The Maintainers: A Blue Cap Community Podcast

Repurposing Rail Steel Since 1893 with Dave Zapata, General Supervisor of Engineering and Maintenance at Chicago Heights Steel

Today on The Maintainers, David & Jake welcome Dave Zapata, the general supervisor of engineering and maintenance at Chicago Heights Steel (CHS). CHS is the largest special-market mill in the United States and has been running the same type of operation since its founding in 1893.  Dave calls his time with CHS “his longest summer job” as he joined the company straight out of high school in 1994 as a summer laborer. He instead stayed on, working his way through departments and up the ladder from engineering to mechanical to electrical.  You’ll hear all about CHS’s history and how they’ve evolved their operations over the years. Dave has been instrumental in leading the implementation of new technologies designed to make their processes safer and more efficient as they produce over 14m fence posts each year. He explains how they’ve managed to reduce downtime while maintaining a delicate balance of maintaining current equipment while replacing outdated machinery. In 2019, the company modernized its mill with a new OT network, virtual machines, and HMI systems, dramatically improving productivity. Dave also reveals exciting plans for further advancements, including new robotic lines for fence post production, underscoring CHS's commitment to staying at the forefront of manufacturing technology. The trio also discuss Dave’s management philosophy, which centers around hands-on leadership and providing his workers with the same opportunities he had coming up at CHS. He stresses the importance of patience and practical learning for those just beginning in their careers and offers his view of the future of the workforce.  — Guest Bio Dave Zapata is the General Supervisor of Engineering and Maintenance at Chicago Heights Steel (CHS), the world's largest special market mill in the United States. Dave's journey with CHS began right out of high school in 1994, when he took what was initially intended to be a summer job. Over the next three decades, Dave transitioned through various roles within the company, gaining in-depth knowledge of mechanical and electrical maintenance. Dave has been instrumental in modernizing CHS operations, focusing on increasing efficiency and safety. Notably, he spearheaded significant equipment upgrades, reducing the need for manual labor and increasing uptime. His leadership style emphasizes hands-on involvement and fostering a strong rapport with his team. — Guest Quote "We went from 1959 to 2020 technology. It was a learning process. My approach is: I take the time to learn. Analyze it, make sure l have all the information. And then come up with a solution, and then implement that solution." – Dave Zapata — Time Stamps  00:00 Episode Start  02:00 Opening Icebreaker 03:40 Dave’s Background 04:30 Segment 01: The Maintainer Mashup 05:00 The operation at Chicago Heights Steel 06:40 Finding rail from 1893 08:40 How operations have evolved over the years 10:45 The importance of your team 11:55 Segment 02: What's in Your Toolkit? 12:35 Leading with a learner's mindset 15:15 Modernizing their manufacturing 18:30 Advice on leveling up in your career 19:50 Segment 03: The Future of Factories 20:40 Dave's recommendations for the future 22:25 Solving for a lack of workers 24:20 Ways to upskill your existing maintainers 26:00 Segment 04: Fix It Funnies — Links * Connect with Dave Zapata on LinkedIn [https://www.linkedin.com/in/david-zapata-31b52921/] * Check out Chicago Heights Steel [https://chs.com/] * Connect with David Lee on LinkedIn [https://www.linkedin.com/in/david-lee-coss-csst-390578b1/] * Connect with Jake Hall on LinkedIn [https://www.linkedin.com/in/jacobrhall/] * Learn more about Tractian [https://tractian.com/en]

Achieving Global Standards in Manufacturing Featuring Rafael Padilha Gama, USCAN Maintenance & Reliability Director with Ingredion Incorporated

