Sign up to save your podcasts
Or
Share The Operations Science Podcast
Share to email
Share to Facebook
Share to X
Share to email
Share to Facebook
Share to X
Or
The Operations Science Podcast
The Operations Science Podcast episodes
- Why Lean Programs Fail And A Proven Fix in Four Levels
Many Lean and continuous improvement programs struggle—not because the tools are wrong, but because organizations overlook the foundation: developing capable people.
In this conversation, Abdulrahman Yossri shares lessons from nearly two decades of manufacturing leadership across consumer goods, chemicals, aluminum, and industrial operations.
Together with Ed Pound, they discuss why capability building is the key to sustainable operational excellence, how leaders can align teams around shared goals, and why companies should think of themselves as training academies.
Key Discussion Points
- 02:10 The common challenge across manufacturing
- 07:15 Why problems are opportunities for improvement
- 08:10 Lessons from becoming a plant manager
- 13:00 Why capability building comes before Lean
- 16:35 The four levels of workforce development
- 23:00 Solving the skilled labor challenge
- 28:20 Connecting education to industry
- 31:00 Using AI without losing expertise
- 38:00 Final thoughts
If this conversation gave you a new perspective on leadership and operational excellence:
👍 Like the video💬 Share your biggest takeaway in the comments📤 Pass this along to someone building high-performing teamsWant to better understand the science behind operational performance? OSI Insider is a free, self-paced introduction designed to help leaders understand why operations behave the way they do.
For a deeper dive, explore Operations Science Applied
#OperationsManagement #LeanManufacturing #ContinuousImprovement #OperationalExcellence #Manufacturing #OSI
40 min - Stop Arguing About Lead Time: How to Commit to a Date and Actually Hit It
Most operations teams spend too much time arguing about lead times.
Customers want products faster. Sales wants shorter lead times. Operations pushes back.
But what if the real goal isn't lead time at all?
Kim Shelby shares how her team shifted from fixed lead times to due-date quoting. The result was better customer communication, stronger operational performance, and more reliable delivery commitments.
The conversation explores demand variability, capacity management, forecasting, leadership, and practical AI applications in supply chain operations.
Key Discussion Points
01:15 Meet Kim Shelby
03:15 Managing operations in a high-change environment04:30 Why production dates create unnecessary noise07:20 The shift from lead times to due-date quoting10:00 Managing customer expectations12:00 Building support through pilot programs13:45 Demand variability and forecasting challenges16:00 Capacity utilization and operational performance20:00 When OTIF improves but customers remain unhappy22:00 Improving cash flow through better commitments24:00 AI applications in supply chain operations27:00 Kim's career journey33:00 Career advice: Say yes to everythingStop relying on fixed assumptions. Learn the science behind reliable delivery, better forecasting, and stronger operational performance with Operations Science Applied: bit.ly/OSA2026
If you want more insights on how to level up your operations, visit insider.opscience.org
#OperationsManagement #SupplyChain #Manufacturing #Leadership #CommitDate #LeadTime #ATP #OperationalExcellence #OperationsScience #ContinuousImprovement #OSI
35 min - Red Flags Before the Delay: Early Warning Signs Every Construction Project Manager Should Watch
Construction projects rarely fail because of one big mistake. More often, they collapse under misalignment, unrealistic schedules, procurement delays, poor sequencing, and operational variability that no one planned for.
Construction manager and mechanical engineer Milton Griffiths shares lessons from greenfield and brownfield infrastructure projects, discussing how contractors, procurement teams, logistics, weather, workforce fatigue, and communication all shape project outcomes in the real world.
The discussion explores practical construction leadership, operational clarity, risk management, supplier coordination, schedule realism, and why successful project delivery starts long before work begins onsite.
