The Voices of Manufacturing

Join Mark Keho and Rob Atkins, veteran general foremen from Kawasaki Engines. Discover their fascinating career journeys from humble beginnings in Iowa and Missouri to leading roles in the machining and die casting departments. Gain insights into their experiences, the evolution of Kawasaki's manufacturing processes, and the importance of continual improvement and mentorship. This episode is packed with industry knowledge, personal stories, and engaging trivia, making it a must-listen for anyone interested in manufacturing. Don't miss out on this enlightening conversation!

Mike Reader, VP of Sales and Engineering at Precision Plus, shares his journey from intern to executive. Mike discusses the evolution of the manufacturing industry, the importance of youth apprenticeships, and the role Precision Plus played in producing ventilator parts during COVID-19. He offers insights into overcoming industry challenges, the significance of family businesses, and the innovative spirit driving modern manufacturing. This episode provides valuable lessons for professionals at all levels, highlighting the dynamic and evolving nature of the manufacturing sector.

In this insightful episode, Jeff Gentry from Shaw Industries shares his philosophy on tackling difficult and often overlooked tasks, emphasizing the importance of stepping outside one's comfort zone and embracing challenges. He encourages listeners to seek out opportunities that others shy away from, as these are often the most rewarding. Gentry also discusses his unique approach to personal management, treating himself like a team and continuously learning new skills to overcome obstacles. His engineering mindset shines through as he advises, "If you run into a brick wall, learn masonry to take it down."

In this episode of the Voices of Manufacturing podcast, we interview Samantha Lawrence, the Learning and Development Coordinator at Johnsonville. Samantha shares her unique career journey from being an English teacher and learning leader in the Sheboygan School District to her current role at Johnsonville. She discusses the joy of supporting diverse member goals, ranging from becoming the best operator to starting a nonprofit. Samantha highlights her certifications in various areas, including mental health first aid and talent optimization, and emphasizes the importance of continuous learning and innovative training methods. The episode also touches on the significance of transferable skills, mentorship, and creating an environment that fosters personal and professional growth.

Allen's impressive career spans from being an automation engineer at Colgate Palmolive to holding significant roles at Walmart, Tesla, and various tech companies. Tune in as we delve into Allen's journey, starting from his childhood in Long Island, his hands-on experiences in global manufacturing, and his transition into tech leadership as VP of Product at Dozuki.

Starting at the Canada Department of National Defense, Echo worked on aircraft avionics systems and later transitioned to the private sector, becoming an engineering manager and now a senior advisor. She emphasizes a key lesson: ambition doesn't always equate to capacity. Echo also discusses the importance of mentorship, the challenges of moving from public to private sectors, and her interest in green energy's future.

In this episode of the Dozuki podcast, Andrew Dendis from RTX discusses his experience in a leadership development program, emphasizing the importance of versatility, networking, and dynamic problem solving in manufacturing and aerospace industries.

Thomas has been observing the trends of the manufacturing workforce over the past decade as a training manager. He's noticed the workforce has changed dramatically over that time. In this episode, Thomas breaks down the modern manufacturing employee and what they want in a job and employer. During this interview with Thomas, we will cover the three big areas that employees are focused on and how manufacturing companies can align their operations to meet these demands.

Promo Code = VOM20 

Our insightful discussion covers the dangers of insignificant improvements, the challenges posed by an overload of initiatives, and the drawbacks of rigid processes. Learn how to counter these mistakes by adopting strategic focus, embracing a growth mindset, prioritizing key projects, and maintaining the fundamental processes of your business.

Join Chad Moutray and Anjana Radhakrishnan from The Manufacturing Institute as they delve into the challenges of the current manufacturing labor market. Exploring vital statistics, they unveil insights from a recent study on the pivotal role of company culture and employee engagement. Discover practical strategies to elevate your company culture and stand out in the competitive landscape.

Meet Jared Supalla from Imagine Group. They've adopted a "Quality at the Source" methodology. Instead of traditional end-of-line quality checks, they empower their operators to ensure quality right during production. It's a game-changer, making every employee an active participant in maintaining standards. It's a refreshing take on quality management that's making a real difference in their operations.

