The Operations Science Podcast

Drive to Thrive: Operational Leadership | Brian Kendig | The Operations Science Podcast | Ep 106

In this episode of the Operations Science Podcast, host Ed Pound engages in a deep conversation with Brian Kendig, a seasoned leader in manufacturing transformations currently at Ford Motor Company. Brian shares insights from his extensive career in various industries, including manufacturing, medical devices, aerospace, and more. They discuss pivotal topics such as key lessons in driving transformation, the importance of culture and continuous improvement, effective planning processes, and the intersections of lean, Six Sigma, and theory of constraints. Brian also touches on the evolving landscape of artificial intelligence in operations and reflects on his personal journey and influences that shaped his career. This episode offers valuable takeaways for anyone involved in operations and leadership.Key Topics:- Operational transformation- Culture and leadership- Continuous improvement- Planning and execution-Lean philosophy- Variability management-Watermelon metrics- SIOP (Sales, Inventory & Operations Planning)- Communication cadence- Performance visibility- Problem diagnosis- Goal setting- AI in manufacturing- Modern perception of manufacturing- Human-centered transformation- Avoiding tool-based tribalism- Immortal organizationsChapters:00:00 Introduction to the Operation Science Podcast01:19 Meet Brian Kenig: Transformational Leader at Ford02:20 Key Lessons in Leading Transformations03:52 The Importance of Culture in Operations05:06 Balancing Tradition and Innovation07:03 The Reality of Modern Manufacturing13:23 The Role of Lean and Continuous Improvement21:00 Planning and Execution in Operations25:50 Understanding Organizational Cadence26:20 The Role of Frontline Leaders26:54 Communication and Problem Solving27:24 Assessing Organizational Health29:38 Identifying and Addressing Problems33:25 The Impact of Artificial Intelligence39:51 The Value of Talent in Organizations42:42 Learning from Mistakes44:55 Personal Journey and Career Advice48:32 Conclusion and Final Thoughts

AI, Agility & Aerospace | Blaine Alderks | The Operations Science Podcast | Ep 105

In this insightful episode of the Operations Science Podcast, we’re joined by Blaine Alderks, Head of Product Development at Windings, to explore the evolving world of high-performance electromechanical systems. Blaine shares lessons from over a decade in aerospace and defense, highlighting how agile product development, effective capacity planning, and cross-functional collaboration have transformed workflows at Windings. We also dive deep into AI’s emerging role in engineering, how to manage rework and “tribal knowledge,” and the cultural nuances of engineering acquisitions. Whether you're a leader, engineer, or operations strategist, this conversation is packed with real-world takeaways on building reliable, mission-critical solutions while embracing change. Key Topics :- Fail Fast Culture in Product Development - Knowledge Transfer Post-Acquisition - AI in Engineering Workflows (Opportunities and Risks) - Capacity and Lead Time Planning Using Operations Science - Rework, Escapes, and Process Mapping - The Shift from Stage Gates to Milestone-Based Planning - Engineering Empathy and Leadership - Blaine’s Personal Journey in Aerospace and Leadership - Integrating Manufacturing Feedback into Product Development - Managing Virtual Work-in-Process and Commitment Reliability Chapters: 00:00 Introduction of Blaine Alderks from Windings 03:40 The Rise of Agile Product Development 09:20 Impacts of M&A on Engineering Teams 14:10 AI in Product Design 22:00 Working with Legacy Systems & Drawings 26:30 Capacity Planning & Lead Time Management 33:00 From Theory to Forecasting 37:30 Rework & Escape Tracking 42:10 Integrating Manufacturing Early 47:50 Milestones vs. Stage Gates 52:10 WIP Management & Virtual Queues 56:00 Weekly Planning & Commitment Reliability 1:00:30 Blaine’s Journey to Engineering 1:07:00 Leading with Empathy 1:11:00 Life Outside Work 1:14:00 Final Thoughts & Reflections

Medical Device Operations | Frankie Swindell | The Operations Science Podcast | Ep 104

