The Operations Science Podcast

The Other Side of the EV Revolution: Turning Toxic Waste Into Critical Materials

Electric vehicles are accelerating faster than ever.
But there’s a massive operational challenge most people aren’t talking about. What happens to the batteries when they reach end-of-life?
This conversation explores the systems, strategy, and leadership required to build large-scale battery recycling operations, from the ground up. From navigating uncertainty in a brand-new industry to balancing capital investment, AI, hiring, and operational excellence—this is a real look at building industrial infrastructure for the future.
If you care about operations, sustainability, manufacturing, or scaling new technology. This one connects the dots.
 
Key Discussion Points
00:01 - Building a large-scale battery recycling operation03:30 - Structured decision-making under uncertainty07:00 - Why battery recycling is a complex emerging industry10:25 - How lithium-ion batteries are actually recycled14:25 - Second-life batteries vs recycling16:25 - Managing capital risk in a new industry19:35 - Building culture and leading high-performance teams23:20 - Where AI fits into battery recycling operations28:50 - Hiring and scaling a fast-growing company31:00 - Government support and sustainability incentives33:00 - Operational excellence while building a new plant35:40 - Project management for large capital projects41:00 - Julian’s background and career path46:00 - Work-life balance and leadership mindset47:17 - Closing thoughts
 
The EV revolution is here.
The operational infrastructure behind it is just getting started.
 
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#Operations #OperationalExcellence #Manufacturing #EV #ElectricVehicles #BatteryRecycling #Sustainability #Leadership #SupplyChain #IndustrialEngineering #AI #ContinuousImprovement #ProcessImprovement #OperationsManagement #CleanEnergy

Scaling Medical Device Operations: Leadership, Kaizen, and Managing Variability

What does operational excellence look like when the product you manufacture directly impacts a person’s dignity and quality of life?
In this conversation, Mindaugas Valkavicius shares what it takes to lead 200+ frontline operators in a high-sensitivity environment—where safety, quality, and service aren’t abstract metrics, but daily commitments.
From ramping up capacity during the pandemic to consolidating production across borders, Mindaugas unpacks the realities of scaling responsibly while keeping people at the center.
This isn’t theory. It’s practical leadership from the factory floor.
Key Discussion Points
00:00 – Introduction to Operations Science01:39 – Scope of leading 200+ operators in medical device manufacturing02:47 – From prototyping to mass manufacturing05:13 – Where variability hides in operations06:50 – Leading remotely during the pandemic08:40 – Doubling plant capacity during COVID09:46 – Balancing automation and manual inspection12:29 – Continuous improvement as daily habit16:21 – Structured Kaizen events and rapid gains18:26 – Prioritizing improvement after low-hanging fruit22:00 – Overcoming fear around job loss and Kaizen24:02 – 24-month forecasting and consolidation strategy26:40 – Executing cross-border production transfers29:35 – Measuring efficiency: OEE and budget alignment31:24 – Why finance should join the Gemba walk33:40 – Advice for new operations leaders36:17 – Building trust: Lessons from family and early leadership
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#Operations #OperationalExcellence #ManufacturingLeadership #ContinuousImprovement #Kaizen #MedicalDevices #Leadership #LeanManufacturing #OperationsManagement #IndustryLeadership

Vitoria Vellani on Demand Planning, Disruption & the Brazilian Market

Global supply chains don’t fail all at once. They bend, stretch, and quietly test every assumption you’ve made about planning, inventory, and timing.
In this conversation on the Operation Science Podcast, Vitoria Vellani shares what it actually looks like to manage demand planning and import operations in Brazil—where long lead times, currency swings, port congestion, and seasonal demand collide.
From importing luggage across three continents to balancing forecast accuracy with real-world uncertainty, this episode digs into the decisions supply chain teams rarely get credit for, but everyone feels when they go wrong.
You’ll hear practical insights on:
Planning for volatility instead of pretending it doesn’t exist
Why inventory accuracy is non-negotiable
How communication across sales, operations, and logistics keeps the system moving
Where AI helps — and where human judgment still matters most
No theory. Just how global operations actually work when conditions change faster than your forecast.
 
