The Operations Science Podcast

Ed Pound
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The Operations Science Podcast: Authentic Leadership Stories from Operations and Project LeadersWelcome 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 PodcastOur guests include C-level executives, VPs of operations and supply chain, directors, manage...

  1. Why Lean Stalls: Standards, Accountability, and What It Really Takes to Sustain Results

    15 APR

    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 Points 00:47 Why early Lean efforts failed 03:21 Consultant-led vs internally driven transformation 04:24 Why maintenance is a cost lever, not a cost center 06:16 Managing seven plants and cross-industry lessons 08:45 Labor scarcity and system-based productivity 10:09 Time-to-competency by role 11:49 Building labor pipelines through schools and partnerships 15:09 Upskilling maintenance technicians with a structured curriculum 17:13 Factory Physics, bottlenecks, and SMED 20:53 How leaders learn systems thinking 24:39 Leadership variability across seven plants 28:51 Sustaining gains with layered process audits 30:39 Practical AI use cases in manufacturing 35:05 Chris Morehouse’s leadership journey 40:29 Advice for non-engineers entering operations Stay Connected If 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 industry   Stop 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
  2. Start with Value: Why Process Must Lead Technology for Digital Transformation Success

    1 APR

    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 Points 00:00 Why transformation should start with business value 02:10 Fixing process gaps across CRM, SAP HANA, ServiceNow & workflows 06:48 Portfolio thinking vs managing isolated systems 10:32 Why poor scope definition kills projects 14:25 ERP upgrades: reduce customization, maximize value 19:40 Why every company thinks they’re “unique” 23:12 Where AI actually creates business value 27:05 Real use case: AI agents for document validation & order workflows 31:28 Consultant mindset vs internal transformation leadership 35:50 How Marta diagnoses business constraints fast 40:15 Hidden logistics bottlenecks and process heat maps 44:22 Marta’s career journey: gaming, Microsoft, consulting & enterprise transformation 49:10 Leadership, running, scouting & community service If 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
  3. The Other Side of the EV Revolution: Turning Toxic Waste Into Critical Materials

    24 MAR

    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 uncertainty 07:00 - Why battery recycling is a complex emerging industry 10:25 - How lithium-ion batteries are actually recycled 14:25 - Second-life batteries vs recycling 16:25 - Managing capital risk in a new industry 19:35 - Building culture and leading high-performance teams 23:20 - Where AI fits into battery recycling operations 28:50 - Hiring and scaling a fast-growing company 31:00 - Government support and sustainability incentives 33:00 - Operational excellence while building a new plant 35:40 - Project management for large capital projects 41:00 - Julian’s background and career path 46:00 - Work-life balance and leadership mindset 47:17 - Closing thoughts   The 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

    48 min
  4. Scaling Medical Device Operations: Leadership, Kaizen, and Managing Variability

    4 MAR

    Scaling Medical Device Operations: Leadership, Kaizen, and Managing Variability

    What does operational excellence look like when the product you manufacture directly impacts a person’s dignity and quality of life? In this conversation, Mindaugas Valkavicius shares what it takes to lead 200+ frontline operators in a high-sensitivity environment—where safety, quality, and service aren’t abstract metrics, but daily commitments. From ramping up capacity during the pandemic to consolidating production across borders, Mindaugas unpacks the realities of scaling responsibly while keeping people at the center. This isn’t theory. It’s practical leadership from the factory floor. Key Discussion Points 00:00 – Introduction to Operations Science 01:39 – Scope of leading 200+ operators in medical device manufacturing 02:47 – From prototyping to mass manufacturing 05:13 – Where variability hides in operations 06:50 – Leading remotely during the pandemic 08:40 – Doubling plant capacity during COVID 09:46 – Balancing automation and manual inspection 12:29 – Continuous improvement as daily habit 16:21 – Structured Kaizen events and rapid gains 18:26 – Prioritizing improvement after low-hanging fruit 22:00 – Overcoming fear around job loss and Kaizen 24:02 – 24-month forecasting and consolidation strategy 26:40 – Executing cross-border production transfers 29:35 – Measuring efficiency: OEE and budget alignment 31:24 – Why finance should join the Gemba walk 33:40 – Advice for new operations leaders 36:17 – Building trust: Lessons from family and early leadership If this conversation adds value to you: 👍 Like this video 🔔 Subscribe for more real conversations from the frontlines of operations 💬 Comment with the leadership insight that stood out most 🔗 Share this with someone building or leading a team #Operations #OperationalExcellence #ManufacturingLeadership #ContinuousImprovement #Kaizen #MedicalDevices #Leadership #LeanManufacturing #OperationsManagement #IndustryLeadership

