Why "No Alerts" Can Mean Success: Colin Morris of MaintainX on AI, Digital Logs, and Predictive Maintenance

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Overview

Predictive maintenance powered by AI has been promised to manufacturers for years, and in many plants it still hasn't delivered. In this episode of Manufacturing Happy Hour, host Chris Luecke asks Colin Morris, Senior Director of Solution Consulting at MaintainX, why predictive initiatives stall, what data has to exist before AI can help, and where AI actually fits in day-to-day maintenance work. Colin's position is that the data mostly exists but is scattered and unstructured, that the foundations are often skipped, and that AI's biggest near-term value lies less in exotic predictive models than in supporting technicians' routine work, especially scheduling, voice capture, and knowledge transfer.

16 min read

Revisiting the data question

Chris frames the conversation around an interview from roughly two years earlier with Nick, a MaintainX co-founder. At that point AI discussions in this space were just beginning, and Nick had argued that AI only works in a maintenance environment if it has good data. Chris asks whether manufacturers now have that data and infrastructure.

Colin believes many customers and prospects do have the data. The problem, in his view, is its form: it is highly unstructured and spread across disparate systems. Centralizing it in an easy-to-understand format that AI can "layer on top of" remains a major challenge for the industry. He also notes that some companies pull from data sources that are on-premise only, and moving that data into a cloud solution can still be difficult.

Moving beyond the predictive-only mindset

Asked about other gaps between the promise of AI-driven predictive maintenance and what frontline workers actually experience, Colin describes a longstanding default in the industry. When people think of AI in maintenance, they think of predictive or prescriptive maintenance: how can the machine tell me what's broken, and how can I make sure it doesn't break again? Historically, approaches such as vibration analysis and fault classification have required substantial resources, expertise, and time.

Colin sees a larger opportunity in using AI to supplement technicians' everyday work. His questions are practical ones: how to make it easier to repair assets, and how to surface information and data quickly, instead of building up "a very particular set of individuals with a very particular set of skills" just to get predictive insights.

What the platform does, in plain terms

Chris asks Colin to explain the job as if talking to someone over a drink. Colin jokes that after eight years in the industry, his wife still doesn't know what he does. His description is that MaintainX is a tool that makes maintenance people more effective, presents digital work instructions for performing tasks in a facility, and simplifies asset management. In his shorthand, the goal is making sure machines make widgets "faster, better, and easier."

Chris offers his own framing from when he worked in the space. Manufacturers talk constantly about digital transformation of the factory or enterprise, but Chris liked to describe a "micro transformation" at the maintenance level. That means getting rid of Post-it notes and spreadsheets that track recurring tasks every 28 days or every week, and moving everything into a single cloud-based source of truth that is accessible from a desktop or a phone.

Why predictive initiatives stall: no news can be good news

On why predictive projects get stuck, Colin says people often expect predictive or prescriptive analytics to "solve world hunger." In practice, results depend on where in its life cycle you begin monitoring an asset. If the asset is in a healthy phase, there may simply be nothing wrong with it, and you can go long periods without detecting an issue or surfacing any insights.

He compares this to a car. If it runs well, you don't take it in, and you can't say it is about to fail because you haven't heard or seen a problem. If monitoring begins while an asset is performing well, nothing will happen. In his view, people often fail to understand that "no insights are sometimes good insights": things are running well, or repairs are happening at the right cadence. He describes a kind of confirmation bias in which people really want the system to flag something, when "no news is sometimes good news."

Chris agrees and relates it to software in general. The less he has to think about a tool, the more confident he is that it is doing its job. A quiet system can show that processes have moved the team from reactive into proactive work.

The skipped foundation: knowing what's in your facility

Chris asks whether companies skip foundational steps when they digitize maintenance. Colin says some people expect to stand up an application in seconds. The biggest challenge still facing the market, he argues, is that many facilities lack good digital records of what equipment they actually have. That can mean a period in which a company has to outsource the work or send an intern around the plant to collect data that exists nowhere else. Only the facility itself can make sure its data is accurate.

