliability to the bigger business goal of getting products to patients, uses leading and lagging indicators to guide decisions, and applies root cause analysis when maintenance isn’t delivering the expected results. Key topics include: 🔹 Maximizing failure mode coverage on critical equipment 🔹 Using P-F curves to build more effective maintenance strategies 🔹 The “Goldilocks” approach to preventive maintenance 🔹 Using asset criticality to guide reliability investments 🔹 Balancing leading and lagging reliability indicators 🔹 Using RCA to improve PM effectiveness and reduce repeat problems 🔹 Sharing lessons learned across a global manufacturing network This episode is available on: 📺 YouTube 🎧 Apple Music Or wherever you get your podcasts! Want to strengthen your RCA process alongside your maintenance data? 👉 https://easyrca.com/engage #Reliability40 #ReliabilityEngineering #Maintenance #PreventiveMaintenance #RootCauseAnalysis #AssetManagement

October 20, 202618 min

E63: Lubrication Excellence: How Owens Corning Cut Bearing-Related Downtime by 36%

“The plants that are consistently winning aren’t necessarily the ones with the best technology.” In this episode of Reliability 4.0, Matthew Hoffner , Reliability Engineer at Owens Corning , discuss about how root cause analysis revealed lubrication as a recurring contributor to equipment failures at the company’s Jacksonville facility. Matt shares how the team responded with automatic lubrication systems, technician and operator training, updated PMs, clearer labeling, and better lubrication practices. But the biggest lesson was that tools alone were not enough. Lasting improvement required getting operators, maintenance, engineering, and leadership involved in reliability. The conversation explores the practical changes behind those results, from calibrating grease guns and strengthening operator care to improving how teams approach root cause analysis and use AI in maintenance. Key topics include: 🔹 How RCA identified lubrication as a recurring cause of failures 🔹 Reducing bearing-related downtime by more than 36% in 12 months 🔹 Why grease gun calibration can make a significant difference 🔹 Giving operators greater ownership of equipment reliability 🔹 Bringing cross-functional teams together for RCA 🔹 Where AI can help with maintenance data and condition monitoring This episode is available on: 📺 YouTube 🎧 Apple Music Or wherever you get your podcasts! Want to strengthen your RCA process alongside your maintenance data? 👉 https://easyrca.com/engage #Reliability40 #ReliabilityEngineering #Maintenance #Lubrication #RootCauseAnalysis #PreventiveMaintenance

October 6, 202622 min

E62: The Future of Asset Management: AI, Predictive Maintenance & the Workforce with Kevin Clark

“We don’t want to run to technology when we’ve got something new and cool. We run to it when the workforce begins to shift towards it.” In this episode of Reliability 4.0 , Kevin Clark , VP, Head of Industrial Strategy and Asset Management at Siemens , shares about the changing landscape of asset management, AI, and maintenance technology. Kevin shares his journey from spending a decade turning wrenches in maintenance and operations to leading asset management strategy at Siemens. He explains how that experience shaped his perspective on technology, workforce development, and what maintenance teams actually need from their software. The conversation also explores where AI is already creating value, why much of what the industry calls predictive maintenance may actually be advanced condition monitoring, and why technology adoption needs to follow how people actually work. Key topics include: 🔹 Bringing product and asset lifecycle management together 🔹 Why modern maintenance software needs to remain flexible and modular 🔹 Matching technology adoption with workforce readiness 🔹 Where AI is creating value in maintenance workflows and analytics 🔹 Why predictive maintenance may not be as predictive as we think 🔹 Keeping CMMS and EAM focused on what maintenance teams actually need This episode is available on: 📺 YouTube 🎧 Apple Music Or wherever you get your podcasts! Want to strengthen your RCA process alongside your maintenance data? 👉 https://easyrca.com/engage #Reliability40 #ReliabilityEngineering #AssetManagement #Maintenance #PredictiveMaintenance #AI

September 15, 202618 min

E61: How Nick Smith from Simmons Foods Breaking the Reactive Maintenance Cycle with Better Processes

