Great Question: A Manufacturing Podcast

Joe Kuhn, CMRP, former plant manager, engineer, and global reliability consultant, is now president of Lean Driven Reliability LLC. He is the author of the book “Zero to Hero: How to Jumpstart Your Reliability Journey Given Today’s Business Challenges” and the creator of the Joe Kuhn YouTube Channel, which offers content on starting your reliability journey and achieving financial independence. In our monthly podcast miniseries, Ask a Plant Manager, Joe considers a commonplace scenario facing the industry and offers his advice, as well as actions that you can take to get on track tomorrow. This episode explains why running time-based and condition-based maintenance in parallel is a costly mistake. Key takeaways Condition monitoring won't be perfect at first—expect a learning curve and commit for long-term gains. Avoid running time-based and condition-based maintenance systems together—it wastes resources. Pair condition monitoring with root cause analysis to drive real business impact. Protect condition monitoring resources from daily disruptions—require plant manager approval to reassign.

In this episode, listeners will gain insights into how air seal technology is revolutionizing the plastics film industry to reduce waste, save money, and promote more sustainable manufacturing processes. Addressing things like: Environmental and sustainability concerns, waste and housekeeping improvements and enhanced plant safety initiatives.

Electricity demand is soaring around the world, and in the U.S. electric supply is dwindling. Manufacturers may not have realized this – but they will, and very soon, as electric utilities begin to apply capacity charges to their supply costs. In this installment of the Great Question podcast, energy consultant Brian Reinke – author of a new article – diagnoses the problem and suggests how manufacturers might prepare themselves to address the surging electricity costs. 

Mental Health First Aid (MHFA) at Work for Manufacturing, launched by the National Council for Mental Wellbeing, is a series of four courses designed to improve mental health literacy among employees and leaders in the manufacturing industry. Lynn Burke Hennighausen and Rob Vallentine, national trainers for the program, joined IndustryWeek during Mental Health Awareness Month to discuss mental health challenges in manufacturing and how the MHFA training program can lead to a safer and more productive work environment.

Keith Bartels, Director of Products and Solutions at Tobii, delves into the revolutionary role of eye-tracking technology in workforce training. He discusses how this innovative approach streamlines onboarding, reduces errors, and strengthens standard operating procedures. With tools like Glasses X, new hires can quickly learn from experienced colleagues, improving skill transfer and safety in manufacturing settings. Bartels also highlights cost-effective support models for implementing this game-changing technology, ensuring a boost in efficiency and operational excellence.

In this episode of Great Question: A Manufacturing Podcast, Thomas Wilk, chief editor of Plant Services, is joined by Christine Nishimoto, director of asset management software at IBM, for an insightful discussion on how AI agents are reshaping data-driven asset management. Together, they explore the evolving role of artificial intelligence in improving productivity, sustainability, and safety across manufacturing sectors. From tackling long-standing data challenges to envisioning multi-agent systems that can automate complex workflows, the conversation highlights the transformative potential of AI tools in industrial environments. Christine also emphasizes the importance of transparency, data integrity, and regulatory compliance as organizations adopt these technologies. Key takeaways Clean, accessible, and accurate data is critical for effective AI-driven asset management. AI agents can automate multistep tasks like work order creation, boosting efficiency. Tailored AI tools must respect industry-specific privacy and compliance standards. Adoption of AI across sectors is accelerating, revealing untapped optimization potential.

Suketu Gandhi, partner and chair of strategic operations with Kearney, offers advice on how to deal with supply chain disruptions in this new era of tariffs.

Hey, have you heard that this AI thing is a big deal? That companies are slapping AI labels on every product they sell? That our benevolent robot overlords will favor those humans who speak highly of them now before they take over?  There was a lot of talk about that at Automate in Detroit this week, the annual trade show for industrial automation in which we imperfect biological organisms really do sit in awe of our technological superiors. Really, this is love, not fear. Sharing their observations on how much they look forward to this utopian future in which we'll be sure the keep the machines oiled and the software patched were: Mike Bacidore, Editor-in-Chief of Control Design Rehana Begg, Editor-in-Chief of Machine Design Robert Schoenberger, Editor-in-Chief of IndustryWeek and Editorial Director of Endeavor Business Media's Manufacturing Group Sharon Spielman, Technical Editor for Machine Design Linda Wilson, Editor-in-Chief of Vision Systems Design

Glen Powell is a senior engineering analyst with Hydro, Inc.’s Global Engineering division. He has nine years of experience in centrifugal pumps, vibration analysis, machinery reliability, and 3D simulation and design. Glen recently spoke with Thomas Wilk, chief editor of Plant Services, about the evolving challenges of workforce development in the maintenance and reliability space. The conversation also touches on the role of emerging technologies like AI in reliability workflows and dives deep into vibration analysis, including its limitations and advanced applications for diagnosing issues like resonance. Key takeaways Formal training alone isn't enough—intentional, hands-on experience accelerates workforce readiness. Bridging generational gaps requires clear career paths and trust in leadership follow-through. AI tools should support, not replace, critical thinking and field expertise on the plant floor. Modal analysis and motion amplification are powerful tools to diagnose and fix elusive resonance issues in aging equipment.  

Discover how automation can empower manufacturing businesses to weather economic storms. Explore ways it enhances efficiency, safety, and sustainability. Learn about reducing labor dependencies while boosting productivity. Hear insights on customized strategies for resilience, ensuring long-term success even in downturns. This discussion reveals the compelling benefits of automation, transforming challenges into opportunities for growth.