Key Discussion Points- 02:20 – What separates successful projects from failing ones
- 04:45 – Greenfield vs. brownfield construction realities
- 05:20 – Why unrealistic schedules destroy projects
- 07:00 – Procurement lead times and remote project logistics
- 09:15 – Managing inventory and equipment on construction sites
- 12:00 – Weather, climate, and operational variability in construction
- 14:00 – Laydown areas, theft risks, and inventory control
- 18:15 – Early warning signs that projects are falling behind
- 20:00 – Workforce fatigue, morale, and productivity
- 21:00 – Change orders, contractor incentives, and schedule pressure
- 24:00 – Standing time, coordination, and contractor claims
- 27:00 – Buffers, contingencies, and risk management
- 28:00 – Common misunderstandings that derail construction performance
- 30:00 – Ubuntu culture and collaboration between contractors
- 31:00 – Why brownfield projects are more predictable
- 33:00 – AI, drones, and emerging technology in construction
- 35:00 – Milton’s engineering journey and early influences
- 38:00 – Transitioning from design engineering into construction management
- 41:00 – Art, mentorship, and launching The Hidden Strength Podcast
Construction leadership isn’t just about getting work done faster. It’s about understanding flow, variability, coordination, and the operational realities that determine whether projects succeed or spiral into chaos.
Operations become easier to improve when you understand the science behind how work actually flows.
Explore the principles behind variability, coordination, and operational performance with Operations Science Applied: bit.ly/OSA2026
You may also find OSI Insider useful. It's a free guided tour through operations science that's structured, self-paced, and designed to be a quick read: https://insider.opscience.org
If this conversation challenged the way you think about project execution:
👍 Like this video
🔔 Subscribe for more conversations on operations, leadership, and project execution💬 Share your biggest takeaway in the comments🔗 Send this to someone managing complex projects or construction teams#ConstructionManagement #ProjectManagement #OperationsManagement #Leadership #Engineering #Infrastructure #ConstructionProjects #OperationalExcellence #MechanicalEngineering #OperationsScience #OSI
45 min - From Aircraft Carriers to Factory Floors: Lessons in Operations
When you’re managing operations where a single mistake can cost millions—or put lives at risk—process discipline stops being theoretical.
Josh “Tree” Dittmar shares lessons from two worlds where operational excellence is non-negotiable: semiconductor manufacturing and U.S. Navy flight operations. From planning multi-million-dollar semiconductor capacity years in advance to coordinating aircraft launches on an aircraft carrier, this episode explores what it really takes to lead in complex, high-stakes environments.
The discussion dives into variability, operational constraints, safety systems, AI adoption, leadership culture, and why the best operators never stop learning.
Key Discussion Points:00:00 – Introduction
01:10 – Tree Dittmar’s role in semiconductor manufacturing02:14 – Long-term capacity planning and expensive equipment constraints04:49 – Why semiconductor manufacturing is incredibly complex06:05 – 3D heterogeneous integration and the future of chips07:08 – Coordinating operations across multiple business functions08:28 – Brownfield vs. greenfield manufacturing challenges10:48 – Why semiconductor tools can’t simply be “leaned out”12:05 – Variability, buffers, and Operations Science principles14:18 – Demand planning and operational forecasting15:50 – AI in semiconductor manufacturing17:13 – AI governance, policy, and security concerns19:17 – Lessons from Navy aircraft carrier operations21:33 – Designing systems for Six Sigma-level safety22:26 – Flight deck communication and operational coordination24:17 – Fast feedback loops and operational discipline26:26 – How the Navy trains operators for high-risk environments28:25 – What semiconductor fabs can learn from military training28:37 – Foreign object damage and contamination parallels31:15 – Safety culture in dangerous operational environments33:58 – Mission, purpose, and team culture36:50 – Leadership, adaptability, and lifelong learning39:34 – Working across cultures and global teams41:17 – Career advice for future operations leaders43:20 – Final thoughtsOperations isn’t magic. It’s systems, tradeoffs, discipline, and leadership under uncertainty.
If you lead teams, manage production systems, or operate in high-complexity environments, this conversation will change how you think about operational performance.
A better operation starts with understanding the science behind it. Discover how variability, flow, and operational constraints shape performance in the real world with Operations Science Applied: bit.ly/OSA2026
Don’t forget to:
👍 Like this video🔔 Subscribe for more conversations on operations, leadership, and systems thinking💬 Comment with your biggest takeaway🔗 Share this episode with someone leading complex operations#OperationsManagement #Semiconductor #Leadership #Manufacturing #OperationsScience #SupplyChain #ArtificialIntelligence #SystemsThinking #LeanManufacturing #Engineering #Navy #OperationalExcellence #SemiconductorIndustry #BusinessLeadership #OSI
44 min - Simplicity as Strategy: Kate Kowalczuk on Procurement, Resilience, and Data Integrity
Global supply chains don’t fail all at once.
