Maintenance & Manufacturing Insights

Martin Engster
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Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader at a manufacturing company, this show is for you. Host Martin Engster sits down for conversations with people who actually work in the trenches of industry, for real talk about what’s working, what’s not, and what they're dealing with day-to-day. From reducing unplanned downtime and managing MRO inventory to leading maintenance teams and optimizing tool crib workflows, Maintenance and Manufacturing Insights delivers practical, real-world stories you can learn from. Whether you’re struggling with spare parts chaos, implementing a new CMMS, or just trying to get through the week without a production stop — you’ll find honest insights from peers who’ve been there. Listen anywhere you get your podcasts.

  1. 1d ago

    Richard Horn: Manufacturing Insights from Ford's Production Floor

    The Power of Planning Ahead: Lessons from Ford's Production Floor Guest: Richard Horn | Production Supervisor, Ford Motor Company What does it take to keep thousands of automotive parts moving through production every day? And how can a little planning prevent a major manufacturing headache? In this episode of Maintenance Manufacturing Insights, host Martin Engster welcomes Richard Horn, a production supervisor at Ford Motor Company's Kansas City Assembly Plant. Richard shares his experiences overseeing two automotive stamping press lines responsible for producing parts for the Ford Transit van and F-150 pickup truck. With ten years of experience in the railroad industry and more than two years in automotive manufacturing, Richard brings a unique perspective on production, maintenance, leadership, and the value of hands-on experience. Keeping Production Moving Richard explains what goes into managing high-volume automotive stamping operations, where production can exceed 12,000 parts per shift across two press lines. He discusses the importance of preventive maintenance, regular equipment inspections, and something that often gets overlooked: keeping equipment and work areas clean. As Richard explains, a clean production environment can make troubleshooting easier and help maintenance teams identify problems faster. When Planning Ahead Saves the Day One of the highlights of the conversation is Richard's story about a broken stamping die. After noticing additional storage racks were available, Richard made the decision to produce approximately 1,200 extra parts ahead of schedule. When unexpected material problems caused a die failure, that additional inventory provided roughly a day and a half of production coverage while the equipment was repaired. It's a great example of how proactive thinking and production planning can help protect manufacturing operations from unexpected downtime. The Growing Challenge of Skilled Labor Martin and Richard also discuss a challenge facing manufacturers: the loss of experienced skilled tradespeople. Richard shares how retirements have affected the tool and die trade, leaving experienced workers responsible for training the next generation. Their conversation highlights why transferring knowledge, developing apprentices, and encouraging continuous learning are essential to the future of manufacturing. Advice for the Next Generation Richard offers a simple but valuable piece of career advice: don't limit yourself to learning only what's required for your current job. Drawing from his transition from the railroad industry into automotive manufacturing, he explains how being willing to learn new skills and explore different opportunities can open unexpected doors. Meet Richard Horn Richard Horn is a production supervisor at Ford Motor Company's Kansas City Assembly Plant in Missouri. He oversees steel and aluminum stamping press operations supporting Ford Transit and F-150 production. Before entering automotive manufacturing, Richard spent ten years working in the railroad industry, developing hands-on technical knowledge and supervisory experience. His background gives him an appreciation for both the people maintaining equipment and the production teams responsible for keeping operations running.