In this episode of The Maintainers, hosts David Lee and Jake Hall chat with Rafael Padilha Gama, AKA Rafa, the U.S. and Canada Maintenance and Reliability Director at Ingredion. Rafa shares his extensive background in the maintenance and reliability industry, including his roles at InBev and Unilever. He discusses his journey from electrical electronics in Brazil to handling global operations, bringing a wealth of insights into maintenance, reliability, and automation practices across diverse industries and geographies.  Rafa emphasizes the blend of technical expertise and leadership needed in effective maintenance roles. He believes the critical aspects include having the right people, robust processes, and utilizing appropriate tools. Rafa’s philosophy of focusing on what one can control and improving what they have autonomy over is central to his approach. He provides examples of how successful maintenance programs can enhance operational efficiencies, such as using asset criticality concepts to unlock bottlenecks and employing technology like sensors to improve predictive maintenance.  The discussion also touches on cultural challenges and communication strategies necessary for managing teams across different countries. Rafa finds value in ensuring that the message delivered is precisely the message received, especially while dealing with diverse cultures from Brazil to Colombia to the United States. His effective communication practices help ensure alignment and consistency across various teams and operations.  Finally, Rafa talks about the future of factories, highlighting the increasing role of technology and data in maintenance and reliability. He envisions a future where maintenance professionals become data scientists, utilizing AI and smart sensors to foresee and prevent failures. Rafa’s insights serve as useful guidelines for listeners who strive to drive change and adopt innovative technologies in their maintenance practices. — Guest Bio Rafael Padilha Gama boasts decades of experience in the maintenance and reliability industry. He currently serves as the U.S. and Canada Maintenance and Reliability Director at Ingredion, a global manufacturer of ingredients and solutions. Rafael has a rich background in electrical electronics and automation, with an impressive career including notable stints at InBev and Unilever, where he honed his expertise in automation, maintenance, and reliability. Rafael is passionate about optimizing maintenance processes and leveraging technology to enhance industrial efficiency. His philosophy centers on continuous improvement, leadership, and leveraging technology to enhance maintenance and reliability processes. — Guest Quote “Every time I had a problem, I said, 'What am I going to do to not have this problem again?'   I hate having the same problems twice or more. So the first [solution] is reliability. Maintenance & reliability is not only technical, it's a lot of leadership. You need to have the right people in the right place” – Rafael Padilha Gama — Time Stamps  00:00 Episode Start  02:30 Opening Icebreaker 03:20 Rafael's Background 04:25 Segment 01: The Maintainer Mashup 04:40 What is Ingredion? 07:05 How Rafael and his team ensure all 40 facilities operate on the same standards 09:30 Setting a high bar for yourself 12:15 Proving the power of maintenance and reliability 15:50 Segment 02: What's in Your Toolkit? 16:25 What sets Rafael apart 20:05 The importance of good communication 23:30 Tips for implementing new initiatives and earning buy-in 27:20 Segment 03: The Future of Factories 28:20 Why Ingredion leverages Tractian 33:50 The evolution of maintenance routes 38:00 Empowering workers with technology 40:30 Segment 04: Fix It Funnies — Links * Connect with Rafael Padilha Gama on LinkedIn [https://www.linkedin.com/in/rafael-padilha-gama-67807753/] * Check out Ingredion [https://www.ingredion.com/na/en-us.html] * Connect with David Lee on LinkedIn [https://www.linkedin.com/in/david-lee-coss-csst-390578b1/] * Connect with Jake Hall on LinkedIn [https://www.linkedin.com/in/jacobrhall/] * Learn more about Tractian [https://tractian.com/en]

Maintaining 100% OEE with Lean Manufacturing Featuring Jim Kozel, COO of World Emblem

