Ep. 43 - Your Supply Chain Problem Is Psychological - Sean Culey

Ep. 44 - Inside Britain's Smart Factory - Zen Gregory

Manufacturing is changing rapidly as AI, robotics, and intelligent automation move from theory into everyday operations. But successful transformation isn't driven by technology alone. It depends on clean data, continuous improvement, strong leadership, and a culture that embraces change. KEY CONCEPTS COVERED: * How AI employees and robotics are transforming manufacturing operations * Why people, culture, and data are the foundations of successful automation * Practical ways manufacturers can use AI to improve efficiency and decision-making In this episode of Chain Reaction, Michael Ostroumov is joined by Zen Gregory, Head of Supply Chain and Automation at British Rototherm, to explore what it really takes to build an intelligent factory. Zen introduces the Alien Dreadnought framework and explains how his team is using AI agents, autonomous robots, predictive analytics, and lean manufacturing principles to modernise a 170-year-old business without replacing its people. This episode is particularly relevant for manufacturing leaders, supply chain professionals, operations managers, automation specialists, and anyone interested in the practical application of AI in industrial environments. Watch this episode on YouTube: https://youtu.be/610J_MUVjec [https://youtu.be/610J_MUVjec]  TIMESTAMPS: (0:00) - Introduction and guest overview (1:36) - Zen's journey from Amazon to supply chain automation (4:13) - What is the Alien Dreadnought Intelligent Factory? (8:51) - The Alien Dreadnought Automation System explained (13:48) - AI agents, automation, and practical business applications (15:15) - AI employees and intelligent decision support (21:49) - Introducing automation into a 170-year-old manufacturer (25:40) - How AI helps to overcome physical and technological challenges (31:01) - How robotics and AI improve operations (34:46) - Measuring ROI from automation and AI (37:44) - Magic wand question: creating a culture of experimentation CONNECT WITH THE HOST & GUEST: Michael Ostroumov – https://www.linkedin.com/in/michaelostroumov/ [https://www.linkedin.com/in/michaelostroumov/] Zen Gregory – https://www.linkedin.com/in/zen-g-b04ab28b/ [https://www.linkedin.com/in/zen-g-b04ab28b/]  CONNECT WITH FLOX: Website: https://www.flox.is/ [https://www.flox.is/] LinkedIn: https://www.linkedin.com/company/flox-logistics-services/ [https://www.linkedin.com/company/flox-logistics-services/] Related Service Page: https://www.flox.is/for-lsps/transport-providershttps://flox.is/for-buyers/e2e-visibility [https://flox.is/for-buyers/e2e-visibility]  ABOUT THIS EPISODE: In this episode, Chain Reaction explores how AI, robotics, and intelligent automation are reshaping manufacturing with Zen Gregory, Head of Supply Chain and Automation at British Rototherm. The discussion covers AI employees, autonomous robots, predictive analytics, lean manufacturing, data quality, change management, and the practical framework behind the Alien Dreadnought Intelligent Factory. It demonstrates how combining people, technology, and continuous improvement can help manufacturers build smarter, more resilient operations. #ChainReactionPodcast #SupplyChain #Manufacturing #ArtificialIntelligence #Automation