Join Ed Pound as he sits down with Frankie Swindell, Operations Manager at Flexon (Ingersoll Rand), for an in-depth conversation about managing operations in the critical medical device manufacturing sector. Discover how a seasoned operations leader navigates global supply chains, tariff challenges, and the transition from private equity to public company ownership.Tune in inside:Tariff impact strategies, supply chain resilience, private equity to public transition, operations excellence frameworks, capacity management, inventory optimization, cross-functional leadership, coaching methodologies, AI implementationTake away:Build supply chain resilience through dual-site operations and redundant capacity strategiesUnderstand operational differences between private equity and public company ownership modelsEstablish effective standard work frameworks while maintaining employee autonomyMaster cross-functional communication by learning to speak different departmental languagesImplement coaching-based leadership approaches that develop people rather than manage processesBalance capacity utilization with variability management to optimize customer serviceCreate positive constraints to maximize productivity and work-life integrationNavigate complex customer relationships and supply chain partnershipsChapters:00:00 Introduction - The Hidden Heroes of Medical Device Manufacturing01:26 Current Tariff Challenges and Global Operations Strategy08:09 Private Equity to Public Company Transition Impact17:01 Operations Excellence and Standard Work Frameworks26:20 Chess and Wrestling Coaching Influence on Leadership35:04 Cross-Functional Communication and Finance Partnership42:10 Customer Relations and Supply Chain Integration48:16 Artificial Intelligence in Manufacturing Operations52:03 Personal Background and Entrepreneurial Journey1:02:15 Family Life Lessons Applied to Operations ManagementQuote of the show:"Great coaches ask the questions to enable a good athlete or a good employee to solve their own problems"Flexon manufactures critical rubber and silicone components found in brain shunts, pacemakers, and other life-saving medical devices. Under Frankie's leadership, the company manages operations across two sites with 190 employees, generating approximately 40 million dollars annually. His unique background combines ten years of manufacturing experience with competitive chess and wrestling coaching, bringing a distinctive perspective to operations management.The conversation explores how global events like COVID-19 and tariff policies have shaped manufacturing strategies. Frankie shares insights on building resilient supply chains through geographic diversification and redundant capacity planning. The discussion reveals how operational excellence creates systems that adapt and thrive under uncertainty.Listeners will gain practical insights into operations science principles in high-stakes medical device manufacturing, where precision directly impacts patient outcomes. The episode demonstrates how concepts like Theory of Constraints translate into real-world decisions affecting both performance and life-saving treatments.Subscribe to The Operations Science Podcast for more insights from industry leaders applying scientific principles to solve operational challenges. Like this episode if you found value in Frankie's perspective on leadership and operations management.#operationsmanagement #medicaldevicemanufacturing #supplychainresilience #leadershipcoaching #operationsscience #manufacturingexcellence #processimprovement #capacitymanagement #inventoryoptimization #crossfunctionalleadership #AIinmanufacturing #tariffstrategy #flexon #ingersollrand

Global Operations Leadership with | The Operations Science Podcast

In this episode of The Operations Science Podcast, your host Ed Pound welcomes Rahul Teotia, a seasoned executive with vast global experience in leading supply chain and operations functions across various industries. Rahul shares his invaluable insights on building high-performing teams, navigating digital transformations, and simplifying complex processes to achieve significant impacts. This conversation is packed with actionable advice for any leader looking to drive operational excellence in a global context.Tune in inside to learn about:Building high-performing international teams. The importance of listening and servant leadership. Effective change management strategies. The role of AI and automation in modern operations. Simplifying complex processes for major impact. Navigating cross-cultural challenges in global business. Maintaining work-life balance in a demanding career. Takeaways:When stepping into a new leadership role, the first couple of months should be dedicated to listening to understand the company's strategy, culture, and business pain points before implementing changes. Building trust with a new team is crucial; this can be fostered by meeting people face-to-face, involving them in decision-making, and appreciating their existing knowledge and contributions. Successful change management hinges on identifying the "why" behind the change, structuring a dedicated team to lead the initiative, and managing stakeholders' expectations through clear and consistent communication. Technology and automation should be implemented to make people more effective and enable strategic decision-making, not just to replace them. It's vital to understand the process you want to improve before applying a technological solution. Simplifying processes, such as centralizing purchasing for multiple sites, can lead to significant improvements in material availability and efficiency, even with complex legacy systems. Living and working in different countries provides invaluable experience in managing cross-cultural relationships and adapting to new environments, a key skill for global leaders. Chapters:00:00 - Intro02:05 - Best Practices for Forming High-Performing Teams05:04 - Balancing Leadership Styles to Establish Trust08:00 - The Impact of Cross-Cultural Experience10:10 - Biggest Challenges in Supply Chain and Operations Leadership12:34 - The Critical Role of Planning in Operations16:02 - Evaluating the Trade-offs of Automation19:15 - Simplifying Complex Processes for Major Impact25:25 - Mastering the Art of Change Management31:02 - Understanding Flow, Variability, and Capacity33:05 - Opportunities and Challenges of AI in Operations39:39 - Favorite Mistakes and Leadership Lessons45:55 - Early Life and Path to Operations Leadership49:31 - Maintaining Work-Life Balance55:21 - OutroQuote of the show:"If you are working too late in the night, that means either you're not being productive and smart in what you do, or you have too much on your plate." Hashtags:#OperationsScience #SupplyChain #Leadership #GlobalOperations #RahulTeotia #OperationalExcellence #ChangeManagement #TeamBuilding #DigitalTransformation #AIinBusiness #ProcessImprovement #LeanManufacturing #PodcastFor more on Thermo Fisher Scientific seehttps://corporate.thermofisher.com/us/en/index/newsroom/Our-stories.htmlIf you enjoyed this episode, please subscribe, leave a review, and share it with your colleagues! Join the conversation and learn more at Opscience.org.

