You Don't Need New Machines — You Need This Engineer with Dr. Thorsten Wuest
What if the single biggest lever for unlocking capacity on your shop floor isn't a new piece of equipment, a new ERP system, or a costly consultant — it's a discipline most mid-market manufacturers have never even considered hiring for?
In this episode of the Allied Advisors Podcast, Justin sits down with Dr. Thorsten Wuest, full professor of mechanical engineering and founding program director of the brand-new Industrial Engineering program at the University of South Carolina's Molinaroli College of Engineering and Computing. Dr. Wuest arrived in Columbia in August 2024 with a mandate that would make most academics sweat: build a world-class IE program from scratch in a single semester. In one year, the program grew from 19 students to 66 — with another 30–40% growth projected — because, as it turns out, industrial engineering is the single most requested major from South Carolina employers that USC wasn't offering.
Dr. Wuest is also the founding director of USC's new Center for Industry Solutions, designed to close the gap between academic research and real-world manufacturing — with a particular focus on giving mid-market companies access to the kind of engineering talent that only the Fortune 500 could previously afford. His advisory board already includes the CTO of Scout Motors, the head of engineering from Mercedes-Benz, and representation from Siemens. He has been named one of SME's 20 Most Influential Professors in Smart Manufacturing and has authored over 180 peer-reviewed articles.
This is a conversation Justin has been wanting to have for a long time, and it delivers.
What We Cover in This Episode
The IE talent gap hiding in plain sight. Industrial engineering is the most-requested major from South Carolina employers — yet most high school students have never heard of it. Dr. Wuest breaks down why IE remains a "hidden major" and what USC is doing to change that, including a strategic partnership with Glimpse to better educate school advisors across the state.
The ROI of a single industrial engineer. Justin shares a story you'll want to write down: one client increased production output by 80% using nothing more than a Process FMEA (PFEP) and some combines — a strictly industrial engineering project that drove millions in additional monthly revenue. Dr. Wuest echoes this with his own firsthand example: just one hour walking a mid-sized manufacturer's shop floor surfaced improvement opportunities that would pay back in weeks, not years. The savings don't stop at throughput — better routing and layout also reduce forklift crossings, lower accident risk, and can even reduce insurance premiums over time.
Why your operations team will never solve this problem. You don't ask your shift supervisors how the process standards are coming along — you ask them how many parts came off the line. Justin and Dr. Wuest dig into why improvement work will always fall to the bottom of the pile unless you dedicate a resource to it, and why that resource pays for itself fast when given the right support and direction.
Change management is the real barrier. Mid-market hesitancy around hiring industrial engineers often isn't really about the salary — it's about what an IE's recommendations actually require: organizational change. Dr. Wuest and Justin discuss why proactive change (on your timeline, with your resources) is almost always cheaper and less painful than reactive change forced by a crisis.
How to start small: co-ops, capstones, and student consulting. Not ready for a full-time IE hire? Dr. Wuest makes the case for starting with a co-op or a structured student consulting project through the Center for Industry Solutions. These aren't ordinary class projects — they're interdisciplinary teams of competitively selected, paid students from IE, supply chain, and finance, supervised by professional staff and faculty, executing semester-long engagements run like real consulting engagements. Manufacturers get consulting-grade deliverables at a fraction of the cost. Students get real shop floor experience — and employers get an extended job interview with their best future candidates. The onboarding cost savings alone may justify the engagement.
USC's Center for Industry Solutions: a new front door for manufacturers. Dr. Wuest walks through the three pillars of the Center — workforce readiness, talent retention, and industry-university connectivity — and explains how it functions as a matchmaking service for the whole breadth of what the Molinaroli College has to offer, from student consulting projects to full-scale applied research partnerships. He also details how the Center is working to dramatically reduce the legal friction that typically slows university-industry collaboration to a crawl.
AI in engineering education: use it wisely, or pay for it later. Dr. Wuest has spent the last 10–15 years in machine learning research, so this isn't a surface-level conversation. He and Justin explore USC's proactive, transparency-first AI policy, the risk of students outsourcing their critical thinking before they've ever developed it, and why the analogy holds: if you never work as a junior coder, you can never become a senior one. The best use of AI — as Justin puts it — is as an "efficiency multiplier" for professionals who already have the foundational knowledge to evaluate and direct its output. You can't get there without doing the hard work first.
Retaining talent in the Palmetto State. South Carolina's $3,000 internship incentive is a start, but the real retention play is giving students meaningful, challenging work with employers who treat them as intellectual contributors — not just cheap labor. Dr. Wuest lays out the chicken-and-egg dynamic driving engineering talent out of the Southeast, why that is beginning to reverse, and what Scout Motors' move toward Charlotte signals about the region's trajectory.
Key Takeaways
* Industrial engineering is the most-requested major from South Carolina employers — and one of the highest-ROI hires a mid-market manufacturer can make.
* A dedicated IE resource is the only way to ensure process improvement actually becomes someone's first priority.
* One hour of structured shop floor observation can surface savings that pay back in weeks.
* Co-ops and student consulting through USC's Center for Industry Solutions offer a low-risk, high-value on-ramp for manufacturers who aren't ready for a full-time hire.
* AI is a powerful efficiency multiplier — but only for professionals who have already done the hard work of developing foundational expertise.
* The Southeast's talent retention problem is solvable, but it requires proactive investment from both universities and employers.
About Our Guest
Dr. Thorsten Wuest is a full professor of mechanical engineering and the founding program director of the Industrial Engineering program at the University of South Carolina's Molinaroli College of Engineering and Computing. He is also the founding director of USC's Center for Industry Solutions. Dr. Wuest is one of SME's 20 Most Influential Professors in Smart Manufacturing and the author of over 180 peer-reviewed articles. His research sits at the intersection of smart manufacturing, machine learning, and industrial AI.
📧 Contact Dr. Wuest: twuest@sc.edu [twuest@sc.edu] 🌐 Center for Industry Solutions: [sc.edu — search "Center for Industry Solutions"]
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