Manufacturing the Future

Meet James Butler, SVP & Chief Supply Chain and Corporate Strategy Officer at Brinker International, "I always tell the team, our vision is to be the world's leading supply chain, restaurant supply chain organization. And that really comes down to five pillars that I've ordered in exactly their level of importance. And the very first one is food safety and quality," says James Butler, SVP & Chief Supply Chain and Corporate Strategy Officer at Brinker International, showcasing his unwavering commitment to excellence in supply chain management. James addresses one of the most complex challenges in modern business: managing supply chains that must deliver consistent quality across thousands of locations while maintaining the highest food safety standards. Restaurant supply chains face unique pressures, including perishable inventory, multiple daily deliveries, and the need to support rapid growth without compromising operational excellence. His role uniquely combines supply chain operations with corporate strategy, allowing him to align tactical execution with long-term business objectives. James's journey to Brinker began with a diverse career spanning sales, consulting at Deloitte, and supply chain leadership at major companies including Georgia Pacific and KFC. His experience during the pandemic at KFC, where he navigated product shortages, steep inflation, and changing consumer demands, prepared him for the strategic challenges he faces today. This breadth of experience across industries has given him a unique perspective on creative problem-solving and the importance of building resilient, forward-thinking supply chain operations. In This Episode James Butler's leadership philosophy centers on transforming traditional supply chain teams from reactive "firefighters" into proactive "fire preventers." Through his innovative Smokey Bear Award and emphasis on building stronger processes, he demonstrates how strategic thinking can elevate supply chain operations from tactical necessity to competitive advantage, ultimately supporting Brinker's mission to deliver exceptional dining experiences across their global restaurant network.   Topics Pandemic-era lessons in supply chain resilience, including managing product shortages and rapidly changing consumer demands. The "fall in love with the problem, not the solution" methodology to drive effective problem-solving. Transforming supply chain teams from reactive firefighters to proactive fire preventers through cultural change and recognition programs. Food safety and quality as the non-negotiable foundation of all restaurant supply chain operations and decision-making processes. Managing complex logistics for thousands of suppliers delivering to 1,600+ restaurants while maintaining consistency and availability. Technology implementation strategies that prioritize understanding optimal processes before selecting and customizing software solutions to fit workflows. Aligning supply chain operations with corporate strategy to drive restaurant growth and enhance the guest experience. Sustainability initiatives and responsible sourcing practices in restaurant supply chains, including partnerships with suppliers on emissions reduction. Innovation management in traditionally risk-averse environments, including balancing creativity with operational reliability and food safety requirements. Get in touch with James Butler:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube

Meet Tyler Madsen, Director of Madsen's Millwork & Custom Cabinets Tyler Madsen, Director of Madsen's Millwork & Custom Cabinets, exemplifies how traditional craftsmanship can thrive through technological innovation. "If you're not updating your technology, updating your equipment, updating your processes, you're going to be left behind," Tyler explains. "The most important thing here is speed. It's not just quality, it's how rapidly we can pump out quality." Madsen's Millwork, founded in 1962, specializes in high-end custom woodworking for educational, residential, and commercial spaces, employing 75 skilled craftsmen and producing up to 30% of the region's architectural woodwork. The company needed to maintain its reputation for excellence while adapting to post-pandemic business realities and evolving customer expectations. Under Tyler's leadership alongside his brother Josh, the company has embraced digital transformation while honoring traditional values. They've implemented sustainable practices like their innovative biomass heating system, which converts wood waste into energy, demonstrating their commitment to both environmental responsibility and operational efficiency. In This Episode In this milestone 50th episode, Tyler shares how upgrading from Epicor 905 to Kinetic and implementing AI tools like Prism has revolutionized their operations. From streamlining complex estimating processes to empowering field teams with real-time data access, Madsen's proves that embracing technology enhances rather than replaces traditional craftsmanship, enabling faster delivery without compromising quality.  