  2. 2d ago

    Why Preventive Maintenance Matters More Than Ever | Richard Kaczmarek

    In this episode of Maintenance Manufacturing Insights, host Martin Engster welcomes Richard Kaczmarek, an experienced manufacturing professional and aviation enthusiast, for a conversation about preventive maintenance, workforce challenges, and the technologies changing modern manufacturing. With experience at Briggs & Stratton, Gulfstream, and GE Aviation, Richard brings a unique perspective on equipment reliability, production efficiency, and the importance of keeping manufacturing operations running smoothly. Why Preventive Maintenance Matters Richard believes maintenance should be a top priority in every manufacturing operation, not the first thing eliminated when budgets get tight. He and Martin discuss how preventive maintenance helps companies identify potential equipment problems before they cause costly production shutdowns. They also explore why reactive maintenance often leads to bigger problems, lost production time, and unnecessary expenses. Technology Is Changing Faster Than Maintenance Teams Can Keep Up Today's manufacturing equipment is becoming increasingly advanced, but are maintenance teams receiving the training they need? Richard shares his experience working with sophisticated manufacturing equipment and explains why companies sometimes have to rely on equipment manufacturers to diagnose and repair problems. The conversation also addresses the growing need for maintenance professionals who understand both mechanical systems and modern computer technology. Manufacturing's Workforce Challenges Finding and retaining skilled workers remains a major challenge for manufacturers. Richard and Martin discuss employee turnover, the importance of hands-on leadership, and how workplace attitudes affect production. Richard also shares his perspective on how changes in employee benefits and retirement programs may have influenced long-term employee loyalty. Giving Old Aircraft a Second Wind Richard introduces his new venture, Second Wind Aviation, which focuses on restoring older aircraft and finding affordable ways to manufacture hard-to-find replacement parts. He explains how technologies such as 3D scanning, 3D printing, and CNC machining are making aircraft restoration more practical and affordable. In one example, Richard describes how he recreated a custom aircraft wingtip using digital scanning and 3D printing, completing the hands-on work in approximately four hours. His goal is to combine traditional aviation craftsmanship with modern manufacturing technology to help keep older aircraft flying.

  3. 3d ago

    Jay Olivo: The Secrets of Successful Maintenance Leadership

    What does it take to turn a maintenance team that is always fixing broken machines into a team that prevents problems before they happen? In this episode of Maintenance Manufacturing Insights, host Martin Engster talks with Jay Olivo, an engineering and reliability manager, leadership trainer, and author. Jay shares how he helped change a reactive maintenance operation into a more proactive and organized team. By using a computerized maintenance management system (CMMS), reviewing maintenance data, and building trust with his team, Jay reduced reactive maintenance work to less than 20%. His team also reached approximately 93% on-time completion of preventive maintenance tasks. But Jay explains that better maintenance isn't just about better tools. It's also about better leadership. Martin and Jay discuss the importance of helping employees understand the bigger picture, developing skilled technicians, and creating a workplace where people take pride in their work. Jay also gives listeners a behind-the-scenes look at the specialized manufacturing processes used to make coatings for jet engines and turbines. He shares stories from his years working in manufacturing and distribution, including a challenging equipment failure that required his electrical troubleshooting experience. The conversation also explores Jay's passion for helping young people become stronger leaders through his nonprofit organization, Leadership Team Builder. Whether you're a maintenance technician, reliability engineer, plant manager, or manufacturing leader, this episode offers practical lessons about improving equipment reliability and building stronger teams.

  4. Oct 9

    Building the Next Generation of Skilled Trades with Dan Walker.

    What does it take to run a manufacturing plant producing around 50,000 parts every day? For Dan Walker, one of the biggest challenges isn’t production capacity. It’s finding and developing skilled people. In this episode of Maintenance & Manufacturing Insights, Martin Engster talks with Dan Walker, Plant Manager for Mako International in Shelby Township, Michigan. Dan oversees a 331,000-square-foot facility with 46 molding machines, 112 pieces of secondary equipment, and approximately 340 employees. The facility produces injection-molded interior components, including parts used in the Jeep Wrangler and Jeep Gladiator. Dan explains how automation has changed the skills manufacturers need. His facility uses robotics, sonic welders, vibration welders, heat staking equipment, and camera systems. Keeping that equipment running requires skilled maintenance technicians, process technicians, and automation professionals. Finding those people isn’t easy. Dan shares how his plant is responding by developing talent from within. Working with Macomb Community College, the company has created apprenticeship opportunities in areas where skilled employees are especially difficult to find. For Dan, developing people is personal. He started as a machine operator more than 40 years ago and worked his way through the ranks to plant manager. Now he wants to give other employees the opportunity to build their own careers. Martin and Dan also discuss why skilled trades can provide strong career opportunities for young people entering the workforce. From electrical and hydraulics to HVAC, maintenance, and automation, Dan believes learning practical skills can create opportunities almost anywhere. Outside the plant, Dan enjoys hunting, fishing, camping, motorcycles, and training his hunting dog. He also teaches hunter safety and helps introduce younger generations to the outdoors. About Dan Walker Dan Walker is a Plant Manager for Mako International in Shelby Township, Michigan. His manufacturing career began as a machine operator, and over more than four decades he worked his way into plant leadership. Dan is passionate about developing employees, creating career opportunities, and building the next generation of skilled manufacturing professionals.