In this episode of The Maintainers, hosts David Lee and Jake Hall sit down with Jim Kozel, COO at World Emblem, the largest patch producer in the world, to delve into the intricacies of lean manufacturing and operational excellence. Jim is a seasoned pro when it comes to running high-efficiency manufacturing plants, and he has some stories to share! Throughout the conversation, Jim highlights how his team embraced lean principles with guidance from the True Lean Toyota-University of Kentucky partnership. By implementing these strategies, his team has achieved substantial productivity gains and on-time performance while sustaining quality in their custom patch manufacturing. They have made major improvements in each of their facilities across North America and Mexico.  Jim is not stuck in the past, and he shares his thoughts on how competitive manufacturing can be brought back to US soil by leveraging AI, automation, and modern tools. Jim's passion for manufacturing extends to personal anecdotes, including his love for coffee and lifelong learning, making this episode a blend of professional wisdom and personalized storytelling. — Guest Bio Jim’s extensive experience in both plant management and the industry World Emblem caters to has propelled Jim from Plant Manager of the Atlanta location to his current title as Vice President of Plant Operations for the United States and Canada. Despite his Six Sigma Black Belt in Lean Manufacturing and his technical training at the Plant Managers Institute, Jim attests to his 20 years of experience in team leadership as the biggest contributing factor to the successes he has attained throughout his career. It is this factor that helps him motivate his current team to achieve success. As World Emblem’s Vice President of Operations, Jim provides for the consistency and predictability of all products to World Emblem customers from  every production facility throughout the United States and Canada. — Guest Quote “AI is going to redfine managers’ roles. But you will always need to have the leadership role if you have people in there. The evolution of the personnel and getting people to be able to stay up with technology is key. That’s your biggest hurdle.” – Jim Kozel — Time Stamps  00:00 Episode Start  01:50 Opening Icebreaker 04:00 Jim's Background 07:15 When Jim joined the team at World Emblem 09:05 The definition of lean manufacturing 10:35 Segment 01: The Maintainer Mashup 11:00 Origins of World Emblem 12:45 How Jim succesfully implemented the lean framework 14:35 The University of Kentucky <> Toyota Partnership 17:30 True Lean for Executive Leadership 19:40 Segment 02: What's in Your Toolkit? 20:25 Jim's advice from his own career 21:40 How to hit 100% OEE 24:15 Setting realistic expectations for your team 26:35 The daily impact on workers' lives 30:10 Segment 03: The Future of Factories 30:35 Leveraging automation to nearshore and reshore 33:30 The constant need for labor 34:40 Segment 04: Fix It Funnies — Links * Connect with Jim Kozel on LinkedIn [https://www.linkedin.com/in/james-kozel-a439a3166/] * Check out World Emblem [https://www.worldemblem.com/] * Connect with David Lee on LinkedIn [https://www.linkedin.com/in/david-lee-coss-csst-390578b1/] * Connect with Jake Hall on LinkedIn [https://www.linkedin.com/in/jacobrhall/] * Learn more about Tractian [https://tractian.com/en]

Embracing New Tech and Empowering Teams with Sam Hancock, Maintenance Manager at Sumitomo Drive Technologies

In this episode of The Maintainers, hosts David Lee and Jake Hall dive deep with Sam Hancock, the maintenance manager at Sumitomo Drive Technologies. Sam's journey, spanning decades in the industry, offers a wealth of insights into the world of maintenance and reliability. The discussion delves into practical advice for developing robust maintenance programs, leveraging advanced CMMS systems, and cultivating a safety-first culture inspired by Sam's time at DuPont. He emphasizes the critical need for proper training, team collaboration, and smart technology integration. He also shares intriguing insights on bridging the gap between engineering design and real-world application, peppered with lighthearted anecdotes about challenges faced and lessons learned. The conversation then shifts to the future of factory maintenance, exploring emerging technologies like robotic thermography and the ongoing evolution of CMMS. With an optimistic outlook, Sam discusses how his team has embraced digital work orders and other technological advancements to enhance efficiency. The episode concludes with Sam's personal tips for maintaining work-life balance and his curiosity about developments in autonomous vehicles, offering listeners a blend of professional wisdom and relatable experiences. — Guest Bio Sam Hancock is an accomplished maintenance manager at Sumitomo Drive Technologies, with over a decade of experience at the company. He began his career at DuPont, where he gained invaluable experience in various roles related to maintenance and reliability. Known for his innovative approach, Sam has worked across different industries, excelling in both engineering and management. Currently, he is deeply involved in advancing maintenance practices at Sumitomo, ensuring that equipment is always operational and effective. — Guest Quote "Stay grounded. Machines are still machines and people are still people. That being said, there's a lot of technology that makes things easier. That make the paperwork and administration work so much better. Take advantage of the technologies there.” – Sam Hancock — Time Stamps  00:00 Episode Start  01:40 Opening Icebreaker  02:15 Sam's Background 08:00 Segment 01: The Maintainer Mashup 08:30 Sam's journey with Sumitomo 10:45  How Sumitomo approaches maintenance 12:50 The push for more customized machinery 14:45 Where you can turn to software for assistance 16:45 Segment 02: What's in Your Toolkit? 17:10 The importance of safety & mentorship 18:40 Advice for those starting out their careers 22:10 Segment 03: The Future of Factories 22:40 Don't forget the human element while adopting new tech 26:40 Dedicating roles for software management 29:20 Segment 04: Fix It Funnies — Links * Connect with Sam Hancock on LinkedIn [https://www.linkedin.com/in/samuel-hancock-1a077126/] * Check out Sumitomo Drive Technologies [https://www.sumitomodrive.com/en-us] * Connect with David Lee on LinkedIn [https://www.linkedin.com/in/david-lee-coss-csst-390578b1/] * Connect with Jake Hall on LinkedIn [https://www.linkedin.com/in/jacobrhall/] * Learn more about Tractian [https://tractian.com/en]

