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. 3d ago

    Building Reliable Maintenance Systems: Gabe Little on Asset Management and Automation

    Building Reliable Maintenance Systems: Gabe Little on Asset Management and Automation What does it take to keep a large distribution center running while preparing for the future of automation? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Gabe Little, a maintenance leader with experience at Jacobson Logistics, Amazon, ThredUP, and Ross Stores. Gabe shares how his career evolved from HVAC technician to leading maintenance teams and transitioning into equipment engineering focused on asset management and lifecycle planning. The conversation explores the importance of preventive maintenance, CMMS systems, vendor management, documentation, spare parts organization, and maintaining conveyor systems that keep distribution centers operating efficiently. Gabe also shares one of the biggest equipment failures of his career—a catastrophic carousel collapse—and explains how that experience led to better reliability practices and improved drive technology. Martin and Gabe also discuss how AI is beginning to assist maintenance professionals through analytics and dashboard reporting while emphasizing that experience, reliability, and strong maintenance fundamentals remain the foundation of successful operations. Whether you're a maintenance technician, supervisor, reliability engineer, or plant leader, this episode offers practical insights into building stronger maintenance programs and preparing facilities for the future.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  2. Aug 5

    Inside Manufacturing Facilities with Nathan Santiago

    Every minute of downtime matters in manufacturing. In this episode, Martin Engster sits down with Nathan Santiago, Facilities Engineer at C&H/New Holland, to discuss what it really takes to keep a large manufacturing campus operating efficiently. Nathan shares how preventive maintenance goes far beyond simply following OEM schedules. He explains how maintenance teams adapt service intervals for equipment that runs around the clock, organize specialized tools and spare parts at critical machines, and work closely with production teams to minimize downtime. The conversation also explores the growing role of predictive maintenance. Nathan discusses how sensors and cycle-count monitoring are helping manufacturers identify failing components before they create costly production interruptions. Beyond equipment maintenance, Nathan shares real-world examples of solving operational challenges. From eliminating hundreds of hours of laser downtime through a simple logistics improvement to responding quickly after severe roof leaks threatened production, he demonstrates how thoughtful problem-solving and teamwork can dramatically improve manufacturing performance. Whether you're involved in maintenance, facilities engineering, operations, or manufacturing leadership, this episode offers practical insights into reducing downtime, improving reliability, and supporting production through better planning.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  3. Jul 30

    Helmuth Lara: Maintenance Excellence in the World's Largest Machines

    What does it really take to keep the lights on for thousands of people? In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Helmuth Lara, an experienced mechanical engineer and plant manager whose career has spanned nearly three decades in oil & gas, gas turbines, rotating equipment, and power generation. From his early days working in South American refineries to managing power generation for the U.S. Virgin Islands, Helmuth shares what it takes to maintain some of the world's largest and most complex machines. The conversation explores the importance of preventive maintenance, how major overhauls are planned, and why successful maintenance is about far more than fixing broken equipment. Helmuth explains how coordination, planning, logistics, and teamwork all play critical roles in keeping critical infrastructure operating safely and reliably. He also shares one of the most dramatic equipment failures he has ever experienced—a gas turbine explosion caused by an undetected gas leak—and explains how careful investigation and engineering allowed the team to safely restore the plant. Martin and Helmuth also discuss today's biggest maintenance challenges, including long supply-chain lead times, predictive maintenance technologies, equipment reliability, and the changing landscape of power generation. They even dive into electric vehicles, energy efficiency, and why understanding where electricity actually comes from is more important than ever. Whether you work in maintenance, manufacturing, reliability, or simply enjoy learning how massive industrial systems operate, this episode provides valuable real-world insight from someone who has spent his career keeping critical equipment running.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  4. Jul 28

    The Hidden Side of Medical Manufacturing with Cory James

    Most people never stop to think about where the medical tubing inside catheters, stents, and other life-saving devices actually comes from. In this episode, Martin Engster sits down with Cory James, Plant Manager at Zeus Industrial Products, to pull back the curtain on one of the most important—but least visible—parts of medical manufacturing. Cory shares how Zeus Industrial Products manufactures precision medical-grade tubing used by many of the world's leading medical device companies. The conversation explores the challenges of balancing preventive maintenance with increasing production demands, the importance of investing in people, and why in-house engineering has become a competitive advantage. Drawing from his military background and leadership experience, Cory also discusses how discipline, teamwork, and continuous improvement help drive manufacturing excellence while navigating the growing pains that come with rapid business growth. Whether you're in maintenance, manufacturing leadership, engineering, or simply curious about how everyday products are made, this episode offers an inside look at an industry that quietly impacts millions of lives every day.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  5. Jul 24