If it’s not organized, it’s chaos. And in reliability, a repeatable process is what turns reactive work into consistent results. In this episode of Reliability 4.0, Nick Smith , Maintenance and Reliability Manager at Simmons Foods , discuss why being process-driven is fundamental to improving maintenance and reliability. Nick shares lessons from working across multiple facilities, including how Simmons Foods is strengthening PM programs, improving root cause analysis, making storeroom decisions based on process instead of gut feeling, and using AI to uncover insights hidden in maintenance data. They discuss: 🔹 Why PM optimization is the foundation for reducing reactive maintenance 🔹 The difference between containing a failure and preventing it from happening again 🔹 Why RCA needs to happen close to the event, with the right people involved 🔹 How AI is helping analyze maintenance data and identify gaps 🔹 Why training and clearly defined processes are essential for sustainable reliability Nick’s takeaway is simple: “A process delivers the same results every time, and that more or less defines reliability.” This episode is available on: 📺 YouTube: https://youtu.be/_qIAxjkVyE0 🎧 Apple Music: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to strengthen your RCA process alongside your maintenance data? 👉 https://easyrca.com/engage #Reliability40 #Reliability #Maintenance #RootCauseAnalysis #PreventiveMaintenance #AssetManagement

September 1, 202624 min

E60: Good Data Is the Foundation of Reliability with Ryan Chan from UpKeep

You can't improve reliability if you don't trust your maintenance data. And without quality data, even the best AI and analytics will fall short. In this episode of Reliability 4.0, Ryan Chan , Founder & CEO of UpKeep , shares how a frustrating experience as a process engineer led him to build a mobile-first CMMS—and why high-quality data is the foundation for AI, root cause analysis, and better maintenance decisions. Ryan explains why reducing downtime often creates more value than increasing production speed, why technicians should capture information where the work happens, and how AI is changing the way reliability teams analyze data not replace them. We discuss: 🔹 Why reducing downtime can deliver bigger gains than increasing line speed 🔹 How mobile-first maintenance improves data quality 🔹 Why AI is only as good as the data behind it 🔹 The difference between a CMMS and Root Cause Analysis 🔹 Why quality and quantity of data determine better reliability decisions If you're investing in AI, CMMS, or reliability improvement, this conversation is a reminder that better decisions always start with better data. This episode is available on: 📺 YouTube: https://youtu.be/c80gqKCRVcU 🎧 Apple Music: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to strengthen your RCA process alongside your maintenance data? 👉 https://easyrca.com/engage UpKeep is the CMMS platform trusted by 4,000+ companies to manage maintenance, safety, and reliability. With built-in AI tools that customize the platform to each organization's workflows, the platform empowers maintenance teams to reduce downtime and extend asset life — which is why UpKeep is the CMMS chosen by organizations like McDonald's, Caterpillar, and Chevron. #Reliability40 #Maintenance #CMMS #RootCauseAnalysis #AssetManagement #ArtificialIntelligence #ReliabilityEngineering

August 18, 202620 min

E59: The Generational Shift Reshaping Maintenance & Reliability with Casey Pritt

“What happens when your most experienced maintenance technicians retire? And how prepared is your organization to retain the knowledge they take with them?” In this episode of Reliability 4.0 , Casey Pritt from Smurfit WestRock explores one of manufacturing’s biggest challenges: preserving decades of maintenance knowledge while embracing new technology. Drawing from her IMC presentation, Casey explains how each generation has shaped maintenance practices—and why the future depends on combining hands-on experience with modern digital tools rather than choosing one over the other. We discuss: 🔸 Why maintenance knowledge is disappearing as experienced workers retire 🔸 How different generations have shaped maintenance strategies 🔸 Why technology should complement—not replace—equipment knowledge 🔸 The challenge of planning large paper mill outages with thousands of contractors 🔸 How AI could help capture expertise before it leaves the workforce If your organization is preparing for the next generation of maintenance professionals, this episode offers practical insights into protecting knowledge while driving reliability forward. This episode is available on: 📺 YouTube: https://youtu.be/RDo_8PsbQwY 🎧 Apple Music: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to explore how EasyRCA helps capture and standardize reliability knowledge?👉 https://easyrca.com/engage #Reliability40 #Maintenance #ReliabilityEngineering #KnowledgeTransfer #AssetManagement #Manufacturing

August 4, 202617 min

E58: Why Reactive Maintenance Is Not a Career Strategy

“Being the best firefighter is not a career strategy.” In this episode of Reliability 4.0 , Jeremie Lieb from Worthington Steel shares how his team is transforming maintenance culture by moving away from reactive firefighting and toward proactive reliability practices. Jeremie explains how Worthington Steel is combining reliability strategy, condition monitoring, AI tools, and frontline engagement to improve maintenance performance across multiple facilities. We discuss: 🔸 Why reactive maintenance creates long-term safety and reliability risks 🔸 How Worthington Steel is approaching NFPA 70B compliance and electrical reliability 🔸 Why PM follow-up quality matters more than simply completing tasks 🔸 How AI can support planners, maintenance leaders, and RCA thinking 🔸 Why proactive maintenance starts with changing culture—not just adding technology If your organization is trying to reduce downtime, strengthen reliability culture, or improve maintenance execution, this episode is packed with practical insights. This episode is available on: 📺 YouTube: https://youtu.be/r89eT9eQohc 🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to explore how EasyRCA can support your reliability program?👉 https://easyrca.com/engage #Reliability40 #ReliabilityEngineering #Maintenance #RootCauseAnalysis #AssetManagement #Manufacturing