Topics Taking over a family business during COVID-19 pandemic while dealing with personal loss and operational challenges. Upgrading from legacy Epicor 905 system directly to Kinetic cloud ERP for improved operational efficiency. Implementing Epicor's Prism agentic AI to streamline estimating processes and specification document review workflows. Using AI to filter through complex architectural drawings and door schedules to eliminate human errors. Balancing traditional woodworking craftsmanship standards with modern technology adoption for competitive advantage in manufacturing. Empowering field installers with cloud-based tablets for real-time access to project data and documentation. Sustainable manufacturing practices including biomass heating systems that convert wood waste into building energy. Team adoption strategies for AI technology and overcoming resistance to digital transformation initiatives. Career paths in the woodworking industry including vocational training, apprenticeships, and skill development opportunities. Get in touch with Tyler Madsen:   LinkedIn  Website    Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube

Meet Zeeshan Zia, CEO & Co-founder of Retrocausal "If the operator is about to put the tip of the soldering iron at the wrong place, the system offers an alert right there and then, helping them reduce that scrap rate from 30% down to 3%," says Zeeshan Zia, CEO & Co-founder of Retrocausal, describing a process his team helped a medical device manufacturing client improve. His story showcases how enterprise partners want AI that understands human activities, not just fancy interfaces. Retrocausal tackles the forgotten 80 percent of manufacturing jobs still performed by humans while robotics investments focus on the automated 20 percent. Their AI doesn't replace workers — it catches mistakes like double-torquing bolts while missing others entirely, preventing $1,200 endoscopy cameras from hitting trash bins. Born from Zeeshan's realization that augmented reality hardware wasn't the bottleneck, Retrocausal decoupled AI capabilities from head-mounted displays. The Seattle company now deploys facial blurring and body pixelation so thoroughly that even strict union environments show the least resistance to their tools compared to other process analytics solutions. In This Episode Beyond preventing defects, their platform enables production supervisors to perform industrial engineering tasks through simple video uploads — the AI breaks down processes, generates Excel sheets, and suggests line rebalancing. Zeeshan reflects on how manufacturers have shifted from innovation teams driving AI adoption to plant managers and line leaders becoming true believers, largely thanks to ChatGPT educating the broader public on AI's potential. Topics People-centric approach to AI implementation in manufacturing environments that empowers workers rather than replacing them. Real-world applications of AI copilots including Assembly, Kaizen, and Ergo systems for different manufacturing roles. Dramatic quality improvements achieved through AI intervention, reducing scrap rates from thirty percent to three percent. Addressing worker concerns about privacy, standardization, and individual work preferences when implementing AI monitoring systems. Challenges of implementing AI in high-mix, low-volume job shops versus standardized assembly line operations. The role of AI in accelerating worker onboarding and enabling career advancement from operator to supervisor roles. Evolution of manufacturer attitudes toward AI adoption, with investment rates increasing from thirty to forty percent annually. Importance of choosing holistic AI solutions over point solutions to avoid system fragmentation and integration challenges. Accessibility features built into AI tools to accommodate workers of different skill levels and physical capabilities. Impact of reshoring trends and Industry 4.0 on creating new opportunities for AI-enabled manufacturing agility. Get in touch with Zeeshan Zia:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube Or search “Manufacturing the Future” wherever you listen to podcasts!

