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 Podcast

00:49 Meet Juan Maldonado: Logistics Expert

02:02 Evolution of the Logistics Industry

03:08 Balancing Customization and Standardization

06:29 Importance of Gemba and Employee Engagement

10:34 Key Performance Indicators (KPIs) in Logistics

14:13 Managing Efficiency During Growth

16:14 Warehouse Layout and Adaptability

21:22 Technology and Automation in Warehousing

23:15 Inventory Accuracy and Final Thoughts

24:13 Evolution of Inventory Management

24:46 Daily Cycle Counts and System Integration

27:20 Best Practices for External Warehouses

31:22 Operational Discipline in Companies

33:16 Lessons from Working at Toyota

37:22 Personal Background and Career Journey

42:44 Conclusion and Podcast Wrap-Up

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