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 Podcast

00:49 Meet Sanjay Hooper Car: A Leader in Electronics Manufacturing

01:50 Global Trade Policies and Their Impact on Electronics Manufacturing

05:21 Challenges Facing the Electronics Industry

13:13 The Evolution of the Global Electronics Association

20:07 Training and Upskilling in Electronics Manufacturing

22:49 Upskilling in Engineering: Opportunities and Challenges

24:10 The Excitement of Soldering Competitions

28:04 AI's Impact on the Electronics Industry

30:16 Advocacy and Industry Leadership

32:52 Personal Journey and Early Career

37:15 Hobbies and Personal Interests

38:43 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 Podcast

00:56 Meet Our Esteemed Guest: Mark Gray

02:29 Mark Gray's Journey to Thought Leadership

05:36 The Inspiration Behind 'The Mistakes That Make Us'

08:59 Balancing Process and Innovation Mistakes

15:09 Creating Psychological Safety in the Workplace

17:58 Mark Gray's Favorite Mistakes

28:01 The Power of Saying It Out Loud

29:50 Switching Topics: Northwestern and Factory Physics

32:43 Applying Operation Science in Healthcare

34:11 Challenges in Healthcare Operations

40:20 Integrating Lean and Other Methodologies

44:53 The Role of AI in Improvement Work

48:56 Personal Background and Influences

52:26 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 organizations

Chapters:

00:00 Introduction to the Operation Science Podcast

01:19 Meet Brian Kenig: Transformational Leader at Ford

02:20 Key Lessons in Leading Transformations

03:52 The Importance of Culture in Operations

05:06 Balancing Tradition and Innovation

07:03 The Reality of Modern Manufacturing

13:23 The Role of Lean and Continuous Improvement

21:00 Planning and Execution in Operations

25:50 Understanding Organizational Cadence

26:20 The Role of Frontline Leaders

26:54 Communication and Problem Solving

27:24 Assessing Organizational Health

29:38 Identifying and Addressing Problems

33:25 The Impact of Artificial Intelligence

39:51 The Value of Talent in Organizations

42:42 Learning from Mistakes

44:55 Personal Journey and Career Advice

48:32 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 implementation

Take away:

• Build supply chain resilience through dual-site operations and redundant capacity strategies
• Understand operational differences between private equity and public company ownership models
• Establish effective standard work frameworks while maintaining employee autonomy
• Master cross-functional communication by learning to speak different departmental languages
• Implement coaching-based leadership approaches that develop people rather than manage processes
• Balance capacity utilization with variability management to optimize customer service
• Create positive constraints to maximize productivity and work-life integration
• Navigate complex customer relationships and supply chain partnerships

Chapters:

00:00 Introduction - The Hidden Heroes of Medical Device Manufacturing

01:26 Current Tariff Challenges and Global Operations Strategy

08:09 Private Equity to Public Company Transition Impact

17:01 Operations Excellence and Standard Work Frameworks

26:20 Chess and Wrestling Coaching Influence on Leadership

35:04 Cross-Functional Communication and Finance Partnership

42:10 Customer Relations and Supply Chain Integration

48:16 Artificial Intelligence in Manufacturing Operations

52:03 Personal Background and Entrepreneurial Journey

1:02:15 Family Life Lessons Applied to Operations Management

Quote 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 - Intro

02:05 - Best Practices for Forming High-Performing Teams

05:04 - Balancing Leadership Styles to Establish Trust

08:00 - The Impact of Cross-Cultural Experience

10:10 - Biggest Challenges in Supply Chain and Operations Leadership

12:34 - The Critical Role of Planning in Operations

16:02 - Evaluating the Trade-offs of Automation

19:15 - Simplifying Complex Processes for Major Impact

25:25 - Mastering the Art of Change Management

31:02 - Understanding Flow, Variability, and Capacity

33:05 - Opportunities and Challenges of AI in Operations

39:39 - Favorite Mistakes and Leadership Lessons

45:55 - Early Life and Path to Operations Leadership

49:31 - Maintaining Work-Life Balance

55:21 - Outro

Quote 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 #Podcast

For more on Thermo Fisher Scientific see

https://corporate.thermofisher.com/us/en/index/newsroom/Our-stories.html

If 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 team

Tune in for an episode packed with real-world strategies and expert insights from the frontlines of airline operations!

chapters

1. Introduction & Guest Welcome
2. Navigating COVID-19: Initial Challenges
3. Workforce Reductions and Recovery
4. Parking and Maintaining Aircraft During the Pandemic
5. Rehiring and Training After COVID
6. Overcoming Supply Chain and Turn Time Issues
7. Stabilizing Operations Amid Chaos
8. Building a New Training and Production Model
9. Forecasting and AI-Driven Improvements
10. Reestablishing Continuous Improvement Culture
11. Operations Science Training at Delta Tech Ops
12. Measurable Results in Turnaround Time
13. The Impact of Operations Science on Problem Solving
14. AI and Data in Maintenance Operations
15. Mike McBride’s Career Path and Reflections
16. Closing Remarks and Takeaways

Quote of the show

from 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

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 show

Operations Science is about how people can be more effective and more efficient in the work they do.