Keeping Manufacturing Running: Predictive Maintenance, People & Parts with Tony Ingram

What does it take to keep a manufacturing plant running when some machines date back decades and others are brand new?

In this episode of Maintenance Manufacturing Insights with Martin Engster, Martin talks with Tony Ingram, Senior Maintenance Supervisor at Daikin Applied in Faribault, Minnesota.

Tony shares what maintenance really looks like inside a facility producing large air-conditioning systems for data centers, hospitals, factories, and schools. His team works with everything from large punch and shear systems to copper-processing equipment, foam presses, tooling, and machines dating back to the 1950s and earlier.

Martin and Tony discuss the difference between reactive, preventive, and predictive maintenance. Tony explains how his operation is moving further into predictive maintenance by monitoring things such as vibration, temperature, oil levels, and tooling cycles. The goal is simple: spot trouble before a machine stops production.

They also talk about one of the biggest challenges in maintenance—having the right people and the right spare parts when something goes wrong. Tony explains why new equipment should arrive with critical replacement parts already identified and available instead of waiting until the first failure.

Tony also shares one of the most memorable equipment failures of his career: a steel storage system that left roughly two tons of steel about 30 feet in the air after a collision. The recovery took around six hours, with safety taking priority over speed.

The conversation also covers the human side of maintenance, from operator-related problems and staffing challenges to knowing when a repair should be handled internally and when it makes more sense to call an expert.

Outside the plant, Tony brings that same mechanical mindset to motorcycles. He talks about riding and rebuilding his own bike after a third-gear failure turned into a major engine project.

Tony's experience offers a practical look at the people, planning, troubleshooting, parts, and technology required to keep modern manufacturing moving.