Ep. 43 - Your Supply Chain Problem Is Psychological - Sean Culey

Most supply chains are designed to survive disruption. Very few are designed to improve because of it. As volatility, uncertainty, geopolitical pressure, and technological change continue to accelerate, resilience alone is no longer enough. Businesses now need systems that can adapt, evolve, and become stronger under stress. KEY CONCEPTS COVERED: * The difference between resilience and anti-fragility * Why most supply chain problems are actually people and leadership problems * How AI and decision intelligence are reshaping operations In this episode of Chain Reaction, Michael Ostroumov is joined by Sean Culey, supply chain strategist, transformation expert, author, and keynote speaker, for a wide-ranging discussion on anti-fragility, systems thinking, AI, leadership, and organisational change. Sean shares insights from decades of experience across supply chain transformation, ERP evolution, and operational strategy, explaining why businesses often remain trapped in reactive firefighting cultures despite having access to better technology and data. This episode is particularly relevant for supply chain leaders, operations executives, transformation teams, technology strategists, and anyone interested in the future of organisational design and decision-making. Watch this episode on YouTube: https://youtu.be/OdTB5mhVpSw [https://youtu.be/OdTB5mhVpSw]  TIMESTAMPS: (0:00) - Introduction and guest overview (1:15) - Sean's accidental journey into supply chain and SAP (3:22) - Breaking functional silos and early supply chain integration work (5:32) - The rise of automated supply chains and disruptive technologies (6:55) - Why disruption accelerated after 2012 with new technology (12:54) - What anti-fragility actually means in supply chains (18:47) - Why thriving through disruption matters more than resilience (21.02) - Grit, growth mindset, and the foundations of anti-fragile organisations (26:00) - Brexit, disruption, and practical operational realities (29:07) - Leadership, visibility, and creating better future operating models (32:38) - AI, data quality, and decision-driven supply chains (35:31) - Why transformation fails without emotional buy-in (37:35) - Decision-making, automation, and supply chain intelligence (40:31) - Magic wand question: unlocking human potential inside organisations CONNECT WITH THE HOST & GUEST: Michael Ostroumov -  https://www.linkedin.com/in/michaelostroumov/ [https://www.linkedin.com/in/michaelostroumov/]  Sean Culey - https://www.linkedin.com/in/seanculey/ [https://www.linkedin.com/in/seanculey/]  CONNECT WITH FLOX: Website: https://www.flox.is/ [https://www.flox.is/] LinkedIn: https://www.linkedin.com/company/flox-logistics-services/ [https://www.linkedin.com/company/flox-logistics-services/] Related Service Page: https://www.flox.is/for-lsps/transport-providers [https://www.flox.is/for-lsps/transport-providers]  ABOUT THIS EPISODE: In this episode, Chain Reaction Podcast explores anti-fragility, organisational psychology, and supply chain transformation with Sean Culey. The discussion covers why many businesses remain trapped in firefighting cultures, how AI and automation are reshaping operational decision-making, and why resilient organisations are no longer enough in a world defined by constant disruption. Sean explains how businesses can evolve from siloed operational structures into adaptive value networks capable of learning, improving, and growing stronger through volatility. #ChainReactionPodcast #SupplyChain #Logistics #AI #SupplyChainManagement

Ep. 42 - UK Freight Runs on Tiny Firms and Thin Margins - Richard Smith

Road freight keeps the UK economy moving, but much of the industry remains invisible until something goes wrong. Behind every delivery sits a complex network of operators, drivers, SMEs, regulations, infrastructure pressures, and commercial trade-offs that most people never see. KEY CONCEPTS COVERED: - Why road freight is critical but often under-recognised - The pressures facing UK hauliers: cost, skills, regulation, and infrastructure - Why collaboration and technology are essential to reducing empty running In this episode of Chain Reaction, Michael Ostroumov is joined by Richard Smith, Managing Director of the Road Haulage Association, for a practical discussion on the realities of UK road freight. Richard shares his journey from the warehouse floor into senior leadership, and explains how SMEs, micro operators, drivers, technology, and regulation all shape the road transport network that keeps goods moving every day. This episode is particularly relevant for logistics leaders, hauliers, transport operators, policymakers, and anyone working across UK freight, transport, and supply chain operations. Watch this episode on YouTube: https://youtu.be/kXpZ4_yuWCo [https://youtu.be/kXpZ4_yuWCo]  TIMESTAMPS: (0:00) - Introduction and guest overview (1:25) - Richard's route into logistics, from warehouse floor to RHA leadership (6:29) - Why so many people fall into logistics by accident (7:39) - The current state of UK road freight and logistics (9:51) - Infrastructure, congestion, regulation, and regional complexity (12:22) - Border friction, SPS checks, and the cost of slowing freight down (13:55) - Why SMEs and micro hauliers are the backbone of the industry (17:17) - Cost pressure, trading conditions, and technology adoption (20:35) - How route planning and delivery technology have changed operations (25:09) - Tech, integration, collaboration, and the problem of fragmented systems (20:09) - Industry change, consolidation, and the role of new generations (34:50) - Magic wand question: recognising HGV driving as a profession  CONNECT WITH THE HOST & GUEST: Michael Ostroumov -  https://www.linkedin.com/in/michaelostroumov/ [https://www.linkedin.com/in/michaelostroumov/]  Richard Smith - https://www.linkedin.com/in/richard-james-smith-6828b9130/ [https://www.linkedin.com/in/richard-james-smith-6828b9130/]  CONNECT WITH FLOX: Website: https://www.flox.is/ [https://www.flox.is/] LinkedIn: https://www.linkedin.com/company/flox-logistics-services/ [https://www.linkedin.com/company/flox-logistics-services/] Related Service Page: https://www.flox.is/for-lsps/transport-providers [https://www.flox.is/for-lsps/transport-providers]  ABOUT THIS EPISODE: In this episode, Chain Reaction explores the operational reality of UK road freight with Richard Smith, Managing Director of the Road Haulage Association. The discussion covers the structure of the haulage market, the role of SME operators, infrastructure and congestion costs, empty running, regulation, technology adoption, and the need for stronger collaboration across the sector. It also highlights why HGV drivers should be recognised as skilled professionals and why the future of road freight depends as much on people as it does on technology. #ChainReactionPodcast #SupplyChain #RoadFreight #Haulage #UKLogistics

