Manufacturing the Future

Meet Justin Brown, Chief Supply Chain Officer at Dollar Shave Club Justin Brown, Chief Supply Chain Officer at Dollar Shave Club, understands the evolution of direct-to-consumer business models in competitive markets. As he reflects on the company's origins, "We came onto the scene and offered like an eight dollar pack or even obviously in the very early days, dollar razors and you could order them and get them directly shipped to your door, which was incredibly convenient." This approach to market disruption demonstrates how identifying customer pain points can transform entire industries. Justin tackles the challenge facing direct-to-consumer businesses: balancing growth with profitability in an increasingly crowded marketplace. With average order values around ten dollars and customer acquisition costs reaching seventy to eighty dollars, Dollar Shave Club must continuously optimize operations while expanding into retail channels. This requires innovative approaches to cost management, shipping optimization, and technology implementation that maintain competitive advantages without sacrificing customer experience. Dollar Shave Club began as a disruptive force in the razor industry, offering affordable alternatives to expensive traditional products through convenient subscription services. Justin has led the transformation from a pure direct-to-consumer model to an omnichannel business serving major retailers. This evolution required building new supply chain capabilities, implementing advanced technologies, and developing resilient operations that could adapt to changing market conditions and global uncertainties. In This Episode The episode covers Justin's approach to technology adoption, from AI-powered customer engagement systems to automated shipping rate optimization tools. He shares insights on managing geopolitical risks and offers practical advice on building resilient teams through empathetic leadership and clear communication strategies. Topics Direct-to-consumer supply chain challenges and the economics of low-value, high-frequency orders in competitive markets. Technology investment strategies focusing on ROI-driven decisions for planning tools, AI solutions, and shipping optimization platforms. AI implementation in customer engagement operations to reduce costs while improving satisfaction scores and response times. Rate shopping and transportation management systems for optimizing shipping costs across multiple carriers and zones. Managing global supply chain disruptions through tariff mitigation strategies, near-shoring, and supplier diversification initiatives. Geopolitical risk management including maintaining operations in Israel during conflicts while developing contingency plans. Leadership philosophy emphasizing empathy, regular communication, and supporting remote teams through organizational changes and crises. Decision-making frameworks balancing structured annual planning processes with rapid response capabilities for unexpected situations. Supply chain metrics and KPIs focusing on cost per unit, service levels, customer satisfaction, and inventory optimization. Meta Description A conversation with Justin Brown of Dollar Shave Club about building resilient omnichannel supply chains while managing global disruptions, implementing AI solutions, and leading teams through crises. Get in touch with Justin Brown:   LinkedIn  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube

Meet Prashant Shah, Head of Supply Chain & Operations at SwagUp Prashant Shah, Head of Supply Chain & Operations at SwagUp, brings a unique perspective to supply chain transformation shaped by his military background and 15 years of corporate experience. As he explains in our conversation, "In the military, through the military experience, I will say the one thing that came out very clearly that logistics means wars. We continue to say that in the military that if we want to win wars, logistics is the way to go. And same thing in business." The promotional merchandise industry faces significant fragmentation challenges, with companies traditionally working with multiple vendors to source different items like hoodies, mugs, and notebooks. SwagUp addresses this pain point by creating a comprehensive one-stop solution with over 5,000 products available online, handling everything from design and production to warehousing and global fulfillment through their user-friendly platform. Founded in 2017 and headquartered in New Jersey, SwagUp has grown rapidly by positioning itself as both a promotional company and a technology company, building most of their systems internally. Their mission to "make swag simple" resonated strongly in the market, leading to their acquisition by BDA in 2024, which expanded their reach while maintaining their innovative culture and customer-first approach. In This Episode This episode explores Prashant's insights on transforming supply chain operations from traditional cost centers into strategic profit drivers. He discusses his framework for technology implementation, the role of AI in amplifying human judgment rather than replacing it, and shares practical examples of counterintuitive decisions that led to dramatic improvements in operational efficiency and customer satisfaction.   Topics Debunking the myth that cost savings equals supply chain success in modern business operations. Transforming supply chain departments from back-office functions into front-line competitive advantages for organizations. Implementing AI technologies to amplify human judgment and accelerate decision-making processes from days to minutes. Framework for digital transformation focusing on customer friction points and manual bottleneck identification processes. Counterintuitive leadership decisions like slowing warehouse processes to reduce returns from 20% to 3%. Dangerous assumptions about scaling supply chains and why yesterday's solutions won't work for tomorrow's growth. Supply chain leader involvement in acquisition processes and post-merger integration challenges facing growing organizations. Building flexibility into supply chain design early to enable scaling by design rather than brute force. Advice for supply chain leaders to focus on resilience over efficiency and build adaptable teams. Get in touch with Prashant Shah:   LinkedIn  Website  Get in touch with your host, Kerrie Jordan:  LinkedIn  Twitter  Download, Listen, and Subscribe Apple | Spotify | YouTube

Lauren Dunford, CEO & Co-founder of Guidewheel, shares her journey from food delivery to innovative manufacturing solutions. She discusses how Guidewheel’s AI-powered sensors revolutionize factory operations by monitoring energy consumption, offering immediate value without complex installations. Lauren highlights the challenges manufacturers face regarding data integration and how her platform turns legacy machinery into valuable data sources. Emphasizing sustainability, she stresses the importance of user-friendly technology in attracting the next generation of workers.

James Butler, SVP & Chief Supply Chain and Corporate Strategy Officer at Brinker International, dives into the intricacies of managing restaurant supply chains. He discusses the paramount importance of food safety and quality while navigating challenges like perishable inventory and rapid growth. Butler shares insights from his pandemic experiences, emphasizing the need for innovative problem-solving and teamwork in overcoming supply chain hurdles. He also highlights the role of technology in enhancing operational efficiency and fostering collaboration across industries.

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