Meet Alexandre Georgetti, Director of Global i4.0 Automation Strategy at Eaton "Don't go for a technology just because it's cool. Go for a technology that is going to address a problem," advises Alexandre Georgetti, Director of Global i4.0 Automation Strategy at Eaton, emphasizing the importance of strategic thinking over technological fascination in automation decisions. Manufacturing organizations worldwide face increasing pressure to automate processes while maintaining workforce engagement and operational efficiency. The challenge lies in identifying which processes to automate first, ensuring successful human-robot collaboration, and implementing technologies that truly solve business problems rather than just adopting the latest innovations. Eaton, a global power management company operating in more than 175 countries with over 92,000 employees, leads the charge in smart manufacturing adoption. Under Alexandre's leadership, the company's automation strategy spans approximately 200 sites across diverse business units, from electrical components to aerospace systems. This breadth of operations provides unique insights into successful automation implementation across different cultures and manufacturing environments. In This Episode Alexandre shares his expertise on emerging automation technologies, including humanoid robots, collaborative robots with advanced gripping capabilities, and AI-driven learning systems. He emphasizes the importance of maintaining a continuous improvement mindset while implementing automation, and shares practical strategies for ensuring successful human-robot collaboration. Topics The evolution of manufacturing automation technologies, including humanoid robots, collaborative robots, and AI-driven learning systems transforming factory operations. The critical relationship between continuous improvement methodologies and automation implementation for achieving optimal manufacturing outcomes. Strategies for prioritizing automation projects based on factors including worker safety, value-added activities, and process bottlenecks. Cultural considerations and regional differences in implementing automation across global manufacturing facilities. Implementation strategies for autonomous mobile robots in material handling, including considerations for facility-wide compatibility. The role of data analytics in both planning and optimizing automation initiatives across manufacturing operations. Balancing automation investments with workforce development to ensure long-term operational success. Framework development for evaluating and implementing automation technologies across diverse manufacturing environments. Practical advice for manufacturing leaders beginning or advancing their Industry 4.0 automation journey.  Resources “Industry 4.0: The factory of the future becomes the factory of today,” from Eaton’s website   Get in touch with Alexandre Georgetti:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube Or search “Manufacturing the Future” wherever you listen to podcasts!

Gene Marks, a seasoned Business Keynote Speaker and columnist, shares insights on navigating today's complex business landscape. He tackles the challenges posed by current U.S. tariff policies, especially with China, offering practical strategies for cost mitigation. Marks also dives into the transformative potential of AI in business, emphasizing a human-centric approach and the importance of integrating advanced technologies. He warns that talent acquisition focusing on soft skills will be crucial for small and mid-sized businesses to thrive in this evolving environment.

Meet Dan Klepack, Chief Supply Chain Officer at DSG Supply Drawing from his diverse experience across defense, retail, and industrial distribution, Dan Klepack, Chief Supply Chain Officer at DSG Supply, brings a unique perspective to supply chain modernization. From building fighter jets to leading a supply chain, a process is a process and the disciplines transfer seamlessly. Dan explains, “There's a right way to do it and there's a standard operating procedure that needs to be written to do it.” His journey from manually tracking assembly line performance on paper to leveraging advanced ERP systems demonstrates how technology has fundamentally shifted the focus from data collection to problem-solving. DSG faces the complex challenge of managing diverse product categories across electrical, plumbing, HVAC, and industrial automation sectors while meeting growing customer expectations for supply chain visibility. Unlike competitors who specialize in single categories, DSG's breadth creates unique operational challenges that require sophisticated technology solutions to balance the competing demands of operations teams seeking repeatability and sales teams needing flexibility. Founded 125 years ago, DSG operates as an employee-owned company with 62 branches spanning from Montana to Michigan, and leverages Epicor distribution solutions across their business. This employee ownership model creates a distinctive culture where every team member has a financial stake in the company's success, fostering collaborative problem-solving and shared accountability in decision-making processes that impact modernization efforts. In This Episode Dan explores how industrial distribution is evolving to meet B2B customers' expectations for the same level of supply chain transparency they experience as consumers. He discusses the industry-wide "Where's My Stuff?" initiative, where competitors collaborate to solve visibility challenges, and shares practical advice on preparing organizations culturally for technology adoption while emphasizing that successful modernization requires understanding your business fundamentals before investing in solutions.  Topics DSG Supply's employee ownership model and how it influences collaborative decision-making and technology investment strategies across operations. Evolution of supply chain technology from manual tracking systems to integrated ERP solutions that enable problem-solving focus. Balancing operational repeatability requirements with sales team flexibility needs through strategic technology implementation and data-driven decision making. Managing diverse product categories including electrical, plumbing, HVAC, and industrial automation within a single distribution network. Growing customer expectations for supply chain visibility driven by consumer experience standards applied to B2B relationships. Industry-wide collaboration through initiatives like "Where's My Stuff?" bringing competitors together to solve shared visibility challenges. Change management strategies for technology adoption focusing on cultural readiness and team engagement rather than just technical capabilities. Integration approaches for modern distribution centers emphasizing the importance of understanding business fundamentals before technology investment. Future trends including artificial intelligence applications across supply chain functions from inventory management to predictive analytics implementation.