A former director and manager of digital training at leading biotech firms Sanofi and Moderna, Chris Policastro shares valuable insights from his experience in the regulated life sciences industry. The discussion covers topics ranging from navigating FDA regulations for systems validation to establishing internal networks to advocate for innovative solutions supporting frontline operations. Chris, who successfully implemented Dozuki at both companies, provides unique content addressing the challenges life sciences professionals face in adopting new technology, particularly with concerns about validation. His practical advice and success stories make this episode essential for individuals in the life sciences industry looking to embrace innovative solutions.

Learn the importance of standards in your 5S program. From visual controls to supply procurement and accountability, standards play a pivotal role in ensuring lean success. Brian and Michael roll solo on this one, so tune in for valuable insights on building a culture focused on standards.

Andrew Murphy was brought into the company to help Norman Noble mature from a job shop with a mom & pop structure to a corporate structure. We discuss how Andrew and his team are implementing lean manufacturing and changing the company culture along with the tools and systems they use.

Show notes:14:48 -- We're under the work mindset that we can teach them how to use those things.  If they have the mindset that we want to come to work. We want to do the right things. We're already ahead of the game at, at that point, we feel that we can teach people how to do almost anything."18:22 -- "Our training center is relatively new. It's been around for about five years. It was something that myself and the team put together. I was in a different role. I was in quality and we were trying to resolve problems. After the issue had happened, we'd be out there trying to fix issues and then kind of tried to go into more, a little bit more of a proactive approach." 18:44 -- "Myself and a few other people started being a more proactive and kind of evolved to a training center. We've got myself and two other managers, and then we've got a staff of seven union trainers, and again, they all came from the shop floor. Most of them came from the team leader ranks, so we pulled a lot of the high performing team leaders,  and they have become some of our best trainers now." 23:33 -- "They're more accepting because it's not a solution that means more work for them. And that's one of the things, a lot of our solutions that we try and come up with, Needs to be easier for the operator. We can't add technology and make it harder because they already have a lot of work as it is. Building these trucks we have to make it easy for them to use."23:55 -- "When we implemented the Dozuki system, we pilot it for a long period of time. When we pilot things, the easy thing is to go to the most technologically savvy person in the area or in the team and say: Hey, we have this idea. We want you to try it out."30:18 -- "When we're implementing a new process or a new model truck,  some of the stuff we're getting into now with VR, we've been pulling them into some of our conference rooms and we have some VR technology where they can virtually walk around in their new workstation. There's a lot of companies put a lot of effort into tooling, and then it hits the shop floor and the  techs don't like it."

Show notes:12:21 - "One of the very first things I did was put in Dozuki because it was clear that without data collection for work instructions, we were never going to be able to scale or move beyond those key talents, those key individuals where tribal knowledge existed."15:23 - "My whole effort has been focused on how to make them more effective at doing the job that we hired them to do. And take away most of the other stuff that was just getting in the way of them effectively managing their team and people."22:12 - "Most quality assurance systems are centered around the idea of making the transition easy. So if you've got a paper collection form, I'm going to show you a path to digitally collect all the information you would have had in your paper form. What you want is to transform that digital acquisition into information that you can leverage."23:51 - "Every activity in the plant now has an inbound checklist. It might be really short, it might just be that I've got that item in my hands. It's barcode scannable, so it's relatively painless for an operator to scan it at this station. I get that notification and use it to update my production operations reports. We now have a backend to complement all of that system's work."48:16 - "You need to have a champion who's driven by the need to understand. It can't be driven solely by someone having a vision of wanting to go digital. Doing it the way we've done it takes passion, energy, commitment, and that comes from the heart of the people. You need to find that champion in your business."

Show notes:01:16 - "We worked hard. I won't say we ever perfected it, but we were always seeking to make that an effective gathering of the minds, sharing information, having conversations, talking about safety."00:08:33 - "I'm building the most beautiful structure I could ever build so that years from now, when I'm long gone, that generations, you know, ahead of me will be able to enjoy this amazing place to worship and have a sense of awe and wonder as they approach life."00:10:57 - "I need to know I'm spending my time solving problems, not finding them."00:14:07 - "Think how much pride you would have at the dinner table saying, you know, my work literally saves lives!"00:18:26 - "Once people know their purpose. They can't turn from it. They can't look away. They must pursue it."00:21:37 - "It didn't matter whether what you believe, if it's true enough to you and it motivated you to act in a certain way."00:38:30 - "It's all about the people and if you engage people and we think about them first, the results will flow from that."

