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The Equipment Didn't Fail. The Process Outgrew It.
You can walk into a plant and see an older machine still doing exactly what it was built to do. The motors turn. The conveyor runs. It cycles the same way it always has. What changed is everything around it. The product mix changed. Volumes changed. Somebody moved a workstation. Packaging changed. A manual step got added. The layout got tighter. The people learned how to work around the system instead of with it. Then the machine gets blamed. Sometimes that is fair. Sometimes
John Stikes
5 days ago6 min read


The Floor Was Costing Us More Than We Thought
When I was a maintenance manager, we were spending almost $10,000 per month on forklift wheels alone. That number got my attention pretty fast. A lot of those failures traced back to things that did not seem important until they started showing up on the maintenance bill. Shrink wrap and floor debris were getting pulled into wheel bearings. Forklifts were also driving over small broken boards, and that was causing failures too. Not every wheel problem came from the floor, obv
John Stikes
Aug 122 min read


You Get to Choose What You Put Up With: Why the Robot Gold Rush Gives Operators the Upper Hand
Walk onto the floor of any major industry trade show right now, and you’ll see the exact same thing five times before lunch. There’s a shiny new autonomous mobile robot dodging a fake obstacle. There’s a humanoid torso bolted to a pedestal gesturing vaguely at a plastic bin. There’s a pallet-moving machine painted in matte grey or slick white, cruising around a taped-off loop like it just won a science fair. Everyone is building the same machine. Every pitch deck sounds like
John Stikes
Aug 55 min read
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