The Operations Science Podcast

Better Performance Across Sites and Cultures through Continuous Improvement

What does it take to scale continuous improvement across multiple plants, cultures, and operating realities—without turning standardization into bureaucracy? Andre Scarance shares what global manufacturing leaders often learn the hard way: improvement doesn’t scale through tools alone. It scales through alignment, clear mental models, disciplined business systems, and leadership that makes improvement everyone’s responsibility. We explore why some plants sustain gains while others slip back into firefighting, how productivity and quality should never be traded against each other, where AI may fit into future operations systems, and why changing standards too often can quietly destroy performance. If you care about operational excellence, manufacturing leadership, Lean, or building systems that hold under pressure, this one delivers. Key Discussion Points 00:00 Intro 01:34 Meet Andre Scarance 02:30 Scaling strategy across global manufacturing sites 05:22 Making continuous improvement everyone’s job 07:13 What stable operations look like (and warning signs of struggle) 08:18 Why projects fail before they start 09:13 Shared mental models and operational behavior 10:32 Managing improvement projects across sites 12:21 Gaining trust from frontline operations 15:44 Why tools alone don’t create transformation 17:13 Kaizen, practical learning, and capability building 19:00 The productivity challenge every plant is facing 20:01 AI in continuous improvement and operations 23:04 Productivity vs. quality — false tradeoff? 24:50 Measuring productivity in manufacturing 25:21 Selecting projects that actually matter 28:00 Why improvements fail to sustain 31:29 Andre’s career journey from IT to operations 35:13 Mentors, leadership lessons, and career advice 37:24 Advice for the next generation of operations leaders If this conversation sparked an idea: 👍 Like this video 🔔 Subscribe for more conversations on operational excellence and leadership 💬 Share your biggest takeaway in the comments 📤 Send this episode to a leader working to scale improvement across complex operations Sustainable improvement starts with understanding how operations actually behave. Learn the science behind flow, variability, and performance in Operations Science Applied: bit.ly/OSA2026 #OperationalExcellence #ContinuousImprovement #LeanManufacturing #OperationsLeadership #Manufacturing #BusinessSystems #Leadership #ProcessImprovement #IndustrialEngineering #OperationsScience #SupplyChain #AIinManufacturing #OSI

From Multinational Complexity to Startup Speed: Leading High-Performance Pharma Operations

Most organizations don’t struggle because they lack talent. They struggle because they move too slowly, operate in silos, and avoid the hard changes everyone already sees coming. This conversation goes deep into what happens when you bring FMCG-level execution discipline into a pharmaceutical environment—and why most teams resist it at first. Adil Belrhzal shares how he built a fast-growing pharma operation inside a diversified group by combining multinational rigor, startup speed, and a culture that allows people to fail fast and learn faster. There’s a simple idea at the center of this conversation that most leaders overlook. If people don’t understand what’s in it for them, nothing changes. Key Discussion Points 00:00 – Introduction to Operations Science Podcast 00:45 – Adil’s role and building a pharma business in Morocco 03:19 – Multinational vs local companies: speed, culture, decision-making 06:23 – FMCG vs pharma: where discipline really comes from 08:38 – Why change fails: “What’s in it for me?” 10:13 – Weekly vs daily execution: adapting FMCG discipline 12:55 – Performance shift: daily targets + right to fail 15:01 – The power of naïve questions and unlearning 16:00 – Aligning leadership and breaking silos 18:06 – Why organizations lack a shared understanding 19:11 – Variability: the silent killer in pharma operations 21:53 – Inventory, supply chains, and serving patients first 23:17 – Preparing for 6 IPOs in 6 years 26:48 – AI adoption: from fear to full integration 30:15 – Decentralizing AI across the organization 33:14 – Moving from experimentation to strategic AI 35:46 – Personal story: resilience and early responsibility 38:21 – Leadership mindset: staying grounded in chaos 40:00 – Habits, routines, and balance   If this conversation made you rethink how you run your operation: 👍 Give it a like 🔔 Subscribe so you don’t miss what’s next 💬 Drop your biggest takeaway in the comments 🔗 And share this with someone who’s trying to drive real change   Operational excellence shouldn’t rely on guesswork. Learn the science behind flow, variability, and performance in Operations Science Applied: bit.ly/OSA2026 [http://bit.ly/OSA2026]   #Operations #Leadership #Pharma #FMCG #OperationalExcellence #AIinBusiness #SupplyChain #LeanLeadership #BusinessStrategy #Execution #OSI #H&SGroup #DislogGroupHealthcare #Steripharma #GlobalPharmaceuticalIndustryAdvisors #TransformationalLeadership

Why Lean Stalls: Standards, Accountability, and What It Really Takes to Sustain Results