Colin singles out parts information. Replacement components often have some of the longest lead times, and without good parts data a plant ends up waiting, or paying heavily to have something overnighted. A full foundation, in his view, includes maintenance plans and asset plans, knowledge of existing parts and inventory, and a plan for how other data sources connect. That means working out whether data will come from an ERP, a QMS, or an MES, and how those systems will talk to each other. He calls it a progression rather than an overnight journey. He also says it's fine to start with a standalone application, since "you don't need to have all the bells and whistles from day one."

The minimum parts data to capture

Chris asks for an actionable list: if someone is sent out to walk the floor, what should they record about parts? Colin's answer covers several items:

  • Quantity: how many of each part you have.
  • Location: where it sits in the facility, ideally down to aisle, row, and bin if such a system exists. This reduces the time technicians spend hunting for parts.
  • Obsolescence: whether parts are still useful. Colin says customers frequently report things like a motor that has sat on a shelf for 25 years with nobody knowing where it goes. Such items should probably be disposed of or sold.
  • Asset linkage: a direct correlation between each part and the piece of equipment it belongs to, which he calls a major process in itself.
  • Classification and unit counts: good parts classification and accurate counts.

Colin notes that this last group becomes especially important once a company pursues integrations, for example exchanging data between an EAM and an ERP.

Eight years of change: from cost center to cost saver

Chris points out that the older label, CMMS (computerized maintenance management system), now feels somewhat antiquated, and asks about the biggest change over Colin's eight years in the field. Colin names the shift from treating maintenance as a cost center to seeing it as a cost saver. Historically, companies didn't want to spend on maintenance or on software for it, and they kept deferring. Now, as manufacturing returns to North America amid a labor shortage, Colin says companies can't let maintenance remain something that happens in the background. More of them are investing in maintenance and reliability to better understand their equipment and reliability metrics. In his words, maintenance has moved from "the forgotten child" to a key component of digital transformation projects.

The past two years: AI across the whole workflow

For the more recent period, Colin says AI has accelerated this change, with more solutions offering AI tools. The focus used to be predictive and prescriptive analytics, but he now sees AI applied across all segments of the work. He describes it as a tool in the tool belt for getting information and understanding what needs to be done. It doesn't have to act entirely on its own. With a human in the loop, AI can take over repetitive tasks it understands well. He expects another significant leap with agents and more tooling that simplifies the overall maintenance execution journey.

What an agentic future looks like: scheduling first

Colin expects humans to remain in the loop, but he sees agents taking the first pass at actions. The use case he hears most often is scheduling and planning. Schedules are known, and so is who will be available when. An agent could review all pending jobs, their prioritization and criticality, and propose something like "I think Bob should do these tasks and here's why," which a person then accepts or declines. That, he says, is where agents will start. Over time he expects more activities to become fully automated, possibly to the point where scheduling or planning is no longer anyone's full-time job and people simply approve plans or reject them with a reason.

Chris says scheduling is probably the number one topic that comes up on the show when people discuss where AI or agents make sense, and asks how schedulers feel about it. Colin calls it a very challenging job because it requires coordinating across teams with competing priorities. Operations doesn't want to take a line down for maintenance, and maintenance doesn't want to work overtime. He describes the scheduler as "playing traffic cop." Chris draws on a past role as a project engineer at Metal Container Corporation, which made aluminum cans. There, some people wanted the line back up as quickly as possible while others wanted new guarding installed, and Chris agrees the scheduling role is stressful.

Where AI doesn't make sense yet

Chris asks where people might rush in expecting AI to solve their maintenance problems when it isn't ready. Colin's answer is that, at this point, AI can do a lot, though not perfectly. He says he can't think of anything it doesn't do "really, really well in the grand scheme of things." His framing is that AI can handle about 80% of a task, with a human needed for the last 20%. He expects that to remain the case for the next few years, while noting that the technology keeps improving and that each new model release from OpenAI's ChatGPT or Anthropic is very impressive.

