When a deeply entrenched operating habit jeopardizes $14–15B in revenue, you don’t get a second chance to get it right.

This conversation with former Intel manufacturing leader Zane Rakes reveals how a shift in perspective—powered by Operation Science—transformed one of the most complex production environments on earth: semiconductor manufacturing.

From “bear traps” of runaway WIP to a trim, predictable factory capable of cutting cycle time by ~80%, Zane breaks down the real story of transforming Intel’s Fab 23—from chaos, firefighting, and hidden variability… to clarity, stability, and breakthrough performance.

If you work in semiconductor, operations, lean, high‑mix manufacturing, maintenance, or executive leadership, this deep‑dive is a masterclass in how systems actually behave—and what it takes to fix them.

00:00 – 01:00 • Setting the stage: how a single operating habit put billions at risk

01:00 – 03:00 • Introducing guest Zane Rakes & his semiconductor background

03:00 – 06:00 • Early Intel years, operations vs. equipment management

06:00 – 08:00 • First exposure to Factory Physics (Operation Science)

08:00 – 10:30 • “Bear traps,” variability, and the hidden cost of firefighting

10:30 – 12:00 • The Fab 23 turnaround begins: outdated MES & massive WIP problems

12:00 – 14:00 • Why schedules looked better on paper than in reality

14:00 – 16:00 • Taking over as Manufacturing Manager

16:00 – 18:30 • How Intel traditionally measured success: wafer starts vs. true output

18:30 – 21:00 • The case for WIP control—and the uphill battle convincing planning

21:00 – 23:30 • Using Little’s Law to expose the gap between goals and physics

23:30 – 26:30 • What direct observation revealed (including “embarrassing” discoveries)

26:30 – 29:00 • Fixing the send‑ahead process: from 3–6 hours to under 1 hour

29:00 – 32:00 • Transitioning from a “fat fab” to a “trim fab”

32:00 – 34:30 • The politics of starts moderation & gaining executive buy‑in

34:30 – 36:30 • Building the Starts Protocol (the engine of the turnaround)

36:30 – 38:30 • The unexpected win: yield improvements from lower WIP

38:30 – 40:00 • Achieving consistent ~21–22 day cycle times (down from ~110 days)

40:00 – 43:30 • Defining ideal state using scientific principles—not benchmarks

43:30 – 47:00 • Why variability—not tools—is the true enemy

47:00 – 49:30 • Using WIP as a proxy for system health

49:30 – 51:00 • Managing severe capacity loss on critical tools

51:00 – 56:00 • Zane's personal journey: upbringing, military career, and joining Intel

56:00 – end • Closing thoughts and timeless lessons for any production system

Key Takeaways:

How to transition from firefighting to physics‑driven operations?

Why semiconductor fabs (and most production systems) run slower than their tools suggest?

How small changes in variability create massive changes in throughput and cycle time?

The organizational realities of shifting from starts‑driven to flow‑driven thinking

The critical connection between inventory, yield, stability, and cost

If this conversation reshaped how you think about operations, help amplify the message:

Show your support:

👍 Give this video a like to help it reach more ops leaders

🔔 Subscribe for more real, unfiltered conversations on what truly drives performance

💬 Drop a comment: What’s the biggest “bear trap” you’ve faced in your own operations?

🔗 Share this episode with someone who needs to rethink how their system really works

#OperationsScience #FactoryPhysics #SemiconductorManufacturing #OperationalExcellence #LeanManufacturing #ContinuousImprovement #ManufacturingLeadership #CycleTimeReduction #SystemsThinking #HighTechManufacturing #Intel #ManufacturingTransformation #WIPControl #VariabilityReduction #ProcessEngineering

Managing global medical device projects is no small feat—especially when teams span multiple time zones and cultures. In this episode of the Operations Science Podcast, host Ed Pound interviews Diana Dimitrova, Senior Project Manager, who shares her proven strategies for leading complex programs that bring life-changing drug delivery devices to market.

Discover how Diana:

✅ Coordinates cross-functional teams across Denmark, China, India, Europe, and the U.S.