  5. Oct 7

    Finding the Real Problem: Mike Escobedo on Data, Maintenance, and Manufacturing

    What makes a great manufacturing operator? For Miguel “Mike” Escobedo, it starts with knowing your machine. In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Mike Escobedo, Manufacturing Fabrication Manager at Jackrabbit Manufacturing, to talk about the connection between manufacturing, maintenance, leadership, and problem-solving on the shop floor. Mike has worked in manufacturing since 1999, starting out sweeping floors and eventually moving into leadership. Along the way, he has worked with manufacturing operations including pipe processing, non-destructive testing, hydrostatic testing, chamfering, fabrication, and automated equipment. Mike shares why he believes manufacturing and maintenance have to work hand-in-hand. When operators understand their equipment, they can recognize changes in sounds, performance, quality, and behavior before those changes become bigger problems. One story from Mike’s previous workplace shows why this matters. Operators were initially blamed when a chamfering machine began producing inconsistent bevels. Instead of assuming it was a training problem, Mike collected data and compared results across multiple pieces and materials. That investigation helped the team trace the problem back to a mechanical change: too much tension had been placed on a spring during previous maintenance work. Once the tension was corrected, the machine returned to producing consistent results. Martin and Mike also discuss Industry 4.0, the Internet of Things, preventive maintenance, automation, equipment monitoring, and how technology is changing manufacturing. But technology is only part of the story. Mike believes manufacturing is a team effort. Whether someone is an operator, maintenance technician, manager, or engineer, everyone contributes to getting a quality product out the door. The conversation also gets personal as Mike talks about his love of barbecue, his involvement with his church, and “One Minute with Big Mike,” where he shares scripture and advice on TikTok.

  6. Oct 2

    Why the Right Parts Matter in Spindle Repair with Martin Engster

    This month, the tables are turned on Maintenance and Manufacturing Insights. Instead of interviewing someone else in the industry, Martin Engster takes the guest seat and gives us a look at what he is seeing in manufacturing and what is happening inside Centreline. Martin shares what he heard while speaking with manufacturers, machine builders, and vendors at recent machine tool shows in Chicago. He also explains why changes in manufacturing do not always show up immediately for a spindle repair facility. New machines often come with warranties, so there can be a delay before repair work begins to follow broader industry activity. We also get a closer look at Centreline’s work. Martin explains the company’s three main areas: spindle repair for CNC machines, precision part manufacturing, and on-site taper grinding. He shares just how tight their tolerances can be, often between 2 and 5 microns. For comparison, Martin says a human hair is about 100 microns. One topic Martin stresses is the importance of OEM parts. He explains how using the wrong parts, installing components incorrectly, or trying to save money with a short-term fix can lead to bigger problems later. Then Martin takes us behind the scenes of a current repair involving a spindle that weighs more than 4,000 pounds. A more typical spindle may weigh around 100 to 200 pounds, making this repair a very different challenge. The team has to manage the bearings, electrical components, cooling systems, alignment, and reassembly while handling a piece of equipment Martin compares to the size of a desk or even working on a car. To close things out, Martin talks about his love of travel and machines. He shares what impressed him at the IMTS show, including a robotic arm moving a full-size car, and tells the stories behind his 1986 Porsche 944 and 1974 Porsche 914.