Ep. 41 - Fashion Has a Waste Problem. Batch LDN Doesn't. - Pim Vellenga

Overproduction isn't a fashion trend. It's a design flaw. Batch LDN built the opposite: made-to-order production, low inventory, local manufacturing - and a supply chain that only moves when demand does. KEY CONCEPTS COVERED: - How made-to-order fashion reduces waste, overstock, and returns - Why local manufacturing changes lead times, risk, and operational control - How logistics becomes central to customer experience in a zero-inventory model In this episode of Chain Reaction, Michael Ostroumov is joined by Pim Vellenga, Head of Operations at Batch LDN, for a practical discussion on how fashion supply chains can work differently. Pim explains how Batch LDN uses a made-to-order model to avoid sitting on finished stock, reduce markdowns, keep returns low, and put operations at the centre of the customer promise. This episode is particularly relevant for fashion brands, supply chain leaders, logistics operators, sustainability teams, and anyone interested in leaner retail operating models. Watch this episode on YouTube: https://youtu.be/fRSWlV-3khI [https://youtu.be/fRSWlV-3khI]  TIMESTAMPS: (0:00) - Introduction and guest overview (1:33) - Pim's journey from engineering and public art into fashion operations (2:42) - Becoming a Batch LDN customer before joining the business (4:37) - Why Batch LDN chose a made-to-order fashion model (8:45) - Zero inventory vs low inventory: what Batch actually stocks (11:20) - Managing fabric availability and supplier risk (13:50) - Why Batch manufactures locally in London (16:52) - Production capacity, quality, and scaling local manufacturing (19:31) - Outsourcing vs in-house operations in fashion logistics (20:30) - Why traditional warehousing doesn't fit Batch's model (24:17) - Why the company is called Batch LDN (26:04) - The role of technology in keeping the model scalable (28:44) - Managing customer expectations when products take two weeks (29:44) - Returns, waste, and why made-to-order changes the economics (33:12) - Magic wand question: fixing customs and import delays  CONNECT WITH THE HOST & GUEST: Michael Ostroumov -  https://www.linkedin.com/in/michaelostroumov/ [https://www.linkedin.com/in/michaelostroumov/]  Pim Vellenga - https://www.linkedin.com/in/pim-vellenga/ [https://www.linkedin.com/in/pim-vellenga/]  CONNECT WITH FLOX: Website: https://www.flox.is/ [https://www.flox.is/] LinkedIn: https://www.linkedin.com/company/flox-logistics-services/ [https://www.linkedin.com/company/flox-logistics-services/] Related Service Page: https://www.flox.is/retail-fashion-logistics [https://www.flox.is/retail-fashion-logistics]  ABOUT THIS EPISODE: In this episode, Chain Reaction Podcast explores how made-to-order fashion can reduce overproduction, excess inventory, and returns while still delivering a high-quality customer experience. Pim Vellenga of Batch LDN explains how the brand manages local manufacturing, raw material availability, production batching, fulfilment partnerships, and customer communication in a low-inventory operating model. The discussion also covers the operational trade-offs behind scaling a fashion business without relying on traditional stock-heavy supply chains. #ChainReactionPodcast #SupplyChain #FashionLogistics #MadeToOrder #SustainableFashion