Meet Michael Matisz, Vice President of Supply Chain at Leaf Home "You have to have a component of quality with all the components of speed," says Michael Matisz, Vice President of Supply Chain at Leaf Home. This philosophy has driven Leaf Home's remarkable transformation from a single-product company to North America's largest home improvement enterprise, serving over 2 million households with solutions from gutter protection to water purification and stair lifts. The home improvement industry traditionally suffers from lengthy delivery and installation timelines, creating customer frustration and slowing business growth. Michael's team tackled this challenge by developing a revolutionary supply chain model that enables Leaf Home to deliver custom solutions anywhere in the United States within 48 hours, allowing installation within the same business week while competitors might take months to complete similar projects. Leaf Home's journey began with a simple supply chain for their flagship LeafFilter product, consisting of just 12 SKUs and a few vendors. Michael joined in 2015, and helped establish inventory and supplier management systems that positioned the company for the hypergrowth it would experience during the COVID pandemic. Starting with affordable warehouse and transportation management systems costing just $1,000 annually, the company gradually built more sophisticated operations while maintaining its commitment to rapid customer service. In This Episode Michael shares practical wisdom on building resilient supply chains despite economic volatility, treating suppliers as strategic partners rather than just vendors, and balancing inventory positions across a hub-and-spoke distribution network. His engineering background provides a unique perspective on understanding supplier operations, while his retail experience from Joann Stores equipped him to manage exponential SKU growth. He also offers valuable insights on forecasting, sustainability initiatives, and creating supply chains flexible enough to navigate everything from seasonal fluctuations to unexpected tariff changes and interest rate impacts. Topics Transforming a simple 12-SKU supply chain into a nationwide network that delivers custom home improvement solutions within 48 hours of order placement. Building strategic vendor partnerships by "selling" suppliers on your company's growth potential rather than just focusing on procurement negotiations. Implementing a hub-and-spoke distribution model with six locations across North America to ensure 48-72 hour delivery times nationwide. Leveraging a manufacturing engineering background to better understand supplier operations and align business needs with manufacturing capabilities. Balancing inventory positions across multiple distribution centers to optimize speed while managing increased inventory investment costs. Starting with affordable technology solutions that evolve alongside company growth rather than overinvesting initially. Navigating volatility in forecasting caused by economic factors like Federal Reserve rate changes impacting customer financing options. Creating redundancy in the supply chain network to provide flexibility for introducing new product lines and expanding into new geographical markets. Addressing sustainability initiatives through reverse logistics, lifetime product warranties, and minimizing manufacturing waste in plastic-based products. Identifying opportunities during supply chain disruptions like tariff changes rather than merely reacting defensively to challenging circumstances. Meta Description A conversation with Michael Matisz of Leaf Home about how he built a nationwide supply chain network that delivers custom home improvement solutions within 48 hours, fueling the company's transformation into North America's largest home improvement enterprise.   Get in touch with Michael Matisz:   LinkedIn  Website    Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Listen on WEBSITE  Listen on Apple  Listen on Spotify  Watch on YouTube

Meet Jeremy Codiroli "I tell everybody I want to hire on my team that you need to love chaos," says Jeremy Codiroli, VP of Global Supply Chain at AVI-SPL, highlighting his leadership philosophy that has transformed the company's supply chain operations. This embracing of chaos, rather than trying to eliminate it, has become a competitive advantage as his team navigates the complexities of global supply chain management. AVI-SPL faced significant challenges as a global audio-visual integration company with no dedicated supply chain team. The audio-visual industry traditionally lacked supply chain maturity, with each office handling logistics independently. This fragmented approach created inefficiencies, inconsistencies, and missed opportunities for cost savings and customer satisfaction. Additionally, as the last contractors on job sites, they faced unique scheduling pressures and the risk of technology obsolescence with expensive inventory. Founded in 1979 and headquartered in Tampa, Florida, AVI-SPL has grown to become the world's largest audio-visual and unified communications integrator, serving 80% of Fortune 100 companies globally. Jeremy joined the company during an acquisition and initially focused on process improvement