Chris Morehouse leads operations across seven manufacturing plants where labor is tight, margins are real, and leadership consistency directly shapes performance. What makes this conversation especially valuable is Chris’s grounded perspective: Lean transformation does not begin with tools—it begins with standards, leadership routines, and a shared understanding of what good looks like. From sustaining gains through layered process audits to building maintenance capability, reducing tribal knowledge, applying Factory Physics, and exploring how AI can support predictive maintenance and troubleshooting, this discussion is packed with practical lessons for operations leaders. If you’re leading plants, building systems, or trying to reduce variability across teams, this conversation offers a blueprint for turning operational chaos into disciplined flow. Key Discussion Points 00:47 Why early Lean efforts failed 03:21 Consultant-led vs internally driven transformation 04:24 Why maintenance is a cost lever, not a cost center 06:16 Managing seven plants and cross-industry lessons 08:45 Labor scarcity and system-based productivity 10:09 Time-to-competency by role 11:49 Building labor pipelines through schools and partnerships 15:09 Upskilling maintenance technicians with a structured curriculum 17:13 Factory Physics, bottlenecks, and SMED 20:53 How leaders learn systems thinking 24:39 Leadership variability across seven plants 28:51 Sustaining gains with layered process audits 30:39 Practical AI use cases in manufacturing 35:05 Chris Morehouse’s leadership journey 40:29 Advice for non-engineers entering operations Stay Connected If this conversation gave you a new lens on leadership, Lean, or operational systems: ✅ Like and subscribe for more authentic operations conversations 💬 Share your biggest takeaway in the comments 🔁 Send this to an operations leader who needs to hear it 🎯 Follow for more real-world lessons from the front lines of industry   Stop managing in the dark. Learn the science behind every operation—and finally get variability under control. Get your copy of Operations Science Applied today: bit.ly/OSA2026 [http://bit.ly/OSA2026]   #OperationsLeadership #LeanManufacturing #FactoryPhysics #ContinuousImprovement #OperationalExcellence #ManufacturingLeadership #AIinManufacturing #LeadershipDevelopment #SupplyChain #IndustrialEngineering #OSI

Start with Value: Why Process Must Lead Technology for Digital Transformation Success

Big transformation programs rarely fail because of technology alone. They fail when teams optimize systems instead of outcomes. Marta Moreira Rodriguez shares what nearly 25 years in transformation leadership has taught her about turning complexity into measurable business value—across ERP modernization, CRM workflows, ServiceNow, AI agents, process redesign, and enterprise-scale change. What stands out in this conversation is how she frames transformation through business outcomes first, systems second. From reducing unnecessary ERP customization to using agentic AI for document validation, tender workflows, and order processing, Marta breaks down what actually works when organizations are trying to modernize legacy operations without losing compliance, speed, or customer experience. If you lead PMOs, digital transformation, ERP programs, operations, supply chain, or enterprise delivery teams, this one will feel very familiar. Key Discussion Points 00:00 Why transformation should start with business value 02:10 Fixing process gaps across CRM, SAP HANA, ServiceNow & workflows 06:48 Portfolio thinking vs managing isolated systems 10:32 Why poor scope definition kills projects 14:25 ERP upgrades: reduce customization, maximize value 19:40 Why every company thinks they’re “unique” 23:12 Where AI actually creates business value 27:05 Real use case: AI agents for document validation & order workflows 31:28 Consultant mindset vs internal transformation leadership 35:50 How Marta diagnoses business constraints fast 40:15 Hidden logistics bottlenecks and process heat maps 44:22 Marta’s career journey: gaming, Microsoft, consulting & enterprise transformation 49:10 Leadership, running, scouting & community service If you're leading transformation work right now, the most valuable takeaway may be this: start with the value stream, not the software vendor.   Don’t forget to: 👍 Like this video 🔔 Subscribe for more real conversations from the front lines of operations 💬 Comment with your biggest takeaway 🔗 Share this with someone leading transformation right now   #OperationsScience #DigitalTransformation #ERP #AI #ProjectManagement #Leadership #BusinessTransformation #SAP #ServiceNow #OperationalExcellence #EnterpriseSystems #ChangeManagement #OSI

The Other Side of the EV Revolution: Turning Toxic Waste Into Critical Materials

Electric vehicles are accelerating faster than ever. But there’s a massive operational challenge most people aren’t talking about. What happens to the batteries when they reach end-of-life? This conversation explores the systems, strategy, and leadership required to build large-scale battery recycling operations, from the ground up. From navigating uncertainty in a brand-new industry to balancing capital investment, AI, hiring, and operational excellence—this is a real look at building industrial infrastructure for the future. If you care about operations, sustainability, manufacturing, or scaling new technology. This one connects the dots.   Key Discussion Points 00:01 - Building a large-scale battery recycling operation 03:30 - Structured decision-making under uncertainty 07:00 - Why battery recycling is a complex emerging industry 10:25 - How lithium-ion batteries are actually recycled 14:25 - Second-life batteries vs recycling 16:25 - Managing capital risk in a new industry 19:35 - Building culture and leading high-performance teams 23:20 - Where AI fits into battery recycling operations 28:50 - Hiring and scaling a fast-growing company 31:00 - Government support and sustainability incentives 33:00 - Operational excellence while building a new plant 35:40 - Project management for large capital projects 41:00 - Julian’s background and career path 46:00 - Work-life balance and leadership mindset 47:17 - Closing thoughts   The EV revolution is here. The operational infrastructure behind it is just getting started.   Don't forget to: 👍 Like this video 🔔 Subscribe for more authentic conversations 💬 Comment with your biggest takeaway 🔗 Share with someone who needs to hear this #Operations #OperationalExcellence #Manufacturing #EV #ElectricVehicles #BatteryRecycling #Sustainability #Leadership #SupplyChain #IndustrialEngineering #AI #ContinuousImprovement #ProcessImprovement #OperationsManagement #CleanEnergy