Delta’s Post-Pandemic Comeback | Operations Science, AI, and Lean at Work - Mike McBride - E #102

In this episode of the Operations Science Podcast, host Ed sits down with Mike McBride, the leader of Delta Tech Ops, Delta Air Lines’ maintenance, repair, and overhaul powerhouse. Together, they explore the monumental operational challenges faced during and after the COVID-19 pandemic, including grounding and maintaining a fleet of over 900 aircraft, navigating supply chain chaos, and rebuilding a workforce after significant attrition. Mike shares insights on how Delta Tech Ops not only stabilized its operations but transformed into an industry leader in efficiency and innovation.The discussion delves into the practical application of operational science and continuous improvement throughout the organization, from rethinking training approaches to leveraging artificial intelligence for predictive maintenance and inventory forecasting. Hear real stories about team reinvention, shop-floor problem-solving, and why a strong foundation in operational science helped Delta Tech Ops become two to four times faster than competitors in engine turnaround time.This episode is a compelling story of resilience, reinvention, and the science behind superb, sustained performance in airline operations. Whether you’re a professional in aviation, operations, or just fascinated by how big organizations adapt to seismic change, you’ll come away with valuable lessons and fresh perspectives.Key Topics:• Overcoming operational and supply chain chaos in post-pandemic aviation• Workforce transformation: Training and integrating a new generation of technicians• Rethinking shop-floor processes and stabilizing engine repair operations• The power of operational science in building a common language and framework for improvement• How AI-driven forecasting revolutionizes inventory management and reliability• Insights on leadership, problem-solving, and building a resilient teamTune in for an episode packed with real-world strategies and expert insights from the frontlines of airline operations!chapters Introduction & Guest WelcomeNavigating COVID-19: Initial ChallengesWorkforce Reductions and RecoveryParking and Maintaining Aircraft During the PandemicRehiring and Training After COVIDOvercoming Supply Chain and Turn Time IssuesStabilizing Operations Amid ChaosBuilding a New Training and Production ModelForecasting and AI-Driven ImprovementsReestablishing Continuous Improvement CultureOperations Science Training at Delta Tech OpsMeasurable Results in Turnaround TimeThe Impact of Operations Science on Problem SolvingAI and Data in Maintenance OperationsMike McBride’s Career Path and ReflectionsClosing Remarks and TakeawaysQuote of the showfrom ground level experience to executive leadership, from wrench turning to wide body strategy, this is a story of resilience, reinvention and the science behind superb sustained operations performance