✅ Builds trust and bridges cultural differences for high-performing teams

✅ Implements risk management and standardized processes to avoid costly delays

✅ Leverages AI and digital twins to accelerate development and reduce costs

✅ Balances speed, cost, scope, and patient safety without compromising quality

Key Topics Covered:

• Global project management in the medical device industry

Connect with Us:

🌐 Learn more at opscience.org

📌 Subscribe for more episodes on operational excellence

👍 Like, comment, and share if you found this helpful!

#OperationsScience #MedicalDevices #ProjectManagement #Leadership #AI #GlobalTeams #RiskManagement #OperationalExcellence

In this episode of the Operations Science Podcast, host Ed Pound speaks with Ricardo Monge, a seasoned program manager specializing in medical device manufacturing. Ricardo shares his experiences orchestrating complex, multimillion-dollar project transfers across borders—merging technical rigor with human influence.

You’ll learn:

✔ How to balance strategic timelines with tactical operations

✔ Best practices for managing scope creep and regulatory compliance

✔ The role of AI as a supportive tool in project management

✔ Why effective communication and cultural sensitivity matter

Timestamps:

00:00 Introduction to the Operations Science Podcast

00:48 Meet Our Guest: Ricardo Monge

02:32 Ricardo's Role and Project Management Insights

04:57 Challenges and Best Practices in Project Transfers

23:47 The Role of AI in Project Management

26:58 Regulatory and Compliance Considerations

30:40 Effective Communication and Cultural Sensitivity

33:52 Personal Insights: Ricardo's Background and Interests

38:04 Conclusion and Final Thoughts

#MedicalDevices #ProjectManagement #AIinBusiness #GlobalOperations #Leadership #Manufacturing #RiskManagement #PodcastEpisode #Innovation #OperationsScience

In this episode of the Operations Science Podcast, host Edward Pound sits down with Oscar Sroor, a global operations leader based in Bordeaux, France, to explore what it really takes to achieve sustainable operational excellence.

With experience spanning manufacturing, medical devices, FMCG, and global supply chains, Oscar shares his journey from classic lean initiatives to leading large-scale business transformations. The conversation goes beyond tools and frameworks, focusing on structured thinking, scientific discipline, cultural adaptation, and systems-level improvement.

Key topics include:

• Why lean tools alone aren’t enough

This episode is essential listening for operations leaders, continuous improvement professionals, transformation leaders, and executives who want to move beyond surface-level optimization and build systems that truly perform.

Timestamps -

00:00 Trailer

00:47 Meet Our Guest: Oscar Sroor

01:31 Oscar's Continuous Improvement Journey

02:30 Explaining Operational Roles and Challenges

04:13 Transforming Business Processes

06:55 Standardizing Tender Processes

09:50 Measuring and Improving Tender Responses

15:31 Doubling Factory Capacity

17:37 Optimizing Distribution Networks

20:30 ERP Systems and Operational Decisions

27:16 Trainer Development and Kaizen Facilitation

28:41 Measuring Cultural Maturity in Lean Practices

29:39 Challenges in Training Facilitators

32:15 Communication and Cultural Adaptation in Europe

36:35 AI and Industry 4.0

41:58 Oscar Sroor's Journey and Influences

45:16 Balancing Work and Family Life

47:44 Podcast Conclusion and Call to Action

#OperationsScience #OperationalExcellence #ContinuousImprovement #BusinessTransformation #LeanThinking #ProcessImprovement

In this episode of the Operations Science Podcast, host Ed Pound sits down with Stefano Relli, an international leader in continuous improvement at a global precision optical lens manufacturer.

Together, they break down the real-world challenges of running a make-to-order, high-variability production system and how balancing a push-pull system can transform flow, efficiency, and customer responsiveness.

Stefano shares how his multicultural leadership journey shaped his approach to operational excellence, people alignment, and driving change in high-precision environments.

From understanding the complexity of lens manufacturing to managing production capacity, optimizing equipment efficiency, and engaging both frontline teams and senior leadership, this episode dives deep into what it takes to run operations at scale.

Perfect for professionals in manufacturing, operations, Lean systems, continuous improvement, and supply chain, this conversation delivers practical insights backed by global experience.