Show notes:09:17  -- Most of my experiences, the technology shows up and then you say, how are we going to do the training or who's going to do it or how does this thing work?12:48 -- We literally have to create the talent if we can't find it.17:30 -- If what you're creating isn't going to solve a problem that they have, they're not interested.21:15 -- You might need that broader overview, which requires classroom training with an instructor.22:41 -- It's really about if I need information, do I know where it is and can I access it quickly to make the changes I need to make on the job?24:42 -- Their expectation for how they're trained, how they're developed, it seems like their expectations are higher than they've ever been because there's organizations doing it really well.26:26 - If you're so concerned that you have to memorize everything that's being written on the board, you're not really paying attention to what they're saying.29:22 -- Every individual in today's workforce is going to have to really adopt that mentality that I'm going to probably have to learn for the rest of the time I'm here.38:34 -- What worked maybe 20 years ago, even 10 years ago, might not be as impactful and effective.

SHOW NOTES03:22 — How the company's motto became, “We design and build really cool stuff”09:01 — What led the company to become a top supplier for NASA14:48 — Why the paperwork have to weigh more than the part?24:11 — Getting rid of blame and ensuring the company owns the process29:53 — Fighting entropy and complacency on the factory floor36:20 — A modern philosophy on audits and certifications44:19 — The different ends of the supplier spectrum

01:45 — Where expertise comes from in world class companies03:02 — Lean is an acronym for “living, engaged, attitude, now”09:51 — Holding a successful rattlesnake hunt to reinforce safety, efficiency & engagement14:23 — How does company culture change after you've killed 6,000 rattlesnakes?18:57 — Preventing yourself from getting bitten by snakes26:22 — How leaders and directors can send a vision of quality to the frontlines

SHOW NOTES01:20 — What role should governments play in manufacturing?07:48 — How state manufacturers unified their voices to become an economic growth engine15:02 — Using digital initiatives to transform the entire manufacturing ecosystem18:33 — Connecting manufacturers with resources & opportunities21:28 — Marketing the manufacturing industry and promoting the benefits to individuals, the state, and local companies29:13 — Train workforces first, before introducing new technology35:11 — State level manufacturing practices other states should be copying37:17 — Creating an environment that will enable manufacturers to thrive by focusing on developing a local supply chain 

Miles Free wears many hats as Director of Industry Affairs at the Precision Machined Products Association (PMPA). We sat down with him and were inspired by his passion, expertise, and of course, quotable pieces of industry insight on building a thriving machine shop. You'll learn how to stay globally competitive through the use of best available information and technology.

02:04 — From garage startup to billion dollar corporation06:00 — Going from the worst plant to the first one in the organization10:43 — How to start your plant's digital transformation journey14:11 — Fixing a single machine to get buy-in across the organization18:45 — Adopting the 80/20 rule for pilot lines in digital transformation28:08 — Using digital tools to uncover issues leading to bad quality32:33 — How employee motivation stems from the value of the tools they use41:11 — Leveraging employee expertise when using new tools

02:48 — What is a daily management system?05:08 — Keeping score and making adjustments for future plays07:25 — Outcomes of daily management and keeping momentum alive12:01 — Why holding meetings halfway through the shift is better than before/after14:02 — Tiering systems for managing manufacturing facilities17:11 — Bolting on a tier structure to an existing standing meeting18:28 — Identifying metrics that are most important to your team25:40 — Diversifying meeting leaders to engage and empower operators28:33 — Should you make daily management automated or analog?

05:47 — Building a robust training program in Mexico09:51 — Focusing on quality, not speed12:25 — Matching employee personality with training opportunities15:15 — Hanging career path posters at every location to inspire growth20:13 — Reinforcing training over time23:54 — Treating the supervisor as the customer of the training32:04 — Making video work instructions to cross language barriers# # # Follow us on LinkedIn to continue this conversation, join us for some AMAs, and keep in the loop: linkedin.com/company/dozukiInterested in learning more about Dozuki? Visit us at dozuki.comFollow Solar Plastics on LinkedInFollow Brian Sallee on LinkedInFollow Michael Muilenburg on LinkedIn