    39 min
  5. Vitoria Vellani on Demand Planning, Disruption & the Brazilian Market

    18 FEB

    Vitoria Vellani on Demand Planning, Disruption & the Brazilian Market

    Global supply chains don’t fail all at once. They bend, stretch, and quietly test every assumption you’ve made about planning, inventory, and timing. In this conversation on the Operation Science Podcast, Vitoria Vellani shares what it actually looks like to manage demand planning and import operations in Brazil—where long lead times, currency swings, port congestion, and seasonal demand collide. From importing luggage across three continents to balancing forecast accuracy with real-world uncertainty, this episode digs into the decisions supply chain teams rarely get credit for, but everyone feels when they go wrong. You’ll hear practical insights on: Planning for volatility instead of pretending it doesn’t exist Why inventory accuracy is non-negotiable How communication across sales, operations, and logistics keeps the system moving Where AI helps — and where human judgment still matters most No theory. Just how global operations actually work when conditions change faster than your forecast.   Key Discussion Points 00:00 – Setting the context: operations under real-world constraints 01:30 – Importing into Brazil: lead times, currency, and global exposure 04:20 – Moving from medical devices to consumer goods 06:10 – Managing disruption: containers, congestion, and freight volatility 09:20 – Forecasting, safety stock, and seasonal pressure 12:40 – Combining historical data with sales insight 15:00 – Inventory accuracy and why errors quietly destroy plans 18:30 – Where demand planning breaks down — and how to strengthen it 21:20 – Using AI in forecasting without over-trusting the output 25:20 – Working across cultures in global supply chains 29:00 – KPIs that actually reflect supply chain health 33:20 – Career lessons, mentorship, and building confidence over time 37:00 – Final reflections and takeaways   If this conversation resonated with you: 👍 Like the episode 🔔 Subscribe for more real conversations about operations 💬 Share your biggest takeaway in the comments 🔗 Send this to someone dealing with planning, inventory, or supply chain volatility right now   #SupplyChain #DemandPlanning #Operations #Logistics #InventoryManagement #Forecasting #GlobalTrade #OperationsScience

    38 min
  6. The Science Behind Stable Flow: Intel Veteran Reveals the Truth About Modern Manufacturing

    4 FEB

    The Science Behind Stable Flow: Intel Veteran Reveals the Truth About Modern Manufacturing

    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: Why high WIP hides problems and destroys performance? 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

    57 min
  7. How to Manage Global Medical Device Projects | Diana Dimitrova Interview

    21 JAN

    How to Manage Global Medical Device Projects | Diana Dimitrova Interview

    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 Cross-cultural collaboration and communication best practices Risk management and resource planning for large-scale programs AI and digital transformation in product development Leadership insights: facilitation vs. top-down decision-making 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

    32 min
  8. Mastering Cross-Border Production Transfers: Project Management Lessons from the Front Lines

    7 JAN

    Mastering Cross-Border Production Transfers: Project Management Lessons from the Front Lines

    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

    40 min
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The Operations Science Podcast: Authentic Leadership Stories from Operations and Project LeadersWelcome 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 PodcastOur guests include C-level executives, VPs of operations and supply chain, directors, manage...

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  • Creator
    Ed Pound
  • Years Active
    2025 - 2026
  • Episodes
    23
  • Rating
    Clean
  • Copyright
    © Copyright 2025 | All Rights Reserved
  • Show Website
    The Operations Science Podcast
  • Provider

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