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 Pound

01:05 Meet Silindile Sitole: Managing global lens supply chains

03:10 Challenges in working with Asian suppliers and time zones

06:40 Switching from air freight to sea freight: Why and how

10:15 Handling port strikes and emergency air shipments

13:05 Communication and customer management during backorders

16:30 Inside the polycarbonate lens production process

20:00 Role of data and MRP in managing 50,000 SKUs

24:40 Expanding operations to Mauritius

28:20 Training new teams and overcoming system differences

32:00 Key KPIs and weekly reporting for operational excellence

37:25 Managing capacity and forecasting with production teams

42:10 Collaboration between finance and supply chain teams

45:20 Thoughts on AI and the future of supply chain automation

49:15 Regulatory challenges, tariffs, and exporting to Africa

53:00 Lessons in leadership, trust, and operational agility

55:30 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 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

#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 Podcast

00:49 Meet Lisa Elles: Transforming the Shipbuilding Industry

02:25 Challenges and Innovations in Shipbuilding

04:57 Historical Insights: The Liberty Ships

08:14 The Decline and Future of US Shipbuilding

11:36 Lean Shipbuilding Model: Principles and Applications

18:10 Impact of Lean Shipbuilding on the Industry

30:55 The Role of AI in Ship Design and Production

35:32 Lisa Elles: Personal Journey and Professional Insights

41:28 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 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