In today’s complex manufacturing environments, success hinges on more than just uptime—it depends on using the right data to make smarter, faster maintenance decisions. In this episode of Reliability 4.0, we speak with Rildo Pereira, Maintenance & Reliability Manager at Gestamp, who oversees reliability strategies across three U.S. plants and supports global operations in 24 countries.

With a focus on predictive technologies, data analytics, and root cause analysis, Rildo shares how his team is shifting the mindset from reactive maintenance to proactive problem-solving.

Quick Overview (TL;DR)

• Rildo Pereira manages maintenance operations across three Gestamp plants in Tennessee.
• His team uses SAP, IoT sensors, and predictive tools to catch failures before they escalate.
• Root cause analysis plays a key role in preventing recurring issues and refining workflows.
• Rildo emphasizes cultural change and proactive thinking: “Fixing is not the same as solving.”

Table of Contents

• Rildo Pereira’s Role at Gestamp
• How Gestamp Uses Data to Improve Reliability
• RCA as a Foundation for Proactive Maintenance
• Final Advice: Fixing vs. Solving
• How EasyRCA Helps Teams Move from Fixing to Solving

Rildo Pereira’s Role at Gestamp

Rildo Pereira leads maintenance and reliability across three Gestamp manufacturing plants in Tennessee, while also supporting standards shared across 24 countries. His work requires balancing local plant needs with global best practices.

Rildo spends his days navigating SAP workflows, asset strategies, and aligning plant operations with KPIs—all while staying grounded in the daily realities of the floor.

How Gestamp Uses Data to Improve Reliability

For Rildo, technology isn’t just a buzzword—it’s how his team keeps plants running and decisions sharp. SAP is the backbone of their asset management system, supported by IoT sensors and predictive tools that track machine health in real time.

“We’re not just collecting data for reports,” he explains. “We use it to trigger action before downtime occurs.”

His approach includes:

• SAP for scheduling, asset lifecycle tracking, and work order analysis
• IoT and sensor data to detect anomalies and flag early warnings
• Predictive analytics to move from time-based to condition-based strategies

It’s a tech-forward approach, but always with people at the center. Interpretation, action, and accountability remain human responsibilities.

RCA as a Foundation for Proactive Maintenance

For Rildo, root cause analysis isn’t optional—it’s a foundational tool in his daily playbook.

At Gestamp, RCA is:

• Triggered by asset criticality and downtime thresholds
• Conducted by cross-functional teams using a formal process
• Logged, tracked, and reviewed consistently to close the loop

He puts it simply: “Most of the problems we face in maintenance are because we either didn’t understand the root cause, or we didn’t prioritize the right PMs.”

One memorable quote from Rildo captures the mindset shift: “I hate doing maintenance—I like thinking about maintenance.” That philosophy drives his push toward smarter workflows and fewer firefights.

Final Advice: Fixing vs. Solving

One mindset Rildo repeats often is simple but powerful: “Fixing is not the same as solving.”

In fast-paced plants, quick fixes are tempting. But to achieve real uptime gains, teams need to:

• Investigate failure patterns using data
• Align fixes with operator behavior and training
• Close the loop with validated outcomes

That mindset shift—solve, don’t just fix—is what Rildo is instilling in his teams every day.

How EasyRCA Helps Teams Move from Fixing to Solving

At EasyRCA, we believe that data-driven strategies and root cause analysis are essential to building proactive maintenance cultures. If your team is ready to move from fixing to solving, see how EasyRCA can help.

To watch the full podcast episode with Todd, click here: YouTube

Further Reading:

• Customer-Focused Reliability: Lessons from Liebherr Mining’s Todd Heindselman
• Transforming Manufacturing Reliability: Insights from Rehrig Pacific’s John Ramirez