Key Discussion Points
00:00 – Setting the context: operations under real-world constraints01:30 – Importing into Brazil: lead times, currency, and global exposure04:20 – Moving from medical devices to consumer goods06:10 – Managing disruption: containers, congestion, and freight volatility09:20 – Forecasting, safety stock, and seasonal pressure12:40 – Combining historical data with sales insight15:00 – Inventory accuracy and why errors quietly destroy plans18:30 – Where demand planning breaks down — and how to strengthen it21:20 – Using AI in forecasting without over-trusting the output25:20 – Working across cultures in global supply chains29:00 – KPIs that actually reflect supply chain health33:20 – Career lessons, mentorship, and building confidence over time37:00 – Final reflections and takeaways
 
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#SupplyChain #DemandPlanning #Operations #Logistics #InventoryManagement #Forecasting #GlobalTrade #OperationsScience

The Science Behind Stable Flow: Intel Veteran Reveals the Truth About Modern Manufacturing

When a deeply entrenched operating habit jeopardizes $14–15B in revenue, you don’t get a second chance to get it right.
This conversation with former Intel manufacturing leader Zane Rakes reveals how a shift in perspective—powered by Operation Science—transformed one of the most complex production environments on earth: semiconductor manufacturing.
From “bear traps” of runaway WIP to a trim, predictable factory capable of cutting cycle time by ~80%, Zane breaks down the real story of transforming Intel’s Fab 23—from chaos, firefighting, and hidden variability… to clarity, stability, and breakthrough performance.
If you work in semiconductor, operations, lean, high‑mix manufacturing, maintenance, or executive leadership, this deep‑dive is a masterclass in how systems actually behave—and what it takes to fix them.
00:00 – 01:00 • Setting the stage: how a single operating habit put billions at risk
01:00 – 03:00 • Introducing guest Zane Rakes & his semiconductor background
03:00 – 06:00 • Early Intel years, operations vs. equipment management
06:00 – 08:00 • First exposure to Factory Physics (Operation Science)
08:00 – 10:30 • “Bear traps,” variability, and the hidden cost of firefighting
10:30 – 12:00 • The Fab 23 turnaround begins: outdated MES & massive WIP problems
12:00 – 14:00 • Why schedules looked better on paper than in reality
14:00 – 16:00 • Taking over as Manufacturing Manager
16:00 – 18:30 • How Intel traditionally measured success: wafer starts vs. true output
18:30 – 21:00 • The case for WIP control—and the uphill battle convincing planning
21:00 – 23:30 • Using Little’s Law to expose the gap between goals and physics
23:30 – 26:30 • What direct observation revealed (including “embarrassing” discoveries)
26:30 – 29:00 • Fixing the send‑ahead process: from 3–6 hours to under 1 hour
29:00 – 32:00 • Transitioning from a “fat fab” to a “trim fab”
32:00 – 34:30 • The politics of starts moderation & gaining executive buy‑in
34:30 – 36:30 • Building the Starts Protocol (the engine of the turnaround)
36:30 – 38:30 • The unexpected win: yield improvements from lower WIP
38:30 – 40:00 • Achieving consistent ~21–22 day cycle times (down from ~110 days)
40:00 – 43:30 • Defining ideal state using scientific principles—not benchmarks
43:30 – 47:00 • Why variability—not tools—is the true enemy
47:00 – 49:30 • Using WIP as a proxy for system health
49:30 – 51:00 • Managing severe capacity loss on critical tools
51:00 – 56:00 • Zane's personal journey: upbringing, military career, and joining Intel
56:00 – end • Closing thoughts and timeless lessons for any production system
Key Takeaways:Why high WIP hides problems and destroys performance?
How to transition from firefighting to physics‑driven operations?
Why semiconductor fabs (and most production systems) run slower than their tools suggest?
How small changes in variability create massive changes in throughput and cycle time?
The organizational realities of shifting from starts‑driven to flow‑driven thinking
The critical connection between inventory, yield, stability, and cost
 
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#OperationsScience #FactoryPhysics #SemiconductorManufacturing #OperationalExcellence #LeanManufacturing #ContinuousImprovement #ManufacturingLeadership #CycleTimeReduction #SystemsThinking #HighTechManufacturing #Intel #ManufacturingTransformation #WIPControl #VariabilityReduction #ProcessEngineering

How to Manage Global Medical Device Projects | Diana Dimitrova Interview

Managing global medical device projects is no small feat—especially when teams span multiple time zones and cultures. In this episode of the Operations Science Podcast, host Ed Pound interviews Diana Dimitrova, Senior Project Manager, who shares her proven strategies for leading complex programs that bring life-changing drug delivery devices to market.Discover how Diana: ✅ Coordinates cross-functional teams across Denmark, China, India, Europe, and the U.S. ✅ Builds trust and bridges cultural differences for high-performing teams ✅ Implements risk management and standardized processes to avoid costly delays ✅ Leverages AI and digital twins to accelerate development and reduce costs ✅ Balances speed, cost, scope, and patient safety without compromising qualityKey Topics Covered:Global project management in the medical device industryCross-cultural collaboration and communication best practicesRisk management and resource planning for large-scale programsAI and digital transformation in product developmentLeadership insights: facilitation vs. top-down decision-makingConnect with Us: 🌐 Learn more at opscience.org 📌 Subscribe for more episodes on operational excellence 👍 Like, comment, and share if you found this helpful! #OperationsScience #MedicalDevices #ProjectManagement #Leadership #AI #GlobalTeams #RiskManagement #OperationalExcellence