  7. Oct 1

    Simple Fixes, Less Downtime: Maintenance Lessons with Kenneth Welch

    What if your maintenance team knew what to do before a machine ever went down? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Kenneth Welch to talk about practical maintenance, manufacturing experience, and the value of preparing for problems before they happen. Kenneth spent 23 years working at Michelin in Ardmore, Oklahoma, before moving into his current role at SendCutSend in Arlington, Texas. His years on the manufacturing floor have taught him that some of the biggest production problems can have surprisingly simple solutions. One idea Kenneth shares is the “pre-mortem.” Instead of waiting for a machine to fail and then figuring out what went wrong, the team looks at the equipment ahead of time and asks: If this machine goes down, what do we do? By identifying the steps before the problem happens, maintenance teams can respond faster and spend less time scrambling for answers. Kenneth also shares a simple lesson from his Michelin days. If a belt was known to break, the team kept a spare belt right where it would be needed. When the belt failed, there was no searching for the correct replacement. The solution was already there. Martin and Kenneth also discuss the importance of listening to the people working on the manufacturing floor. Kenneth believes his floor experience gives him a valuable perspective as a supervisor. The people closest to the equipment often see problems and solutions that may not be obvious from somewhere else in the organization. Kenneth also tells the story of a production problem that had tires stacking up for three days. The solution came from knowing the equipment and recognizing another way to keep production moving. The conversation is a reminder that effective maintenance does not always require a complicated answer. Preparation, communication, experience, and simple solutions can make a major difference.

  8. Sep 30

    Mathew Edwards: Building Maintenance Teams That Keep Manufacturing Moving

    What does it take to keep a highly automated manufacturing plant running while working toward production of 21,000 solar panels a day? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Mathew Edwards, Plant Facilities Manager and Maintenance Manager for First Solar in Gaffney, South Carolina. Mathew shares what goes into building and leading a maintenance operation at a new 1.2-million-square-foot manufacturing facility. With highly automated production lines, robots, drives, conveyors, and other equipment, keeping unplanned downtime under control is a major priority. Mathew explains why his team focuses on predictive and preventive maintenance instead of waiting for equipment to fail. Maintenance schedules are driven by equipment usage, run time, cycle counts, inspections, and data. His team also uses information from other facilities to adjust maintenance intervals and make better decisions. But this conversation is about more than machines. Mathew explains why the people maintaining the equipment are just as important as the technology itself. He shares his approach to building a strong maintenance team, giving employees the tools and training they need, and avoiding the common mistake of relying on the same top performers for every difficult job. Martin and Mathew also discuss the value of skilled trades. Mathew encourages people entering the workforce to learn a trade or technical skill and take advantage of every training opportunity their employer provides. The conversation covers preventive and predictive maintenance, reducing unplanned downtime, maintenance planning, spare-parts management, automation, data-driven decision-making, team leadership, employee development, skilled trades, and the importance of networking. About Mathew Edwards Mathew Edwards is the Plant Facilities Manager and Maintenance Manager for First Solar in Gaffney, South Carolina. He leads a maintenance organization supporting a highly automated solar manufacturing facility as it ramps up production. Mathew believes successful maintenance leadership starts with giving people the tools, training, time, and support they need to succeed.

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Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader at a manufacturing company, this show is for you. Host Martin Engster sits down for conversations with people who actually work in the trenches of industry, for real talk about what’s working, what’s not, and what they're dealing with day-to-day. From reducing unplanned downtime and managing MRO inventory to leading maintenance teams and optimizing tool crib workflows, Maintenance and Manufacturing Insights delivers practical, real-world stories you can learn from. Whether you’re struggling with spare parts chaos, implementing a new CMMS, or just trying to get through the week without a production stop — you’ll find honest insights from peers who’ve been there. Listen anywhere you get your podcasts.

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