They fail slowly—through fragile systems, poor data discipline, supplier consolidation, regulatory bottlenecks, and operational decisions that look efficient until disruption exposes the cracks.
Kate Kowalczuk has spent her career operating inside that reality.
From pharmaceuticals and medical devices to chemicals and consumer products, she’s worked across highly regulated industries where one supplier issue, one manufacturing change, or one delay in approval can ripple across an entire operation.
What makes this conversation compelling is how clearly it reveals the hidden complexity behind modern operations.
A winter storm in Texas disrupts 25% of global chemical capacity.
An ERP system becomes unreliable because teams stop maintaining clean data.A supplier quietly discontinues a low-volume product, forcing entire organizations into reactive mode.An AI system promises end-to-end procurement automation, but still struggles with the human side of negotiation and judgment.Kate brings a grounded perspective to all of it.
She explains why resilience has become just as important as efficiency, why sustainability increasingly matters operationally (not just environmentally), and why strong systems still depend on disciplined people behind them.
The conversation also takes a personal turn as she reflects on growing up in Poland under the Iron Curtain, and how that experience shaped her views on minimalism, leadership, resilience, and overconsumption.
⏱️ Key Discussion Points:
00:00 Introduction
02:08 Regulatory complexity in pharma and med device supply chains04:05 Why manufacturing changes can take months for approval06:12 Batch sizes, operational tradeoffs, and regulatory barriers08:30 The three biggest supply chain challenges today09:42 How the Texas freeze disrupted global chemical capacity11:18 Supplier consolidation and regional manufacturing constraints12:35 Product discontinuations and operational risk14:55 ERP systems: SAP, NetSuite, D365, and operational realities17:42 Customization vs adapting the business to the system19:28 Why ERP data integrity breaks down inside organizations22:10 What separates great planners and procurement leaders24:40 Supplier collaboration and process improvement opportunities27:30 Supply chain visibility and emerging technologies29:18 The real opportunities and limits of AI in procurement31:20 Why regulated industries remain cautious with AI32:30 Growing up in Poland under the Iron Curtain34:05 Minimalism, sustainability, and operational thinking35:48 Overconsumption, resilience, and the future of operations37:08 Leadership lessons from working across cultures39:02 Sustainability, textile recycling, and life outside workOperations become far easier to improve when you understand the science behind them. Explore the principles behind flow, variability, and operational performance with Operations Science Applied: bit.ly/OSA2026
Don’t forget to:
👍 Like this video🔔 Subscribe for more authentic conversations on operations and leadership💬 Comment with your biggest takeaway📤 Share this episode with someone building resilient operations#Operations #SupplyChain #Procurement #Leadership #OperationalExcellence #ERP #Manufacturing #AI #Sustainability #OperationsScience #SupplyChainManagement #Pharmaceuticals #OSI
41 min - Better Performance Across Sites and Cultures through Continuous Improvement
What does it take to scale continuous improvement across multiple plants, cultures, and operating realities—without turning standardization into bureaucracy?
Andre Scarance shares what global manufacturing leaders often learn the hard way: improvement doesn’t scale through tools alone.
It scales through alignment, clear mental models, disciplined business systems, and leadership that makes improvement everyone’s responsibility.
We explore why some plants sustain gains while others slip back into firefighting, how productivity and quality should never be traded against each other, where AI may fit into future operations systems, and why changing standards too often can quietly destroy performance.
If you care about operational excellence, manufacturing leadership, Lean, or building systems that hold under pressure, this one delivers.
