The Operations Science Podcast

Ed Pound

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

    2D AGO

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

    FEB 4

    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
  3. Transforming Operations at Scale: Lessons from Manufacturing to Boardroom | Oscar Sroor

    12/17/2025

    Transforming Operations at Scale: Lessons from Manufacturing to Boardroom | Oscar Sroor

    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 How to standardize and improve tender processes Scaling capacity without burning out teams Optimizing distribution networks and ERP systems Measuring cultural maturity in continuous improvement The evolving role of AI, Industry 4.0, and Industry 5.0 Leading transformation across diverse European cultures 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

    48 min
  4. The Hidden Complexity of Optical Lens Manufacturing | Operations Deep Dive with Stefano Relli

    11/20/2025

    The Hidden Complexity of Optical Lens Manufacturing | Operations Deep Dive with Stefano Relli

    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 Implementing push-pull systems Cultural intelligence in leadership Aligning KPIs with operational goals Managing variability and production capacity Engaging teams in continuous improvement The human side of operational transformation Stefano’s personal passion for road cycling 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

    45 min
  5. Building the Future of Operations: Santiago Camacho on Leadership and AI

    11/05/2025

    Building the Future of Operations: Santiago Camacho on Leadership and AI

    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

    41 min
  6. The Woman Powering Africa’s Optical Industry | Lessons in Supply Chain Leadership | Silindile Sitole

    10/08/2025

    The Woman Powering Africa’s Optical Industry | Lessons in Supply Chain Leadership | Silindile Sitole

    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

    44 min

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out of 5
3 Ratings

About

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...