Mastering Cross-Border Production Transfers: Project Management Lessons from the Front Lines

In this episode of the Operations Science Podcast, host Ed Pound speaks with Ricardo Monge, a seasoned program manager specializing in medical device manufacturing. Ricardo shares his experiences orchestrating complex, multimillion-dollar project transfers across borders—merging technical rigor with human influence.You’ll learn: ✔ How to balance strategic timelines with tactical operations ✔ Best practices for managing scope creep and regulatory compliance ✔ The role of AI as a supportive tool in project management ✔ Why effective communication and cultural sensitivity matterTimestamps: 00:00 Introduction to the Operations Science Podcast 00:48 Meet Our Guest: Ricardo Monge 02:32 Ricardo's Role and Project Management Insights 04:57 Challenges and Best Practices in Project Transfers 23:47 The Role of AI in Project Management 26:58 Regulatory and Compliance Considerations 30:40 Effective Communication and Cultural Sensitivity 33:52 Personal Insights: Ricardo's Background and Interests 38:04 Conclusion and Final Thoughts #MedicalDevices #ProjectManagement #AIinBusiness #GlobalOperations #Leadership #Manufacturing #RiskManagement #PodcastEpisode #Innovation #OperationsScience

Transforming Operations at Scale: Lessons from Manufacturing to Boardroom | Oscar Sroor

In this episode of the Operations Science Podcast, host Edward Pound sits down with Oscar Sroor, a global operations leader based in Bordeaux, France, to explore what it really takes to achieve sustainable operational excellence.With experience spanning manufacturing, medical devices, FMCG, and global supply chains, Oscar shares his journey from classic lean initiatives to leading large-scale business transformations. The conversation goes beyond tools and frameworks, focusing on structured thinking, scientific discipline, cultural adaptation, and systems-level improvement.Key topics include:Why lean tools alone aren’t enoughHow to standardize and improve tender processesScaling capacity without burning out teamsOptimizing distribution networks and ERP systemsMeasuring cultural maturity in continuous improvementThe evolving role of AI, Industry 4.0, and Industry 5.0Leading transformation across diverse European culturesThis episode is essential listening for operations leaders, continuous improvement professionals, transformation leaders, and executives who want to move beyond surface-level optimization and build systems that truly perform.Timestamps - 00:00 Trailer00:47 Meet Our Guest: Oscar Sroor 01:31 Oscar's Continuous Improvement Journey 02:30 Explaining Operational Roles and Challenges 04:13 Transforming Business Processes 06:55 Standardizing Tender Processes 09:50 Measuring and Improving Tender Responses 15:31 Doubling Factory Capacity 17:37 Optimizing Distribution Networks 20:30 ERP Systems and Operational Decisions 27:16 Trainer Development and Kaizen Facilitation 28:41 Measuring Cultural Maturity in Lean Practices 29:39 Challenges in Training Facilitators 32:15 Communication and Cultural Adaptation in Europe 36:35 AI and Industry 4.041:58 Oscar Sroor's Journey and Influences 45:16 Balancing Work and Family Life 47:44 Podcast Conclusion and Call to Action#OperationsScience #OperationalExcellence #ContinuousImprovement #BusinessTransformation #LeanThinking #ProcessImprovement

The Hidden Complexity of Optical Lens Manufacturing | Operations Deep Dive with Stefano Relli

In this episode of the Operations Science Podcast, host Ed Pound sits down with Stefano Relli, an international leader in continuous improvement at a global precision optical lens manufacturer.Together, they break down the real-world challenges of running a make-to-order, high-variability production system and how balancing a push-pull system can transform flow, efficiency, and customer responsiveness.Stefano shares how his multicultural leadership journey shaped his approach to operational excellence, people alignment, and driving change in high-precision environments. From understanding the complexity of lens manufacturing to managing production capacity, optimizing equipment efficiency, and engaging both frontline teams and senior leadership, this episode dives deep into what it takes to run operations at scale.Perfect for professionals in manufacturing, operations, Lean systems, continuous improvement, and supply chain, this conversation delivers practical insights backed by global experience.Topics Covered:Handling high-mix, make-to-order challengesImplementing push-pull systemsCultural intelligence in leadershipAligning KPIs with operational goalsManaging variability and production capacityEngaging teams in continuous improvementThe human side of operational transformationStefano’s personal passion for road cyclingTimestamps - 00:00 Introduction to the Operations Science Podcast 00:49 Meet Stefano Relli: A Leader in Optical Lens Manufacturing 01:57 Stefano's Multicultural Journey and Its Impact on Leadership 08:24 Challenges of Make-to-Order Systems in Lens Manufacturing 12:46 Understanding the Lens Manufacturing Process 19:44 Implementing Push-Pull Systems for Operational Excellence 25:53 Ensuring Equipment Efficiency 26:42 Managing Production Capacity 28:31 Engaging Leadership in Continuous Improvement 34:20 Aligning People and Processes 35:26 Personal Journey and Influences 41:34 The Joy of Road Cycling 43:46 Conclusion and Final Thoughts#OperationsScience#ManufacturingExcellence#ContinuousImprovement#OpticalLensManufacturing#LeanManufacturing#MakeToOrder#PushPullSystem#OperationalExcellence#SupplyChain#LeadershipInManufacturing