Key Discussion Points00:00 Intro
01:34 Meet Andre Scarance02:30 Scaling strategy across global manufacturing sites05:22 Making continuous improvement everyone’s job07:13 What stable operations look like (and warning signs of struggle)08:18 Why projects fail before they start09:13 Shared mental models and operational behavior10:32 Managing improvement projects across sites12:21 Gaining trust from frontline operations15:44 Why tools alone don’t create transformation17:13 Kaizen, practical learning, and capability building19:00 The productivity challenge every plant is facing20:01 AI in continuous improvement and operations23:04 Productivity vs. quality — false tradeoff?24:50 Measuring productivity in manufacturing25:21 Selecting projects that actually matter28:00 Why improvements fail to sustain31:29 Andre’s career journey from IT to operations35:13 Mentors, leadership lessons, and career advice37:24 Advice for the next generation of operations leadersIf this conversation sparked an idea:👍 Like this video
🔔 Subscribe for more conversations on operational excellence and leadership💬 Share your biggest takeaway in the comments📤 Send this episode to a leader working to scale improvement across complex operationsSustainable improvement starts with understanding how operations actually behave. Learn the science behind flow, variability, and performance in Operations Science Applied: bit.ly/OSA2026
#OperationalExcellence #ContinuousImprovement #LeanManufacturing #OperationsLeadership #Manufacturing #BusinessSystems #Leadership #ProcessImprovement #IndustrialEngineering #OperationsScience #SupplyChain #AIinManufacturing #OSI
41 min - From Multinational Complexity to Startup Speed: Leading High-Performance Pharma Operations
Most organizations don’t struggle because they lack talent.
They struggle because they move too slowly, operate in silos, and avoid the hard changes everyone already sees coming.
This conversation goes deep into what happens when you bring FMCG-level execution discipline into a pharmaceutical environment—and why most teams resist it at first.
Adil Belrhzal shares how he built a fast-growing pharma operation inside a diversified group by combining multinational rigor, startup speed, and a culture that allows people to fail fast and learn faster.
There’s a simple idea at the center of this conversation that most leaders overlook. If people don’t understand what’s in it for them, nothing changes.
Key Discussion Points00:00 – Introduction to Operations Science Podcast
00:45 – Adil’s role and building a pharma business in Morocco03:19 – Multinational vs local companies: speed, culture, decision-making06:23 – FMCG vs pharma: where discipline really comes from08:38 – Why change fails: “What’s in it for me?”10:13 – Weekly vs daily execution: adapting FMCG discipline12:55 – Performance shift: daily targets + right to fail15:01 – The power of naïve questions and unlearning16:00 – Aligning leadership and breaking silos18:06 – Why organizations lack a shared understanding19:11 – Variability: the silent killer in pharma operations21:53 – Inventory, supply chains, and serving patients first23:17 – Preparing for 6 IPOs in 6 years26:48 – AI adoption: from fear to full integration30:15 – Decentralizing AI across the organization33:14 – Moving from experimentation to strategic AI35:46 – Personal story: resilience and early responsibility38:21 – Leadership mindset: staying grounded in chaos40:00 – Habits, routines, and balanceIf this conversation made you rethink how you run your operation:
👍 Give it a like
🔔 Subscribe so you don’t miss what’s next💬 Drop your biggest takeaway in the comments🔗 And share this with someone who’s trying to drive real changeOperational excellence shouldn’t rely on guesswork. Learn the science behind flow, variability, and performance in Operations Science Applied: bit.ly/OSA2026
#Operations #Leadership #Pharma #FMCG #OperationalExcellence #AIinBusiness #SupplyChain #LeanLeadership #BusinessStrategy #Execution #OSI #H&SGroup #DislogGroupHealthcare #Steripharma #GlobalPharmaceuticalIndustryAdvisors #TransformationalLeadership
43 min - Why Lean Stalls: Standards, Accountability, and What It Really Takes to Sustain Results
Chris Morehouse leads operations across seven manufacturing plants where labor is tight, margins are real, and leadership consistency directly shapes performance.
What makes this conversation especially valuable is Chris’s grounded perspective: Lean transformation does not begin with tools—it begins with standards, leadership routines, and a shared understanding of what good looks like.
From sustaining gains through layered process audits to building maintenance capability, reducing tribal knowledge, applying Factory Physics, and exploring how AI can support predictive maintenance and troubleshooting, this discussion is packed with practical lessons for operations leaders.
If you’re leading plants, building systems, or trying to reduce variability across teams, this conversation offers a blueprint for turning operational chaos into disciplined flow.
