Challenges in maintenance systems can pose multi-faceted problems, which are difficult to resolve alone. Over a four year period, a partnership evolved a vision for tackling the understanding of fundamentally difficult mechanical failures and their detection, with potential for practical exploitation of the solutions. The partnership assembled a team of researchers and far-sighted project management, to undertake a study of gearbox failures, including finite element modelling, gear testing, and signal analysis. The partnership trained a series of doctoral and postdoctoral staff in running an integrated project, coping with changes in staffing and locations. The final stages of the work will validate the models and signal processing.