Maintenance & Manufacturing Insights

Martin Engster
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  • Management

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. 20h ago

    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.

  2. 5d ago

    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.

  3. 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.

  4. 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.

  5. Sep 24

    Varadarajan Balaraman: From Startup Chaos to a Well-Oiled Machine

    What does it take to build a manufacturing operation from the ground up while also building the maintenance systems that keep it running? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Varadarajan “V” Balaraman, a site plant manager helping build a startup manufacturing operation within an established company. V shares why starting with new equipment does not mean maintenance can wait. New machines may have fewer breakdowns, but that can also mean the team has fewer chances to learn how the equipment will fail. His approach starts with vendor-recommended preventive maintenance, spare parts, and inspection routines. Then, as real-world failures happen, the team turns those problems into lessons. Martin and V discuss root cause analysis and the importance of looking beyond the immediate machine failure. V explains his approach using five areas: man, machine, method, material, and environment. Instead of simply fixing what broke, the goal is to understand why it happened and use that knowledge to improve the maintenance program. V also shares a real example involving a prop shaft balancing machine. A worn chuck was creating vibration that made good parts appear bad, resulting in scrap and repeated correction attempts. By digging into the measurement system and developing a monthly calibration process, the team was able to identify problems before they created larger production losses. Another example comes from V’s current plant, where glue repeatedly clogged a robotic spray system. After exploring the technical solutions available, V realized technology alone could not eliminate the problem. The answer was a better operating process, including flushing the system before production and whenever the line stopped. The lesson is simple: first determine what technology can solve. When technology reaches its limit, build clear and repeatable work procedures around that reality. The conversation also explores the people side of manufacturing. V explains why operators need a clear way to report what they see and hear on the floor. A small noise noticed by an operator could be the first warning of a larger problem. Building a system where those concerns are captured, reviewed, and resolved helps make maintenance everyone's responsibility. V describes his startup role as being an architect. He is helping turn a “jungle” into an organized value stream by building processes, equipment systems, material flow, quality practices, maintenance routines, and a team culture one problem at a time. Outside of manufacturing, V brings that same builder mindset home. His love of DIY projects has led him to build everything from swing sets to large backyard ziplines for his kids. This episode is for maintenance professionals, plant managers, engineers, manufacturing leaders, and anyone interested in preventive maintenance, root cause analysis, manufacturing startups, reliability, continuous improvement, and building stronger teams.

  6. Sep 23

    Ivan Getov: Maintenance Is More Than Fixing Things

    What happens when a company invests in predictive maintenance, AI, and new technology before fixing its basic maintenance processes? In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Ivan Getov, Maintenance Excellence Manager at Eastman Chemical Company, about why strong maintenance starts with the fundamentals. Ivan began his career as a chemical engineer and worked in operations before moving into maintenance management. Today, his focus is maintenance excellence and improving the systems that connect work identification, planning, scheduling, execution, and follow-up. Ivan explains why many maintenance teams stay stuck in reactive mode. Fixing a breakdown can feel rewarding because the results are immediate. The maintenance team gets equipment running again and becomes the hero. But Ivan believes organizations need to move away from that hero mentality and build systems that prevent problems before they become emergencies. The conversation also looks at predictive maintenance and AI. Ivan supports these technologies, but he makes an important point: technology cannot fix a broken process. If communication, planning, scheduling, and accountability are weak, adding more technology may simply make those problems happen faster. Ivan shares a real example involving a major river-water line rupture that affected a continuous manufacturing process. During the early response, people were working hard, but crews were losing time because scaffolding, insulation, lockouts, and other requirements were not properly coordinated. The solution wasn't another piece of technology. It was better organization, clear ownership, communication, accountability, escalation procedures, and a detailed plan. Martin and Ivan also discuss the complexity and safety responsibilities behind industrial maintenance, why communication between operations and maintenance matters, and why continuous learning can open unexpected career opportunities. Ivan's advice to younger professionals is simple: keep learning and stay open to opportunities. His own move from chemical engineering and operations into maintenance led him to a career he never originally expected—and one he has grown passionate about. About Ivan Getov Ivan Getov is a Maintenance Excellence Manager at Eastman Chemical Company. With a background in chemical engineering and operations, Ivan has worked as a maintenance manager and now focuses on improving maintenance processes and systems. Ivan also writes about maintenance and leadership on LinkedIn and Substack. He has published a book about leadership and, at the time of this interview, was working on another book focused on maintenance processes and practical playbooks.