Key Discussion Points00:47 Why early Lean efforts failed
03:21 Consultant-led vs internally driven transformation04:24 Why maintenance is a cost lever, not a cost center06:16 Managing seven plants and cross-industry lessons08:45 Labor scarcity and system-based productivity10:09 Time-to-competency by role11:49 Building labor pipelines through schools and partnerships15:09 Upskilling maintenance technicians with a structured curriculum17:13 Factory Physics, bottlenecks, and SMED20:53 How leaders learn systems thinking24:39 Leadership variability across seven plants28:51 Sustaining gains with layered process audits30:39 Practical AI use cases in manufacturing35:05 Chris Morehouse’s leadership journey40:29 Advice for non-engineers entering operationsStay ConnectedIf this conversation gave you a new lens on leadership, Lean, or operational systems:
✅ Like and subscribe for more authentic operations conversations
💬 Share your biggest takeaway in the comments🔁 Send this to an operations leader who needs to hear it🎯 Follow for more real-world lessons from the front lines of industryStop managing in the dark. Learn the science behind every operation—and finally get variability under control.
Get your copy of Operations Science Applied today: bit.ly/OSA2026
#OperationsLeadership #LeanManufacturing #FactoryPhysics #ContinuousImprovement #OperationalExcellence #ManufacturingLeadership #AIinManufacturing #LeadershipDevelopment #SupplyChain #IndustrialEngineering #OSI
43 min - Start with Value: Why Process Must Lead Technology for Digital Transformation Success
Big transformation programs rarely fail because of technology alone. They fail when teams optimize systems instead of outcomes.
Marta Moreira Rodriguez shares what nearly 25 years in transformation leadership has taught her about turning complexity into measurable business value—across ERP modernization, CRM workflows, ServiceNow, AI agents, process redesign, and enterprise-scale change.
What stands out in this conversation is how she frames transformation through business outcomes first, systems second.
From reducing unnecessary ERP customization to using agentic AI for document validation, tender workflows, and order processing, Marta breaks down what actually works when organizations are trying to modernize legacy operations without losing compliance, speed, or customer experience.
If you lead PMOs, digital transformation, ERP programs, operations, supply chain, or enterprise delivery teams, this one will feel very familiar.
Key Discussion Points00:00 Why transformation should start with business value
02:10 Fixing process gaps across CRM, SAP HANA, ServiceNow & workflows06:48 Portfolio thinking vs managing isolated systems10:32 Why poor scope definition kills projects14:25 ERP upgrades: reduce customization, maximize value19:40 Why every company thinks they’re “unique”23:12 Where AI actually creates business value27:05 Real use case: AI agents for document validation & order workflows31:28 Consultant mindset vs internal transformation leadership35:50 How Marta diagnoses business constraints fast40:15 Hidden logistics bottlenecks and process heat maps44:22 Marta’s career journey: gaming, Microsoft, consulting & enterprise transformation49:10 Leadership, running, scouting & community serviceIf you're leading transformation work right now, the most valuable takeaway may be this: start with the value stream, not the software vendor.
Don’t forget to:
👍 Like this video🔔 Subscribe for more real conversations from the front lines of operations💬 Comment with your biggest takeaway🔗 Share this with someone leading transformation right now#OperationsScience #DigitalTransformation #ERP #AI #ProjectManagement #Leadership #BusinessTransformation #SAP #ServiceNow #OperationalExcellence #EnterpriseSystems #ChangeManagement #OSI
49 min - The Other Side of the EV Revolution: Turning Toxic Waste Into Critical Materials
Electric vehicles are accelerating faster than ever.
But there’s a massive operational challenge most people aren’t talking about. What happens to the batteries when they reach end-of-life?
This conversation explores the systems, strategy, and leadership required to build large-scale battery recycling operations, from the ground up. From navigating uncertainty in a brand-new industry to balancing capital investment, AI, hiring, and operational excellence—this is a real look at building industrial infrastructure for the future.
If you care about operations, sustainability, manufacturing, or scaling new technology. This one connects the dots.
