Episode Details

What does it take to build a manufacturing operation from the ground up while also building the maintenance systems that keep it running?

In this episode of Maintenance Manufacturing Insights, Martin Engster talks with Varadarajan “V” Balaraman, a site plant manager helping build a startup manufacturing operation within an established company.

V shares why starting with new equipment does not mean maintenance can wait. New machines may have fewer breakdowns, but that can also mean the team has fewer chances to learn how the equipment will fail. His approach starts with vendor-recommended preventive maintenance, spare parts, and inspection routines. Then, as real-world failures happen, the team turns those problems into lessons.

Martin and V discuss root cause analysis and the importance of looking beyond the immediate machine failure. V explains his approach using five areas: man, machine, method, material, and environment. Instead of simply fixing what broke, the goal is to understand why it happened and use that knowledge to improve the maintenance program.

V also shares a real example involving a prop shaft balancing machine. A worn chuck was creating vibration that made good parts appear bad, resulting in scrap and repeated correction attempts. By digging into the measurement system and developing a monthly calibration process, the team was able to identify problems before they created larger production losses.

Another example comes from V’s current plant, where glue repeatedly clogged a robotic spray system. After exploring the technical solutions available, V realized technology alone could not eliminate the problem. The answer was a better operating process, including flushing the system before production and whenever the line stopped.

The lesson is simple: first determine what technology can solve. When technology reaches its limit, build clear and repeatable work procedures around that reality.

The conversation also explores the people side of manufacturing. V explains why operators need a clear way to report what they see and hear on the floor. A small noise noticed by an operator could be the first warning of a larger problem. Building a system where those concerns are captured, reviewed, and resolved helps make maintenance everyone's responsibility.

V describes his startup role as being an architect. He is helping turn a “jungle” into an organized value stream by building processes, equipment systems, material flow, quality practices, maintenance routines, and a team culture one problem at a time.

Outside of manufacturing, V brings that same builder mindset home. His love of DIY projects has led him to build everything from swing sets to large backyard ziplines for his kids.

This episode is for maintenance professionals, plant managers, engineers, manufacturing leaders, and anyone interested in preventive maintenance, root cause analysis, manufacturing startups, reliability, continuous improvement, and building stronger teams.