Transforming the Perspective of Manufacturing with Jake Rice, Facilities Maintenance Supervisor at O-I Glass

On today’s episode of The Maintainers, hosts David and Jake welcome Jake Hall, the Facilities Maintenance Supervisor at O-I Glass, a prominent global manufacturer of glass containers. Chances are, you’ve enjoyed a drink from one of their bottles at some point in your life. Jake Rice shares a wealth of experiences, from his time as a Navy Interior Communication Specialist to his adventures as a deep-sea diver, ultimately leading him to a fulfilling career in industrial maintenance. Interestingly, before joining O-I Glass, he was unaware that their manufacturing facility was located just around the corner from his home in Toano. Listeners will gain insights into the challenges of manpower shortages in the post-COVID landscape, as well as the complexities involved in managing continuous and batch processes within glass manufacturing. Throughout the discussion, Rice emphasizes the critical importance of knowledge transfer and his innovative approach to apprenticeship within his team. The episode also provides an insider’s perspective on maintaining a factory that has been operational for decades, producing thousands of glass bottles every minute. Jake discusses how companies should prepare for the future workforce and advocates for a shift in how maintenance careers are perceived. Whether you’re an industry veteran or just starting out, Jake Rice’s stories and advice are sure to inspire and educate. — Guest Bio Jake Rice is 44 years old and has had quite the journey through the maintenance world. Jake joined the navy after high school, worked and received two AS degrees. After the Navy, Jake worked at an R&D company out of the NASA Langley Research Park, worked as an offshore commercial diver, and is now the Facilities Maintenance Supervisor at Owens Illinois (O-I) glass plant in Toano, Virginia.  — Guest Quote "When you take manufacturing and you no longer view it as a last resort career opportunity. But as [one] that people should be excited about because [of] the success that it can create in a person's future...I think that's going to make these companies, and really the future of our factories a lot more successful.” – Jake Rice — Time Stamps  00:00 Episode Start 01:50 Opening Icebreaker 03:15  Jake's Background 07:30 Segment 01: The Maintainer Mashup 08:10 The journey to O-I Glass 13:05 How O-I Glass Operates 17:00 Maintaining a plant that produces over 1,500 bottles per minute 18:45 Managing a declining workforce post pandemic 23:40 Segment 02: What's in Your Toolkit? 24:00 Where Jake makes his impact 27:15 Segment 03: The Future of Factories 28:20 Shifting the perspective of manufacturing 29:30 Why instant solutions are a challenge for the industry 32:45 Tackling outdated equipment 34:10 Segment 04: Fix It Funnies  — Links * Connect with Jake Rice on LinkedIn [https://www.linkedin.com/in/jake-rice-42706918a] * Check out O-I Glass [https://www.o-i.com/] * Connect with David Lee on LinkedIn [https://www.linkedin.com/in/david-lee-coss-csst-390578b1/] * Connect with Jake Hall on LinkedIn [https://www.linkedin.com/in/jacobrhall/] * Learn more about Tractian [https://tractian.com/en]