Topics Covered:

• Handling high-mix, make-to-order challenges

Timestamps -

00:00 Introduction to the Operations Science Podcast

00:49 Meet Stefano Relli: A Leader in Optical Lens Manufacturing

01:57 Stefano's Multicultural Journey and Its Impact on Leadership

08:24 Challenges of Make-to-Order Systems in Lens Manufacturing

12:46 Understanding the Lens Manufacturing Process

19:44 Implementing Push-Pull Systems for Operational Excellence

25:53 Ensuring Equipment Efficiency

26:42 Managing Production Capacity

28:31 Engaging Leadership in Continuous Improvement

34:20 Aligning People and Processes

35:26 Personal Journey and Influences

41:34 The Joy of Road Cycling

43:46 Conclusion and Final Thoughts

#OperationsScience

#ManufacturingExcellence

#ContinuousImprovement

#OpticalLensManufacturing

#LeanManufacturing

#MakeToOrder

#PushPullSystem

#OperationalExcellence

#SupplyChain

#LeadershipInManufacturing

In this episode of The Operations Science Podcast, host Edward Pound sits down with Santiago Camacho, a global supply chain leader with over two decades of experience in manufacturing and operations. Currently spearheading the setup of a new Greenfield site in Portugal for Coloplast, Santiago shares a candid look at the realities of modern supply chain leadership.

From balancing demand forecasts and managing production capacity to integrating AI into planning systems, Santiago explores how technology and people intersect in shaping the future of operations. He also reflects on leadership lessons, cross-cultural experiences, and how resilience and adaptability define successful supply chain transformation.

Whether you’re an operations professional, manufacturing leader, or curious about the human side of global logistics, this episode delivers grounded insights and actionable takeaways.

Timestamps:

00:00 Introduction to the Operations Science Podcast

00:49 Meet Santiago Camacho: A Supply Chain Expert

02:03 Challenges in Modern Supply Chain Management

03:50 AI's Impact on Entry-Level Jobs

07:13 Building a New Greenfield Site in Portugal

14:50 Postponement Strategy in Supply Chain

17:12 Leadership Lessons from Santiago Camacho

21:23 Balancing Demand Forecasts and Capacity

28:52 Global Supply Chain Planning at Coloplast

34:57 Personal Insights: Santiago Camacho's Journey

39:56 Conclusion and Final Thoughts

#SupplyChain #OperationsScience #Leadership #Manufacturing #Coloplast #AIinOperations #GlobalSupplyChain #OperationsExcellence #GreenfieldProject #Logistics #SupplyChainInnovation #BusinessStrategy #IndustrialLeadership #SantiagoCamacho #EdPound #Podcast #OperationalExcellence

In this episode of the Operations Science Podcast, host Edward Pound sits down with Christopher Goss, a sustainability and supplier risk management expert in the medical device industry. Together, they explore how Environmental and Social Governance (ESG) principles are reshaping global supply chains, from responsible sourcing and supplier code of conduct to human rights protections and ethical procurement.

Goss shares his experience at Insect Corporation, building sustainability frameworks that balance compliance with innovation. The discussion covers the challenges of global regulation variability, social compliance audits, and supply chain transparency, along with how AI and data analytics are transforming risk management.

From reimbursing recruitment fees for migrant workers to embedding sustainability KPIs into supplier performance, this episode reveals how ethical leadership can drive both business assurance and positive impact.

Tune in to learn how sustainable procurement isn’t just about doing good, it’s about building resilient, future-proof operations.

Timestamps -

00:00 – Introduction to the Operations Science Podcast

00:49 – Sustainability in Supply Chains: The Global View

02:30 – Building and Measuring Sustainable Frameworks

06:16 – Christopher Goss’s Role at Insect Corporation

08:37 – KPIs and the Metrics of Ethical Impact

11:10 – Audits, Compliance, and Supplier Accountability

16:01 – From “Nice to Have” to “Must Have”: The Shift in Sustainability

20:14 – Circular Economy and Operational Efficiency

23:49 – Leveraging AI and Data for Sustainable Operations

27:16 – Collaborating with Industry and Stakeholders

33:53 – Eliminating Recruitment Fees: A Real-World Success

41:19 – Career Reflections and Future Vision

45:36 – Closing Thoughts and Key Takeaways

#Sustainability #SupplyChain #OperationsManagement #EthicalSourcing #CircularEconomy #SustainableBusiness #Procurement #AIinSupplyChain #Leadership #CorporateResponsibility #SustainableDevelopment #OperationsExcellence #SupplierManagement #ChristopherGoss #OperationsSciencePodcast

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