Ep. 40 - The Demand Planning Mistake Everyone's Making - Simon Eagle

Most companies invest heavily in forecasting, planning systems, and technology. Yet service levels still struggle, costs stay high, and planners spend their time firefighting. The problem isn't just bad forecasts - it's how those forecasts are being used. KEY CONCEPTS COVERED: - Why forecast-driven planning creates instability, cost, and inefficiency - The difference between forecast push and demand-driven pull systems - How expediting drives higher costs, longer lead times, and excess inventory In this episode of Chain Reaction, Michael Ostroumov is joined by Simon Eagle, a supply chain consultant specialising in demand planning and S&OP, for a practical discussion on why traditional planning approaches fail - even with advanced systems in place. Simon explains how most organisations still rely on inaccurate forecasts to drive production, leading to constant expediting, excess inventory, inflated costs, and poor service levels. He breaks down the limitations of forecast-driven planning and introduces a demand-driven alternative that aligns production with actual demand rather than predictions. This episode is particularly relevant for supply chain leaders, planners, operations teams, and anyone responsible for improving service levels, reducing inventory, and stabilising production environments. Watch this episode on YouTube: https://youtu.be/_2mFuBCwEes [https://youtu.be/_2mFuBCwEes]  TIMESTAMPS: (0:00) - Introduction and guest overview (1:23) - From sales to supply chain: how Simon entered demand planning (3:50) - Why forecast accuracy alone doesn't solve planning problems (7:30) - Why companies still rely on spreadsheets despite advanced systems (9:54) - The hidden cost of expediting, changeovers, and instability (12:54) - How forecast-driven planning inflates inventory and lead times (14:59) - Traditional forecast push vs alternative planning approaches (17:40) - Why MRP and ERP systems struggle with forecast inaccuracy (20:49) - Managing spike demand and improving S&OP collaboration (23:54) - Real-world challenges with sales forecasts and volatility (27:58) - Using forecasts differently: from schedules to stock targets (31:15) - Why spreadsheets persist - and where technology fits (32:24) - Demand Driven MRP and modern planning tools (35:54) - Magic wand: what needs to change in supply chain thinking CONNECT WITH THE HOST & GUEST: Michael Ostroumov -  https://www.linkedin.com/in/michaelostroumov/ [https://www.linkedin.com/in/michaelostroumov/]  Simon Eagle - https://www.linkedin.com/in/simoneagle/ [https://www.linkedin.com/in/simoneagle/]  CONNECT WITH FLOX: Website: https://www.flox.is/ [https://www.flox.is/] LinkedIn: https://www.linkedin.com/company/flox-logistics-services/ [https://www.linkedin.com/company/flox-logistics-services/] Related Service Page: https://www.flox.is/services/marketplace/ [https://www.flox.is/services/marketplace/]  ABOUT THIS EPISODE: In this episode, Chain Reaction explores why traditional forecast-driven planning continues to create instability in supply chains despite significant investment in systems and technology. Simon Eagle explains how forecast inaccuracy leads to expediting, increased costs, longer lead times, and excess inventory across both SMEs and large enterprises. The conversation introduces demand-driven planning as a more effective alternative, focusing on decoupling production from forecast error, improving operational stability, and aligning supply with actual demand. It also highlights the need to rethink how forecasts are used, rather than trying to endlessly improve their accuracy. #ChainReactionPodcast #SupplyChain #DemandPlanning #S&OP #Logistics