Tribal knowledge, and why voice matters

Returning to another thread from the earlier interview with Nick, Chris raises skilled workers retiring and taking their knowledge with them, and asks how the industry has handled it. Colin's answer is blunt: a lot of companies haven't. Many are letting tribal knowledge walk out the door. Some try to capture it with pen and paper or video and enter it into a CMMS or EAM application, but in his view most of the market hasn't really gone back to address the problem.

Colin says MaintainX is heavily focused on voice as a way to capture data from users. His reasoning is that people no longer want to type on their devices. The days of good physical QWERTY keyboards like those on BlackBerry phones are over, and typing can be difficult for some workers. He expects voice to become increasingly prevalent in the industry and says it is already in use.

He describes two workflows. The first is creating work. Instead of typing, a user taps a button that opens a voice transcription service MaintainX built in-house. The system captures what the user says, enters it, and can automatically surface work instructions. Colin highlights translation as something AI does well. A worker who speaks Spanish at a business that operates in English can speak Spanish, and the system will create the work instructions in English.

The second is work order completion. After an experienced technician finishes a preventive maintenance task or a reactive work order, they can give a spoken high-level summary of what they did, along with any recommended changes to PMs or other observations, rather than typing out notes. The transcription service captures this and generates a summary. What Colin calls unique about MaintainX's approach is that it also adds the content to a knowledge base. The aim is to transfer knowledge from a 25-year veteran to a technician with two or three years of experience, which he says is increasingly typical now. Since manufacturers have to do more with less and with less-skilled labor, he believes anything that helps upskill the workforce will pay off in the long run.

Chris says the translation capability speaks to the diversity inside manufacturing facilities and welcomes anything that makes the industry more accessible.

Adoption and wrench time

Chris asks whether easier creation and closure of work orders is increasing work orders or usage. Colin says only that MaintainX is seeing a lot of adoption, which is all he can share, along with very positive customer feedback about not having to go back to a computer to enter data. He cites a figure that historically about 60% of technicians' time has gone to administrative work. Even a 10–20% gain in efficiency, and thus more wrench time, would be a big saving for customers. He believes the gains are probably much higher given all the software's functionality, but he doesn't give a specific number. His concrete comparison is between speaking to a device for 30 seconds or less and getting an automatic summary, and an older technician like "Bob" who might need considerably more time to type the same thing on a keyboard or phone.

Is manufacturing getting cooler?

Chris introduces a new hypothetical worker, "Sally," someone new to the industry, and asks whether manufacturing's growing technological profile is drawing in people who might otherwise have gone to build apps in the San Francisco Bay Area, a theme from the earlier interview. Colin thinks so. He points to a resurgence over the past five to ten years and says many people want to work for companies like SpaceX, Blue Origin, or Tesla, North American manufacturers of a kind that he says hasn't really been prominent in the past 20 years. In his view, locally built technology and ongoing digital transformation projects are making manufacturing "a little bit more sexy."

He adds that many people in the industry see a real opportunity to help it mature and adopt more technology, and that this gives them purpose. It does for him: his first real job was in manufacturing and he hasn't left since. He calls it an awesome industry and says the current resurgence makes it a good time to get in.

What's exciting Colin now: agents

Asked what excites him most, including in developing MaintainX as what Chris calls an AI-first work execution platform, Colin again names agents. He expects a large shift in how people do their jobs day to day, because much of that work can be automated. He compares it to earlier transitions from typewriters to computers, and from computers to email and connectivity, each bringing large efficiency gains. He sees AI as the next major innovation that will make work easier and faster, and says he is excited about upcoming AI functionality at MaintainX, particularly agents, though he doesn't describe specific features.

When Chris asks what he should have been asked, Colin says he thinks they covered the core topics. The episode ends with the two planning to continue the conversation over another beer at Left Field Brewery, the former-factory taproom in Toronto that framed the discussion.