before recognizing the critical need for dedicated supply chain management. What began as a one-person initiative has rapidly expanded to a global team of over 100 professionals in just 18 months, delivering significant business impact. In This Episode In this episode, Jeremy shares how his team is leveraging cutting-edge technologies like AI, including a specialized chatbot for international trade decisions and advanced logistics planning systems. He emphasizes the importance of embracing chaos rather than trying to eliminate it, using data to drive every decision, and maintaining a customer-centric approach that passes cost savings directly to clients. Jeremy also discusses their impressive sustainability initiatives, including a 10% reduction in fleet fuel usage and an innovative "hyper-localized" e-waste program. Throughout the conversation, his passion for creating an "elite supply chain" shines through, demonstrating how supply chain excellence can drive competitive advantage in any industry.  Topics The importance of embracing chaos in supply chain management rather than trying to eliminate it, creating competitive advantages through adaptability and responsiveness. How data-driven decision making forms the foundation of all supply chain initiatives, ensuring changes are based on metrics rather than opinions. The unique challenges of the audio-visual industry, including scheduling pressures as the last contractors on site and the risk of technology obsolescence. Innovative AI applications including a specialized international trade chatbot trained on company-specific strengths and weaknesses and advanced logistics planning. The development of a customer-centric supply chain approach that passes cost savings directly to clients and enhances service delivery. Sustainability initiatives including a 10% reduction in fleet fuel usage and a "hyper-localized" e-waste program that minimizes transportation impact. Strategies for managing global supply chain complexities across different regions, systems, and capabilities while maintaining consistency. The importance of upstream data visibility, exemplified by AVI-SPL becoming the first audio-visual integrator to join the Department of Transportation's FLOW program. Creating a culture of continuous improvement through a no dumb ideas philosophy and the "fail fast, learn fast" approach to innovation. Meta Description A conversation with Jeremy Codiroli of AVI-SPL about how he built a data-driven global supply chain organization that embraces chaos, leverages AI innovations, and maintains a customer-centric approach to deliver competitive advantages in the audio-visual integration industry.   Get in touch with Jeremy Codiroli:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter 

Meet Mohamed El Shami, CSCO at Garlock Flexibles "I feel supply chain is like the brain of the operations," Mohamed El Shami, CSCO at Garlock Flexibles. With a background spanning chemical engineering, sales, R&D, and operations, Shami brings a comprehensive perspective to the packaging industry that he describes as "the Switzerland of packaging" — where technical expertise meets operational strategy. The flexible packaging industry faces significant challenges in balancing sustainability with performance requirements. As consumer demands shift toward more environmentally friendly options, manufacturers must innovate with materials like mono-layers, reduced gauging, and post-consumer-recycled content while ensuring products remain functional. For produce packaging specifically, maintaining freshness for perishable items becomes an additional complexity that impacts every aspect of the supply chain. Garlock Flexibles has built its reputation over nearly 40 years as a leader in the packaging industry, with a particular strength in the produce market where they supply approximately 60% of salad kits and fresh-cut vegetables in the US. With manufacturing sites in Massachusetts and Nevada, the company has evolved from a family-owned business to their current position under private equity ownership. Their journey reflects the larger transformation of manufacturing in America, balancing domestic production capabilities with global supply chain realities. In This Episode In this episode, Shami explores how Garlock navigates post-pandemic supply chain disruptions through diversified supplier relationships, implements sustainability initiatives without compromising product integrity, and prepares for emerging technologies like AI-supported equipment. He emphasizes that successful supply chain management requires understanding the entire product lifecycle, from raw materials to consumer experience, while maintaining profitability for both Garlock and their partners. His insights provide valuable guidance for manufacturing leaders facing similar challenges in an increasingly complex global marketplace. Topics The evolution of supply chain management from pre-COVID to post-COVID, shifting from cost efficiency to material availability and supply security considerations. How the packaging design process balances product protection requirements with sustainability initiatives like mono-material structures and post-consumer recycled content. The technology behind flexible packaging