Building the Future of Operations: Santiago Camacho on Leadership and AI

In this episode of The Operations Science Podcast, host Edward Pound sits down with Santiago Camacho, a global supply chain leader with over two decades of experience in manufacturing and operations. Currently spearheading the setup of a new Greenfield site in Portugal for Coloplast, Santiago shares a candid look at the realities of modern supply chain leadership.From balancing demand forecasts and managing production capacity to integrating AI into planning systems, Santiago explores how technology and people intersect in shaping the future of operations. He also reflects on leadership lessons, cross-cultural experiences, and how resilience and adaptability define successful supply chain transformation.Whether you’re an operations professional, manufacturing leader, or curious about the human side of global logistics, this episode delivers grounded insights and actionable takeaways.Timestamps:00:00 Introduction to the Operations Science Podcast 00:49 Meet Santiago Camacho: A Supply Chain Expert 02:03 Challenges in Modern Supply Chain Management 03:50 AI's Impact on Entry-Level Jobs 07:13 Building a New Greenfield Site in Portugal 14:50 Postponement Strategy in Supply Chain 17:12 Leadership Lessons from Santiago Camacho 21:23 Balancing Demand Forecasts and Capacity 28:52 Global Supply Chain Planning at Coloplast 34:57 Personal Insights: Santiago Camacho's Journey 39:56 Conclusion and Final Thoughts#SupplyChain #OperationsScience #Leadership #Manufacturing #Coloplast #AIinOperations #GlobalSupplyChain #OperationsExcellence #GreenfieldProject #Logistics #SupplyChainInnovation #BusinessStrategy #IndustrialLeadership #SantiagoCamacho #EdPound #Podcast #OperationalExcellence

The Woman Powering Africa’s Optical Industry | Lessons in Supply Chain Leadership | Silindile Sitole

In this episode of Operation Science, host Ed Pound sits down with Silindile Sitole, a leader in supply chain and operations who ensures millions of lenses travel seamlessly from Asia to Africa.From navigating time zone gaps and language barriers to optimizing freight methods and managing over 50,000 SKUs, Silindile shares her journey of resilience, precision, and leadership in one of Africa’s most complex supply networks.You’ll hear how her team adapted to port strikes, switched from air to sea freight for cost efficiency, and used data-driven systems like Microsoft D365 MRP to balance inventory across continents.Silindile also opens up about mentoring new teams, aligning production with capacity, and her thoughts on the future role of AI in supply chain operations.Whether you’re a manufacturing professional, operations leader, or just fascinated by how global logistics keep the world moving, this episode delivers deep operational insights and leadership lessons you can apply today.🎧 Listen now to explore how great operations leaders turn complexity into clarity.Timestamps - 00:00 Introduction by Ed Pound01:05 Meet Silindile Sitole: Managing global lens supply chains03:10 Challenges in working with Asian suppliers and time zones06:40 Switching from air freight to sea freight: Why and how10:15 Handling port strikes and emergency air shipments13:05 Communication and customer management during backorders16:30 Inside the polycarbonate lens production process20:00 Role of data and MRP in managing 50,000 SKUs24:40 Expanding operations to Mauritius28:20 Training new teams and overcoming system differences32:00 Key KPIs and weekly reporting for operational excellence37:25 Managing capacity and forecasting with production teams42:10 Collaboration between finance and supply chain teams45:20 Thoughts on AI and the future of supply chain automation49:15 Regulatory challenges, tariffs, and exporting to Africa53:00 Lessons in leadership, trust, and operational agility55:30 Closing thoughts: The future of efficiency in operations#OperationScience #SupplyChainLeadership #LogisticsPodcast #ManufacturingExcellence #OperationsManagement #SupplyChainAfrica #IndustrialInnovation #OperationalExcellence #AIinOperations #ManufacturingPodcast #BusinessOperations #LeadershipInAction #SupplyChainInsights #LensManufacturing #EdPoundPodcast #OperationsStrategy