July 21, 202620 min

E57: How Gold Fields Improved Reliability Through Frontline Coaching

“Dashboards don’t improve reliability. People do.” In this episode of Reliability 4.0, Jordan Gair from Gold Fields shares how his team improved reliability at a large-scale gold mining operation by investing in frontline leaders, coaching, and proactive maintenance culture. Jordan explains why many reliability transformations fail—not because teams lack data or technology, but because organizations spend too little time supporting the people closest to the work. We discuss: 🔸 Why frontline coaching matters more than reporting dashboards 🔸 How Gold Fields improved plant reliability through proactive maintenance 🔸 The role of inspections, defect elimination, and quality notifications 🔸 Why sustaining culture change is harder than launching it 🔸 How AI can support maintenance tactics and improve work management If your organization is trying to improve reliability culture, reduce downtime, or strengthen frontline accountability, this episode is packed with practical insights. This episode is available on: 📺 YouTube: https://youtu.be/sipbGTXSAns 🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to explore how EasyRCA can support your reliability program?👉 https://easyrca.com/engage #Reliability40 #Mining #ReliabilityEngineering #Maintenance #AssetManagement #ContinuousImprovement

July 7, 202622 min

E56: Building Reliability Into Aging Water Infrastructure

Wastewater plants have gotten away with reactive maintenance for decades. That’s changing. In this episode of Reliability 4.0, Lauren Michael from City of Cedar Rapids shares how her team is building a proactive reliability culture inside a 45-year-old wastewater treatment plant. Lauren explains why executive sponsorship was critical to launching their reliability transformation, and how involving leadership from the very beginning helped create buy-in across operations, finance, HR, and city leadership. We discuss: 🔸 Why many wastewater plants are still operating reactively 🔸 How Cedar Rapids launched “Program Phoenix” to improve reliability 🔸 Why executive sponsorship must start at kickoff—not after the fact 🔸 How RCA helped shift the culture away from blame 🔸 Why wastewater operators need reliability more than ever as infrastructure ages If your organization is trying to improve asset performance while working with aging infrastructure and limited resources, this episode is full of practical lessons. This episode is available on: 📺 YouTube: https://youtu.be/65UtsavmfJg 🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to explore how EasyRCA can support your reliability journey?👉 https://easyrca.com/engage #Reliability40 #RootCauseAnalysis #Wastewater #AssetManagement #ReliabilityEngineering #Maintenance

June 16, 202617 min

E55: Go Back to the Basics: Reliability Lessons From Fresenius

Sometimes the perfect RCA becomes the enemy of solving the problem. In this episode of Reliability 4.0, Juan Mendoza from Fresenius Medical Care shares how his team uses Rapid Problem Solving (RPS) to respond to equipment failures faster, reduce repeat downtime, and build stronger problem-solving habits across manufacturing teams. Juan explains why most equipment issues don’t need weeks of investigation—and how setting clear rules around speed, ownership, and execution helps teams stay focused on solving problems instead of endlessly analyzing them. We discuss: 🔸 Why every unplanned downtime over 45 minutes triggers an RPS. 🔸 How “containment first” keeps production moving before investigation starts. 🔸 Why rapid investigations must be completed within five days. 🔸 The difference between rapid problem solving and deep RCA investigations. 🔸 Why most reliability improvements still come from mastering the basics. If your organization struggles with recurring downtime or slow investigations, this episode offers a practical framework for building a faster reliability culture. This episode is available on: 📺 YouTube: https://youtu.be/9CeZ3wcFjAU 🎧 Apple Podcasts: https://podcasts.apple.com/us/podcast/reliability-4-0/id1729943699 Or wherever you get your podcasts! Want to explore how EasyRCA can help your team solve problems faster?👉 https://easyrca.com/engage #Reliability40 #RootCauseAnalysis #Manufacturing #Maintenance #ContinuousImprovement #ReliabilityEngineering