01:36 — You have open roles, but there's a leaky bucket compounding the retention problem08:33 — What job can I do that fits my lifestyle and doesn't displace my sense of balance?10:10 — Hiring athletes from local colleges to run the line. Movie script or hiring strategy?13:43 — Brainstorming hiring ideas creates the question, “Really? You'd let us do that?”17:30 — Investing hiring & training resources in temporary labor pools25:00 — How to capture and bottle all of the excitement as fresh eyes come onto the floor35:00 — Do sports teams who work together on the assembly line win on the offensive line?Follow us on LinkedIn to continue this conversation, join us for some AMAs, and keep in the loop: linkedin.com/company/dozukiInterested in learning more about Dozuki? Visit us at dozuki.comFollow Kawasaki Motors on LinkedInFollow Brian Sallee on LinkedInFollow Michael Muilenburg on LinkedIn

1:40 - How Patrick became a world-renowned authority on TWI3:30 - Why today's economic climate resembles wartime shifts6:20 - The mutual admiration society of Japanese and American management practices10:00 - Does training success come from the trainer, the methodology, or the author?13:30 - The magic of the TWI methodology from a time reduction perspective21:00 - Tactical elements of the TWI approach to job instruction23:20 — Why “starting with why” might not be the best approach for manufacturing workersFollow us on LinkedIn to continue this conversation, join us for some AMAs, and keep in the loop: linkedin.com/company/dozukiInterested in learning more about Dozuki? Visit us at dozuki.comFollow Patrick Graupp on LinkedInFollow Brian Sallee on LinkedInFollow Michael Muilenburg on LinkedIn

We've got a new co-host! Fan favorite Michael Muilenburg joins us to bring his 35+ years of experience from 3M as an operational leader. Join us for a fun conversation talking about how he's the Troy Aikman to Brian's Joe Buck, and why he's thinks this is the most exciting time in manufacturing in his three plus decades in the industry.1:00 - The origins of Brian and Michaels' friendship3:30 - 10 facts about Michael8:00 - Curiosity at 3M10:00 - Favorite role at 3M13:30 - Digital projects at 3M21:00 -  Why manufacturing is still so excitingFollow us on LinkedIn to continue this conversation, join us for some AMAs, and keep in the loop - linkedin.com/company/dozukiInterested in learning more about Dozuki? Visit us at dozuki.com

www.dozuki.com/podcastShow Notes:1:30 - 2:41  // The importance of employee confidence2:45 - 8:20 // High levels of workforce turnover in Food & Beverage manufacturing and production impacts8:21 - 9:55 // Practical solutions the root problem of poor training programs and missed production targets9:55 - 11:35 // Real tips to capturing expert knowledge to share with the new, inexperienced workforce11:35 - 15:28 // Engaging your retiring workforce to produce training content and capture process standards with digital tools. Younger and older generations working together — give them the "why"15:28 - 17:30 // Doing job shadowing the right way — developing a standard to train from it the future — consistency is key17:30 - 19:30 // Amplifying decades of expert knowledge before it retires — who is responsible?19:30 - 24:15 // Automation and the need for human expertise and training24:15 - 26:46 // The future of food and beverage manufacturingFollow Kiley Becker on LinkedIn Follow Brian Sallee on LinkedIn

Ron is the President & CEO of CCAT and is an expert in various ways to secure funding and support for new technological initiatives. More importantly, Ron knows what it takes to truly gain the benefits of technology and how companies of all sizes can find success, long-term.

With thousands of products, 3M has a wide variety of use-cases and considerations when it comes to using tablets or smartphones on the factory floor. Jacob specializes in the management and use of mobile devices for the operational workforce.Once deployed correctly, tablets unlock the potential of endless benefits on the frontline.www.dozuki.com/podcastShow Notes:2:45  -  6:00  Use-cases and benefits of tablets in manufacturing environments6:01  -  7:35  Considerations and requirements for selecting the right device7:36  -  11:04  Managing devices with an MDM (Mobile Device Management) software11:05  -  15:45  Mobile device operating systems  -  key differences15:46  -  20:40  Protective cases and practical considerations20:41  -  25:30  Charging and storage strategies25:31  -  27:37  Practical requirements for screen sizes27:38  -  30:40  How to get employee buy-in and support worker performance Additional Resources:Top Tablet Recommendations for Manufacturing EnvironmentsHow to Get Wifi on the Factory FloorHow Digital Tools Accelerate Communication in ManufacturingHow to Scale Operational Technology Across Manufacturing Operations 