manufacturing, including the complex printing and laminating processes that create everyday food packaging products. Strategies for managing inventory and raw materials for produce packaging, where timing is critical due to the short shelf life of the contents. The importance of building trust and transparency with both domestic and international suppliers while navigating cultural differences and regulatory requirements. Key metrics for measuring operational excellence, including overall equipment effectiveness, on-time delivery, and maintaining profitability throughout the supply chain. How the voice of customer feedback directly influences manufacturing processes and supply chain decisions in the packaging industry. The anticipated impact of AI-supported equipment on manufacturing operations, knowledge preservation, and attracting a new generation of workers. The balance between just-in-time production and maintaining safety stock inventory in response to global supply chain disruptions. Approaches to sustainability that include material innovation, structure simplification, and working within existing recycling infrastructure capabilities. Get in touch with Mohamed El Shami, CSCO at Garlock Flexibles:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter 

Meet Michael Krachon, President of Theragenics Interventional "The manufacturing process itself is challenging because there are really three distinct aspects of it," shares Michael Krachon, President of Theragenics Interventional, in our latest Manufacturing the Future episode. "We have to make the radioisotope itself, then put it into the seeds, and then put the seeds into custom configurations for each patient." This insights-packed conversation reveals the incredible precision required when manufacturing devices smaller than a grain of rice that save lives. Theragenics tackles a manufacturing challenge like no other: creating medical devices that are tiny, radioactive, and perishable. These brachytherapy seeds, used primarily for cancer treatment, must be manufactured with absolute precision because they'll be implanted directly into patients. The complexity is staggering: managing radiation safety, tracking invisible materials, ensuring perfect quality in something the size of a grain of rice, and dealing with a product that has a limited useful life due to radioactive decay. Founded over forty years ago, Theragenics has grown into a global manufacturer with one of the country's largest "cyclotron farms" — specialized equipment that creates the radioactive isotopes used in their products. Through multiple acquisitions, including Needle Tech, Galt Medical, and Aerotech, they've diversified their capabilities while maintaining their focus on life-saving medical technology. Over their history, they've manufactured more than 21 million seeds, a massive production volume that, as Michael notes with wonder, "would all fit in almost a cigar box." In This Episode In this fascinating conversation, Michael takes listeners behind the scenes of this highly specialized manufacturing operation. From the stringent radiation safety protocols that protect workers to the challenges of supply chain management for components measured in fractions of millimeters, the episode reveals manufacturing excellence at its most precise. Michael also discusses how emerging technologies like AI, targeted robotics, and 3D printing are opening new possibilities for Theragenics while they maintain the extraordinary quality standards necessary when manufacturing devices that patients' lives depend on. It's a rare glimpse into a manufacturing environment where there's no room for error — because getting it right means saving lives. Topics The unique challenges of manufacturing radioisotope-based medical devices that are simultaneously tiny, radioactive, and perishable with strict time constraints. How Theragenics operates one of the country's largest "cyclotron farms" to create radioisotopes that become components in life-saving cancer treatment devices. The extensive radiation safety protocols and monitoring technologies implemented to protect employees working with radioactive materials. Managing precise manufacturing processes for implantable medical devices the size of a grain of rice that must be perfectly made every time. Balancing innovation with strict regulatory requirements in a field where product quality directly impacts patient outcomes and safety. Supply chain and inventory management strategies for components measured in fractions of millimeters that cannot use traditional tracking technologies. The impact of COVID-19 on workforce management and the challenges of rebuilding institutional knowledge after experienced staff turnover. Future technology applications including AI for production planning, targeted robotics for employee safety, and 3D printing for specialized components. The critical importance of customization in medical device manufacturing, with each cancer patient receiving a uniquely configured product. Advice for manufacturing leaders about cross-industry learning, relationship building, and engaging directly with technicians to solve manufacturing challenges. Get in touch with Michael Krachon:   LinkedIn Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter