Great Question: A Manufacturing Podcast Ask A Plant Manager: Why Predictive Maintenance Fails Without Problem Solving On The Plant Floor
Oct 30, 2025
Joe Kuhn, a CMRP-certified former plant manager and reliability consultant, dives into the essentials of blending predictive maintenance with practical problem solving. He cautions against over-relying on technology, emphasizing that it can signal issues but not provide solutions. Joe highlights the importance of on-the-floor investigation following condition monitoring, and urges starting predictive programs with targeted KPIs. He also shares common pitfalls to avoid and discusses how balancing tech with experienced insights fosters effective collaboration on the shop floor.
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Blend Tech With Shop-Floor Problem Solving
- Do combine condition monitoring technology with shop-floor problem solving to fix root causes, not just detect anomalies.
- Go see the asset, talk to mechanics, and autopsy failed parts so the issue doesn't repeat.
Alerts Are Not Decisions
- Technology should find anomalies quickly but not replace human judgment or action at the point of use.
- Relying solely on red/green indicators leads to repeated failures and disappointment.
Start Where Failures Matter Most
- Do start condition monitoring where your failures actually are, using KPIs and historians to target problem areas.
- Prioritize critical production assets so early detection yields visible downtime and cost savings.