Show Notes:3:27  -  5:10  Challenges that Ernie Ball Music Man solved with Robotics5:10  -  6:51  Calculating ROI from automation7:00  -  10:51  Getting started/where to start with automation10:59  -  12:00  Choosing and leveraging the right vendors12:13  - 14:46  Empowering others to troubleshoot and maintain machinery14:48  -  17:20  How to communicate the value of Automation and get employee buy-in18:39  -  21:41  Expanding and scaling automation in low-volume, high-mix manufacturing

Dozuki has helped hundreds of businesses transform their frontline workforce with digital tools and we're excited to share an inside look at our playbook.The Frontline Digital Transformation (FDX) Masterclass is a free digital course that will give you all the tools to plan, build, and scale digital tools on the frontline. Hear from industry experts, apply learnings with interactive coursework, and test your knowledge to become an FDX Master.Learn more and sign up for free at - dozuki.com/fdx

In this episode, learn:How to adapt material from the original equipment manufacturer (OEM) to create training and maintenance programs for new machinesThe three most common sources of equipment failureHow operators are essential to good preventative maintenance (PM) programs Why employee training is so important for preventative maintenance How technology will impact the future of machine maintenance (spoiler: people are still essential)Alek's favorite industry quote Learn how to leverage digital tools on the frontline. Take our free Masterclass by visiting https://www.dozuki.com/frontline-digital-transformation-masterclass

Most manufacturing companies don't have people dedicated to evaluating and deploying modern tools. At best, IT or HR takes responsibility for new technology and doesn't have the resources to implement them effectively.Michael Muilenburg is the Director of Operational Technology at 3M and has learned how to leverage key personnel to create a team that successfully evaluates and deploys technology to the frontline operational workforce.  For more episodes and resources, visit https://www.dozuki.com/podcast

From humble beginnings at a community college to growing a cutting-edge 3D printing company with Markforged, Joe knows what it takes to succeed in the industry and offers practical tips for people interested in starting or growing their manufacturing careers.For more episodes and additional resources, visit https://www.dozuki.com/podcast

Join this insight-packed conversation and learn how you can apply Chad's tactical strategies for using standards for process improvements, succession planning, upskilling employees, and more. Visit https://www.dozuki.com/podcast for more.

Change management is a crucial part of any digital transformation or improvement efforts on the plant floor. But how do you deal with stubborn employees or older workers that resist technology?  Taylor Harlin is a Learning and Development Change and Development Coach at Johnsonville and has fascinating insights into the nuances of human behavior on the plant floor. In the fifth episode of The Voices of Manufacturing, Brian talks with Taylor about effective strategies for gaining employee buy-in and unique ways to communicate changes with your frontline workforce. A full transcript along with additional resources are can be found here.

Isaac Brown is an Associate Partner at Landmark Ventures and has worked with countless industrial companies to help evaluate and deploy new technology. In the fourth episode of The Voices of Manufacturing, Brian talks with Isaac about how these digital technology trends are affecting buying processes and the benefits of seeking out tools that empower your workforce. For more resources and information, visit https://www.dozuki.com/podcast

Brian has a knack for simplifying ISO requirements and easing audit anxiety. While ISO 9001:2015 is the most widely adopted ISO standard, many are intimidated by the process of certification or consider it a compliance formality. However, if you are running a successful business, there are likely many quality management best practices that you are already following.Visit our website for more podcast resources and practical insights.

In the second episode of The Voices of Manufacturing, Brian talks with Chad Hertlein, a Training Specialist from General Mills.Chad believes that an investment in the people behind your manufacturing business is the most impactful way that you can improve production. By adapting your training programs to meet the needs of the current generations, you will create a happier and more productive workforce.For full show notes and additional resources, click here.

Welcome to the first episode of The Voices of Manufacturing! Join us in conversation with Jim Vinoski, a Forbes Author who specializes in all things manufacturing.As manufacturing businesses face workforce shortages and perception problems, Jim and Brian talk about the actionable steps that companies of any size can begin implementing today. Jim also focuses on strategies for retaining top talent and giving your workforce clear paths towards improvement and professional development.A full transcript along with additional resources are listed here.

Brian has spent over a decade working with manufacturers from innovative startups, like Tesla, to established and sophisticated manufacturers, like 3M. We're excited to  launch this show and give voice to the real people behind this fascinating industry.Stay tuned for next week's episode, where we'll be interviewing Jim Vinoski a writer from Forbes who specializes in all things manufacturing. We'll be discussing how to attract to right kind of talent and maintain a qualified workforce.