  7. Sep 15

    The Power of Proactive Maintenance with Reinhardt de Jager

    What if you could know a machine was going to fail weeks before it actually happened? Instead of scrambling after a breakdown, your team could order the parts, plan the repair, and choose when to take the equipment offline. In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin sits down with Reinhardt de Jager, a Reliability Area Maintenance Manager whose work includes predictive maintenance, reliability-centered maintenance, lubrication programs, shutdowns, and outages. Reinhardt shares his approach to moving maintenance organizations away from reactive repairs and toward proactive reliability. One of the first places to start is with the preventive maintenance plan itself. A work order that simply tells a technician to “check motor” does not provide much value. Reinhardt explains why maintenance tasks should verify specifications, equipment condition, operating processes, and standards while addressing actual failure modes. The conversation then moves into predictive maintenance and condition-based monitoring. By tracking factors such as vibration, temperature, and current draw, maintenance teams can identify developing problems before they become unexpected failures. That changes the entire maintenance equation. Instead of waiting for equipment to break, teams can order parts, prepare the work, coordinate resources, and schedule downtime when it makes the most sense for production. Reinhardt also explains how better maintenance practices connect directly with spare-parts management. Knowing likely failure modes helps organizations decide what should be kept in the storeroom and where strong vendor relationships and fast turnaround times are needed. Martin and Reinhardt also discuss recurring equipment failures and an important question maintenance teams should ask: Why keep getting better at repairing the same problem when you could determine its root cause and eliminate it? Reinhardt shares a real example of condition monitoring detecting a serious problem inside an induction furnace shortly after a new lining was installed. The team trusted the monitoring system, shut down the furnace, investigated the problem, and discovered a potentially dangerous condition before it could develop into something much worse. The discussion ultimately comes back to a lesson Reinhardt received from one of his mentors. His job wasn't simply to fix equipment. His job was to help “move steel through the door.” Reliability is his function for helping make that happen. It is a perspective that connects maintenance with operations, safety, finance, production, inventory, and the larger goals of the business. About Reinhardt de Jager Reinhardt de Jager works in reliability and maintenance management, with responsibilities covering predictive maintenance, reliability-centered maintenance, lubrication, shutdowns, and outages. His career has given him experience in maintenance, reliability, condition-based monitoring, and manufacturing operations. Outside of work, Reinhardt is also continuing his education while raising a growing family.

  8. Sep 10

    Keeping Manufacturing Running: Predictive Maintenance, People & Parts with Tony Ingram

    What does it take to keep a manufacturing plant running when some machines date back decades and others are brand new? In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Tony Ingram, Senior Maintenance Supervisor at Daikin Applied in Faribault, Minnesota. Tony shares what maintenance really looks like inside a facility producing large air-conditioning systems for data centers, hospitals, factories, and schools. His team works with everything from large punch and shear systems to copper-processing equipment, foam presses, tooling, and machines dating back to the 1950s and earlier. Martin and Tony discuss the difference between reactive, preventive, and predictive maintenance. Tony explains how his operation is moving further into predictive maintenance by monitoring things such as vibration, temperature, oil levels, and tooling cycles. The goal is simple: spot trouble before a machine stops production. They also talk about one of the biggest challenges in maintenance—having the right people and the right spare parts when something goes wrong. Tony explains why new equipment should arrive with critical replacement parts already identified and available instead of waiting until the first failure. Tony also shares one of the most memorable equipment failures of his career: a steel storage system that left roughly two tons of steel about 30 feet in the air after a collision. The recovery took around six hours, with safety taking priority over speed. The conversation also covers the human side of maintenance, from operator-related problems and staffing challenges to knowing when a repair should be handled internally and when it makes more sense to call an expert. Outside the plant, Tony brings that same mechanical mindset to motorcycles. He talks about riding and rebuilding his own bike after a third-gear failure turned into a major engine project. Tony's experience offers a practical look at the people, planning, troubleshooting, parts, and technology required to keep modern manufacturing moving.

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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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