    Keeping Glass Production Running: Maintenance Lessons with Josiah Peterson

    Every building, office, and home depends on glass, but few people ever stop to think about the complex manufacturing process behind it. In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Josiah Peterson, Maintenance Manager at Oldcastle Building Envelope, to discuss what it takes to keep a modern glass manufacturing facility operating efficiently. Josiah shares his unique career journey—from growing up on a dairy farm and working in logging communities to maintaining high-speed manufacturing equipment in industries ranging from Amazon and food production to energy drinks and now architectural glass manufacturing. The conversation explores the challenges of maintaining specialized equipment, sourcing obsolete replacement parts, balancing production demands with preventive maintenance, and introducing predictive maintenance technologies like vibration analysis and infrared inspections. Josiah also explains how glass is cut, tempered, polished, and prepared for residential and commercial projects, including supplying glass for Allegiant Stadium in Las Vegas. If you're interested in maintenance leadership, reliability, manufacturing careers, CMMS implementation, predictive maintenance, or industrial problem-solving, this episode offers practical insights from someone who has worked across multiple manufacturing industries.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  6. Jun 25

    Small Problems, Big Profits: Lessons in Maintenance and Leadership with James Harris

    Small problems often create the biggest losses. In this episode, James Harris shares how focusing on defects, root causes, and reliability transformed struggling operations and delivered major improvements. Martin Engster sits down with James Harris, a U.S. Army Reserve officer and experienced maintenance and engineering professional. James discusses his journey through manufacturing, process improvement, and military leadership. During the conversation, James explains how maintenance teams can move beyond reactive repairs and create lasting reliability. He shares stories from high-speed beverage production lines, discusses the importance of defect elimination, and explains why troubleshooting skills are more valuable than simply being the hero who fixes equipment after it breaks. James also reveals how one project produced a 60% increase in profit by focusing on the small issues that others overlooked. He discusses root cause analysis, preventive maintenance, reliability-centered maintenance, and why quality should sometimes outweigh the lowest price.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  7. Jun 23

    Todd Gibbs: How Small Changes Create Big Reliability Gains

    What does it take to keep thousands of automotive glass components moving through production every day? In this episode, Martin Engster sits down with Todd Gibbs, Maintenance Manager at Carlex Glass, to discuss more than four decades of maintenance experience and the importance of building reliability into manufacturing operations. Todd shares how his time serving in the U.S. Navy's nuclear submarine program helped shape his approach to maintenance and reliability. From vibration analysis and thermography to root cause analysis and planned shutdowns, he explains why reliability-centered maintenance delivers greater value than simply completing preventive maintenance tasks. Listeners will hear real-world examples of maintenance successes, including how upgrading conveyor chains eliminated costly downtime and how creative repairs helped avoid catastrophic failures while replacement parts were being scheduled. Todd also offers insights into automotive glass manufacturing, manpower challenges in the trades, spare parts strategies, and the role of new technologies like AI and 3D printing.   ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done. Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

  8. Jun 19

    Korey Mertz: The Hidden Costs of Ignoring Machine Maintenance

    In this episode of Maintenance Manufacturing Insights, Martin Engster sits down with Korey Mertz of Advanced Machine Engineering to discuss why preventive maintenance is often overlooked and how manufacturers can move from reactive repairs toward a more proactive approach. The show notes follow recommended practices for strong podcast descriptions and listener engagement. Korey shares his journey from studying mechanical engineering to leading business development within the Tool Clamping Systems Division at Advanced Machine Engineering. Drawing on years of experience working with drawbar systems and spindle components, he explains why monitoring pull force and understanding wear trends are essential to maintaining part quality and avoiding costly downtime. ------------------------- Are you responsible for keeping machines running and production on track? If you’re a maintenance manager, tool crib manager, or shop leader — we want to hear how you’re getting it done.   Apply to be a guest on https://maintenancemanufacturinginsights.com/guest and share your expertise with a wide audience eager to learn about you.

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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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