Reliability in Motion

  In today’s plants, maintenance success depends on data as much as wrenches. Sensors, vibration analysis, oil analysis and computerized maintenance management systems (CMMS) provide valuable insights but only when used effectively. Proper training of these devices and monitoring is key to understanding failure rates and problem solving. Data-driven maintenance doesn’t mean drowning in numbers; it means finding meaningful trends. A vibration spike, rising temperature trend, or repeated failure code can point to a root cause before failure occurs. The challenge is turning that data into decisions knowing when to intervene and why . Teams that analyze data weekly and connect it to visual dashboards can reduce unplanned downtime by 15–25%. More importantly, they create a continuous feedback loop between maintenance, production, and engineering. The result is faster troubleshooting, smarter scheduling, and higher equipment reliability. Using maintenance data proactively turns r...

A strong maintenance culture is more than just fixing machines it’s about shaping values, habits, and teamwork that keep operations running smoothly. When maintenance becomes part of an organization’s mindset, equipment lasts longer, downtime drops, and everyone takes pride in reliability and safety. Creating this kind of culture starts with clear policies and strong leadership support. When leaders show that maintenance matters and provide the right tools and training, employees are more motivated to take ownership of their work. Communication also plays a big role sharing updates, documenting repairs, and celebrating maintenance successes keeps everyone on the same page. Technology can help too. A C omputerized Maintenance Management System (CMMS) makes it easier to track work orders, plan preventive maintenance, and monitor performance. Over time, these systems help teams stay proactive instead of reactive. The benefits speak for themselves: fewer unexpected breakdowns, safer wo...

Many maintenance departments still operate   r eactively   fixing equipment only after it fails. While that may seem like part of the job, constant firefighting drains time, budget, and morale. Every unplanned breakdown costs more than just a repair it affects production, quality, and customer trust. As I like to remind teams" Don't be firefighters in Maintenance ", Firefighting may make you look busy, but it’s unproductive and costly. It leads to extended downtime, higher overtime, and missed opportunities for improvement. A strong Preventive Maintenace program changes that mindset from repairing to reliability. The goal isn't to fix what's broken, it's to make sure it never breaks again.  In my experience, successful PM programs begin with three key steps: Understanding failure modes, Schedule around actual usage and train technicians to catch early warning signs. Understanding failure modes, you can't prevent what you don't understand. Every asset h...

  Troubleshooting is more than fixing a problem; it’s uncovering the  reason  it happened. The best reliability engineers approach troubleshooting like detectives. Instead of jumping to conclusions, they ask: What changed just before the failure occurred? Is this a pattern or a one-time event? What conditions were present that may have accelerated wear or damage? Using a root cause analysis (RCA) approach helps move from symptom-based fixes to long-term solutions. For example, a repeated motor failure might not be an electrical issue at all it could stem from misalignment or vibration caused by poor installation. By documenting findings and sharing lessons learned, we turn individual problems into organizational knowledge. That’s how reliability grows one solved problem at a time. There are a few steps that a good troubleshooting maintenance Tech or Engineer should follow. Go to the operator that is running the machine and ask questions, was the machine making and kind of...

  About Me Hardworking Passionate, goal-oriented working Professional.   Hello, my name is Perry Russell. I am a 50-year-old husband and father of 2 wonderful children, both who have already graduated from college. Professionally I am a Maintenance Manager and Reliability Engineer at a Plastic compounding facility. I have been in the trades all my life, starting out as a welder, electrician, robotics and control Engineer and now in my current position with over 30 years of experience. I earned my associate's in electrical engineering technology from Cleveland Community College in 2011 and started my journey to completing my bachelor's in industrial engineering technology in 2024.  I enjoy teaching young people trade crafts in my community and anyone who is willing to get their hands dirty. I restore old cars with my son every chance I get, and we enjoy creating things through welding projects. Some of my hobbies are, running Marathons and strength training. Yes, at 5...

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