In this insightful episode of the Operations Science Podcast, we’re joined by Blaine Alderks, Head of Product Development at Windings, to explore the evolving world of high-performance electromechanical systems. Blaine shares lessons from over a decade in aerospace and defense, highlighting how agile product development, effective capacity planning, and cross-functional collaboration have transformed workflows at Windings.

We also dive deep into AI’s emerging role in engineering, how to manage rework and “tribal knowledge,” and the cultural nuances of engineering acquisitions. Whether you're a leader, engineer, or operations strategist, this conversation is packed with real-world takeaways on building reliable, mission-critical solutions while embracing change.

Key Topics :

- Fail Fast Culture in Product Development

- Knowledge Transfer Post-Acquisition

- AI in Engineering Workflows (Opportunities and Risks)

- Capacity and Lead Time Planning Using Operations Science

- Rework, Escapes, and Process Mapping

- The Shift from Stage Gates to Milestone-Based Planning

- Engineering Empathy and Leadership

- Blaine’s Personal Journey in Aerospace and Leadership

- Integrating Manufacturing Feedback into Product Development

- Managing Virtual Work-in-Process and Commitment Reliability

Chapters:

00:00 Introduction of Blaine Alderks from Windings

03:40 The Rise of Agile Product Development

09:20 Impacts of M&A on Engineering Teams

14:10 AI in Product Design

22:00 Working with Legacy Systems & Drawings

26:30 Capacity Planning & Lead Time Management

33:00 From Theory to Forecasting

37:30 Rework & Escape Tracking

42:10 Integrating Manufacturing Early

47:50 Milestones vs. Stage Gates

52:10 WIP Management & Virtual Queues

56:00 Weekly Planning & Commitment Reliability

1:00:30 Blaine’s Journey to Engineering

1:07:00 Leading with Empathy

1:11:00 Life Outside Work

1:14:00 Final Thoughts & Reflections

Join Ed Pound as he sits down with Frankie Swindell, Operations Manager at Flexon (Ingersoll Rand), for an in-depth conversation about managing operations in the critical medical device manufacturing sector. Discover how a seasoned operations leader navigates global supply chains, tariff challenges, and the transition from private equity to public company ownership.

Tune in inside:

Tariff impact strategies, supply chain resilience, private equity to public transition, operations excellence frameworks, capacity management, inventory optimization, cross-functional leadership, coaching methodologies, AI implementation

Take away:

• Build supply chain resilience through dual-site operations and redundant capacity strategies
• Understand operational differences between private equity and public company ownership models
• Establish effective standard work frameworks while maintaining employee autonomy
• Master cross-functional communication by learning to speak different departmental languages
• Implement coaching-based leadership approaches that develop people rather than manage processes
• Balance capacity utilization with variability management to optimize customer service
• Create positive constraints to maximize productivity and work-life integration
• Navigate complex customer relationships and supply chain partnerships

Chapters:

00:00 Introduction - The Hidden Heroes of Medical Device Manufacturing

01:26 Current Tariff Challenges and Global Operations Strategy

08:09 Private Equity to Public Company Transition Impact

17:01 Operations Excellence and Standard Work Frameworks

26:20 Chess and Wrestling Coaching Influence on Leadership

35:04 Cross-Functional Communication and Finance Partnership

42:10 Customer Relations and Supply Chain Integration

48:16 Artificial Intelligence in Manufacturing Operations

52:03 Personal Background and Entrepreneurial Journey

1:02:15 Family Life Lessons Applied to Operations Management

Quote of the show:

"Great coaches ask the questions to enable a good athlete or a good employee to solve their own problems"

Flexon manufactures critical rubber and silicone components found in brain shunts, pacemakers, and other life-saving medical devices. Under Frankie's leadership, the company manages operations across two sites with 190 employees, generating approximately 40 million dollars annually. His unique background combines ten years of manufacturing experience with competitive chess and wrestling coaching, bringing a distinctive perspective to operations management.

The conversation explores how global events like COVID-19 and tariff policies have shaped manufacturing strategies. Frankie shares insights on building resilient supply chains through geographic diversification and redundant capacity planning. The discussion reveals how operational excellence creates systems that adapt and thrive under uncertainty.

Listeners will gain practical insights into operations science principles in high-stakes medical device manufacturing, where precision directly impacts patient outcomes. The episode demonstrates how concepts like Theory of Constraints translate into real-world decisions affecting both performance and life-saving treatments.

Subscribe to The Operations Science Podcast for more insights from industry leaders applying scientific principles to solve operational challenges. Like this episode if you found value in Frankie's perspective on leadership and operations management.

#operationsmanagement #medicaldevicemanufacturing #supplychainresilience #leadershipcoaching #operationsscience #manufacturingexcellence #processimprovement #capacitymanagement #inventoryoptimization #crossfunctionalleadership #AIinmanufacturing #tariffstrategy #flexon #ingersollrand

In this episode of The Operations Science Podcast, your host Ed Pound welcomes Rahul Teotia, a seasoned executive with vast global experience in leading supply chain and operations functions across various industries. Rahul shares his invaluable insights on building high-performing teams, navigating digital transformations, and simplifying complex processes to achieve significant impacts. This conversation is packed with actionable advice for any leader looking to drive operational excellence in a global context.

Tune in inside to learn about:

Building high-performing international teams.

The importance of listening and servant leadership.

Effective change management strategies.

The role of AI and automation in modern operations.

Simplifying complex processes for major impact.

Navigating cross-cultural challenges in global business.

Maintaining work-life balance in a demanding career.

Takeaways:

When stepping into a new leadership role, the first couple of months should be dedicated to listening to understand the company's strategy, culture, and business pain points before implementing changes.

Building trust with a new team is crucial; this can be fostered by meeting people face-to-face, involving them in decision-making, and appreciating their existing knowledge and contributions.

Successful change management hinges on identifying the "why" behind the change, structuring a dedicated team to lead the initiative, and managing stakeholders' expectations through clear and consistent communication.

Technology and automation should be implemented to make people more effective and enable strategic decision-making, not just to replace them. It's vital to understand the process you want to improve before applying a technological solution.

Simplifying processes, such as centralizing purchasing for multiple sites, can lead to significant improvements in material availability and efficiency, even with complex legacy systems.

Living and working in different countries provides invaluable experience in managing cross-cultural relationships and adapting to new environments, a key skill for global leaders.

Chapters:

00:00 - Intro

02:05 - Best Practices for Forming High-Performing Teams

05:04 - Balancing Leadership Styles to Establish Trust

08:00 - The Impact of Cross-Cultural Experience

10:10 - Biggest Challenges in Supply Chain and Operations Leadership

12:34 - The Critical Role of Planning in Operations

16:02 - Evaluating the Trade-offs of Automation

19:15 - Simplifying Complex Processes for Major Impact

25:25 - Mastering the Art of Change Management

31:02 - Understanding Flow, Variability, and Capacity

33:05 - Opportunities and Challenges of AI in Operations

39:39 - Favorite Mistakes and Leadership Lessons

45:55 - Early Life and Path to Operations Leadership

49:31 - Maintaining Work-Life Balance

55:21 - Outro

Quote of the show:

"If you are working too late in the night, that means either you're not being productive and smart in what you do, or you have too much on your plate."

Hashtags:

#OperationsScience #SupplyChain #Leadership #GlobalOperations #RahulTeotia #OperationalExcellence #ChangeManagement #TeamBuilding #DigitalTransformation #AIinBusiness #ProcessImprovement #LeanManufacturing #Podcast

For more on Thermo Fisher Scientific see

https://corporate.thermofisher.com/us/en/index/newsroom/Our-stories.html

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