Secrets to Boost Efficiency and Effectiveness Across Industries

Welcome to the premiere episode of the Operations Science Podcast, where we dive into the art and science of operational excellence to help you transform the way you work! Hosted by industry veteran Ed Pound, this episode unveils the power of Operations Science—a first-principles approach to boosting efficiency, productivity, and success across all industries, from manufacturing and healthcare to aerospace, software development, and beyond. Whether you're a nurse juggling patient overload, a project manager battling deadlines, or a plant manager tackling excess inventory, this podcast is your guide to mastering operations with practical, science-backed strategies.In this episode, Ed introduces the vision behind Operations Science, explaining how it cuts through the confusion of competing methodologies like Lean, Six Sigma, and Theory of Constraints. Learn how to apply fundamental laws of capacity, inventory, time, and variability to streamline processes and achieve exceptional results. We explore real-world challenges, like Delta Tech Ops’ post-COVID recovery, where Operations Science provided a framework to stabilize and rebuild their production system. Ed also shares his entrepreneurial journey, from oil rig construction to pioneering Operations Science, offering insights into leadership, resilience, and innovation.Expect captivating stories of triumphs and failures from C-suite executives, plant managers, continuous improvement leaders, and project managers across diverse sectors. Discover actionable tips to enhance your operations, reduce chaos, and empower your team—no matter your role or industry. From healthcare to software development, Operations Science reveals universal principles that drive success.Join us weekly for inspiring conversations with industry trailblazers who share their experiences, best practices, and lessons learned. Subscribe now to the Operations Science Podcast on YouTube, Spotify, or Apple Podcasts, and don’t miss out on transforming your operations. Visit opscience.org to connect with the Operations Science Institute, share your insights, and join a community dedicated to operational excellence. Rate, review, and share this episode to help others discover the science of better work! Takeaways  Operations Science Defined: Operations Science is a first-principles approach to improving work effectiveness and efficiency across all industries, not just manufacturing. It focuses on fundamental laws of capacity, inventory, time, and variability to streamline processes. Universal Applicability: The principles of Operations Science apply to diverse sectors, including healthcare (e.g., nurses managing patient loads), project management (e.g., handling delays), software development, aerospace, and construction, addressing both physical and knowledge-based work processes. Cutting Through Confusion: Unlike competing methodologies like Lean, Six Sigma, or Theory of Constraints, Operations Science starts from basic scientific relationships, clarifying how to enhance existing continuous improvement efforts without replacing them. Practical Solutions for Real Challenges: The podcast emphasizes actionable strategies for operational issues, such as stabilizing production systems post-crisis (e.g., Delta Tech Ops’ recovery after COVID) by providing a common framework for training and execution. Learning from Success and Failure: The show will feature guests from various industries (C-suite executives, plant managers, continuous improvement leaders) sharing both triumphs and failures to provide valuable lessons for listeners.Quote of the showOperations Science is about how people can be more effective and more efficient in the work they do.

The Operations Science Podcast

The Operations Science Podcast: Authentic Leadership Stories from Operations and Project LeadersWelcome to The Operations Science Podcast, the premier destination for authentic, in-depth conversations with operations and project leaders who share real-life stories of their career triumphs, setbacks, and the invaluable insights gained along the way. Hosted with a passion for uncovering the strategies and mental frameworks that drive success, this podcast is a must-listen for executives, managers, and aspiring leaders in industries such as general manufacturing, medical devices, aerospace, maintenance, repair, and overhaul (MRO) companies, and diagnostic labs. With a focus on leadership, operational excellence, and continuous improvement, each episode delivers actionable takeaways to help you navigate the complexities of modern business landscapes.What to Expect from The Operations Science PodcastOur guests include C-level executives, VPs of operations and supply chain, directors, managers, and thought leaders from trade associations, industry groups, and standards organizations. These seasoned professionals bring a wealth of experience in leadership, decision-making, and execution, offering unique perspectives on operational challenges like rapid change, uncertainty, innovation, evolving workforce expectations, talent development, and organizational culture. Whether you're a forward-thinking executive or a continuous improvement enthusiast, this podcast provides a platform to learn from the best in the field.Each episode dives deep into the personal journeys of high-performance leaders, exploring their successes, failures, and comebacks. From building high-performance teams to driving strategic transformation and maintaining clarity under pressure, our guests share the mental tools, frameworks, and strategies that have enabled them to lead with confidence, resilience, and foresight. This isn’t just another business podcast—it’s a forum for high-level executives to openly discuss the real challenges of operational management and the mental fitness required to thrive at the top.Why Listen to The Operations Science Podcast?Authentic Storytelling: Hear real-life stories from operations and project leaders who have navigated the highs and lows of leadership in dynamic industries.Actionable Insights: Gain practical strategies for overcoming operational challenges, fostering innovation, and building resilient teams.Diverse Perspectives: Learn from a wide range of guests, including C-suite executives, industry group leaders, and continuous improvement experts.Inspiration for Growth: Discover how top leaders adapt to change, inspire their teams, and make high-stakes decisions with clarity and confidence.Industry-Specific Focus: Explore winning practices and leading trends in general manufacturing, medical devices, aerospace, MRO, and diagnostic labs.Who Should Listen?This podcast is designed for:C-level executives and VPs of operations/supply chain seeking to sharpen their leadership skillsDirectors and managers in operations, project management, or continuous improvement rolesProfessionals in general manufacturing, medical devices, aerospace, MRO, and diagnostic labsAspiring leaders looking to learn from the experiences of seasoned executivesMembers of trade associations, industry groups, and standards organizations interested in industry trends and winning practicesHow to ListenThe Operations Science Podcast is available on major platforms, including YouTube, Spotify, Apple Podcasts, and more. Subscribe today to get notified about new episodes and gain access to a growing library of leadership insights. Follow us on LinkedIn and other social media platforms for daily short-form video clips that deliver quick, actionable tips from our guests.