The Operations Science Podcast

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

In this episode of the Operations Science Podcast, host Edward Pound sits down with logistics veteran Juan Maldonado from Karl Storz, a global leader in medical device manufacturing. With over 25 years in the field, Juan takes us through the evolution of logistics, from paper-based processes to data-driven operations powered by technology and automation.They dive into the challenges of balancing customization vs. standardization, implementing new systems, and designing adaptable warehouse layouts. Juan emphasizes the role of employee engagement, inventory accuracy, and operational discipline in sustaining efficiency during growth.Drawing from his experience at Toyota, Juan also shares lessons on continuous improvement, simplicity in operations, and the importance of Gemba. Whether you’re in logistics, supply chain management, or operations leadership, this conversation offers practical strategies and timeless principles to keep processes efficient, resilient, and people-focused.Timestamps - 00:00 Introduction to the Operations Science Podcast00:49 Meet Juan Maldonado: Logistics Expert02:02 Evolution of the Logistics Industry03:08 Balancing Customization and Standardization06:29 Importance of Gemba and Employee Engagement10:34 Key Performance Indicators (KPIs) in Logistics14:13 Managing Efficiency During Growth16:14 Warehouse Layout and Adaptability21:22 Technology and Automation in Warehousing23:15 Inventory Accuracy and Final Thoughts24:13 Evolution of Inventory Management24:46 Daily Cycle Counts and System Integration27:20 Best Practices for External Warehouses31:22 Operational Discipline in Companies33:16 Lessons from Working at Toyota37:22 Personal Background and Career Journey42:44 Conclusion and Podcast Wrap-Up#Logistics #SupplyChain #WarehouseManagement #Automation #InventoryAccuracy #ContinuousImprovement #OperationsExcellence #ToyotaWay #EmployeeEngagement #Gemba #LogisticsPodcast #SupplyChainPodcast #OperationalDiscipline #LogisticsInnovation

Welcome to the Operations Science Podcast! In this episode, host Ed Pound welcomes Lisa Elles, a trailblazer in the shipbuilding and ship repair industry. With over 30 years of experience, Lisa discusses the challenges and triumphs of the maritime sector, shedding light on the Lean Shipbuilding model and its transformative impact. From the historical significance of Liberty ships to the potential of AI in ship design, this episode delves into the complexities and innovations driving the industry forward. Tune in to explore leadership secrets and operational excellence that could revolutionize your approach to operations.00:00 Introduction to the Operations Science Podcast00:49 Meet Lisa Elles: Transforming the Shipbuilding Industry02:25 Challenges and Innovations in Shipbuilding04:57 Historical Insights: The Liberty Ships08:14 The Decline and Future of US Shipbuilding11:36 Lean Shipbuilding Model: Principles and Applications18:10 Impact of Lean Shipbuilding on the Industry30:55 The Role of AI in Ship Design and Production35:32 Lisa Elles: Personal Journey and Professional Insights41:28 Conclusion and Final Thoughts

In this episode of the Operations Science Podcast, host Ed Pound interviews Sanjay Huprikar, Chief Global Officer of the Global Electronics Association. They delve into the complexities of global trade policies, tariffs, and their impact on electronics manufacturers. Sanjay shares insights into the evolution of the association, its expanded focus on advocacy, training, and industry standards, and the importance of supply chain resilience. They also discuss the growing influence of AI in manufacturing and the importance of lifelong learning and mentorship in the industry. The episode concludes with personal anecdotes from Sanjay's career and his passion for music, baseball, and world travel.00:00 Introduction to the Operations Science Podcast00:49 Meet Sanjay Hooper Car: A Leader in Electronics Manufacturing01:50 Global Trade Policies and Their Impact on Electronics Manufacturing05:21 Challenges Facing the Electronics Industry13:13 The Evolution of the Global Electronics Association20:07 Training and Upskilling in Electronics Manufacturing22:49 Upskilling in Engineering: Opportunities and Challenges24:10 The Excitement of Soldering Competitions28:04 AI's Impact on the Electronics Industry30:16 Advocacy and Industry Leadership32:52 Personal Journey and Early Career37:15 Hobbies and Personal Interests38:43 Conclusion and Final Thoughts

In this episode of the Operations Science Podcast, host Ed Pound interviews Mark Gray, a thought leader in continuous improvement and lean thinking. Mark shares insights from his extensive experience across industries, the importance of learning from mistakes, and the role of leadership in fostering a culture of psychological safety. Learn about the integration of lean principles with statistical process control, the impact of motivational interviewing, and how AI could revolutionize improvement work. The conversation also delves into Mark's personal journey and early influences that shaped his career.00:00 Introduction to the Operations Science Podcast00:56 Meet Our Esteemed Guest: Mark Gray02:29 Mark Gray's Journey to Thought Leadership05:36 The Inspiration Behind 'The Mistakes That Make Us'08:59 Balancing Process and Innovation Mistakes15:09 Creating Psychological Safety in the Workplace17:58 Mark Gray's Favorite Mistakes28:01 The Power of Saying It Out Loud29:50 Switching Topics: Northwestern and Factory Physics32:43 Applying Operation Science in Healthcare34:11 Challenges in Healthcare Operations40:20 Integrating Lean and Other Methodologies44:53 The Role of AI in Improvement Work48:56 Personal Background and Influences52:26 Conclusion and Final Thoughts

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

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

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

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.

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