Key Discussion Points
00:01 - Building a large-scale battery recycling operation
03:30 - Structured decision-making under uncertainty07:00 - Why battery recycling is a complex emerging industry10:25 - How lithium-ion batteries are actually recycled14:25 - Second-life batteries vs recycling16:25 - Managing capital risk in a new industry19:35 - Building culture and leading high-performance teams23:20 - Where AI fits into battery recycling operations28:50 - Hiring and scaling a fast-growing company31:00 - Government support and sustainability incentives33:00 - Operational excellence while building a new plant35:40 - Project management for large capital projects41:00 - Julian’s background and career path46:00 - Work-life balance and leadership mindset47:17 - Closing thoughtsThe EV revolution is here.
The operational infrastructure behind it is just getting started.
Don't forget to:
👍 Like this video🔔 Subscribe for more authentic conversations💬 Comment with your biggest takeaway🔗 Share with someone who needs to hear this#Operations #OperationalExcellence #Manufacturing #EV #ElectricVehicles #BatteryRecycling #Sustainability #Leadership #SupplyChain #IndustrialEngineering #AI #ContinuousImprovement #ProcessImprovement #OperationsManagement #CleanEnergy
49 min
About The Operations Science Podcast
From the publisher's feed
The Operations Science Podcast: Authentic Leadership Stories from Operations and Project Leaders
Welcome to The Operations Science Podcast, the premier…
destination for authentic, in-depth conversations with operations and project leaders who share real-life stories of their career triumphs, setbacks, and the invaluable insights gained along the way. Hosted with a passion for uncovering the strategies and mental frameworks that drive success, this podcast is a must-listen for executives, managers, and aspiring leaders in industries such as general manufacturing, medical devices, aerospace, maintenance, repair, and overhaul (MRO) companies, and diagnostic labs. With a focus on leadership, operational excellence, and continuous improvement, each episode delivers actionable takeaways to help you navigate the complexities of modern business landscapes.
What to Expect from The Operations Science Podcast
Our guests include C-level executives, VPs of operations and supply chain, directors, managers, and thought leaders from trade associations, industry groups, and standards organizations. These seasoned professionals bring a wealth of experience in leadership, decision-making, and execution, offering unique perspectives on operational challenges like rapid change, uncertainty, innovation, evolving workforce expectations, talent development, and organizational culture. Whether you're a forward-thinking executive or a continuous improvement enthusiast, this podcast provides a platform to learn from the best in the field.
Each episode dives deep into the personal journeys of high-performance leaders, exploring their successes, failures, and comebacks. From building high-performance teams to driving strategic transformation and maintaining clarity under pressure, our guests share the mental tools, frameworks, and strategies that have enabled them to lead with confidence, resilience, and foresight. This isn’t just another business podcast—it’s a forum for high-level executives to openly discuss the real challenges of operational management and the mental fitness required to thrive at the top.
Why Listen to The Operations Science Podcast?
- Authentic Storytelling: Hear real-life stories from operations and project leaders who have navigated the highs and lows of leadership in dynamic industries.
- Actionable Insights: Gain practical strategies for overcoming operational challenges, fostering innovation, and building resilient teams.
- Diverse Perspectives: Learn from a wide range of guests, including C-suite executives, industry group leaders, and continuous improvement experts.
- Inspiration for Growth: Discover how top leaders adapt to change, inspire their teams, and make high-stakes decisions with clarity and confidence.
- Industry-Specific Focus: Explore winning practices and leading trends in general manufacturing, medical devices, aerospace, MRO, and diagnostic labs.
Who Should Listen?
This podcast is designed for:
- C-level executives and VPs of operations/supply chain seeking to sharpen their leadership skills
- Directors and managers in operations, project management, or continuous improvement roles
- Professionals in general manufacturing, medical devices, aerospace, MRO, and diagnostic labs
- Aspiring leaders looking to learn from the experiences of seasoned executives
- Members of trade associations, industry groups, and standards organizations interested in industry trends and winning practices
How to Listen
The Operations Science Podcast is available on major platforms, including YouTube, Spotify, Apple Podcasts, and more. Subscribe today to get notified about new episodes and gain access to a growing library of leadership insights. Follow us on LinkedIn and other social media platforms for daily short-form video clips that deliver quick, actionable tips from our guests.