Events

July 8, 2021

OpExChange hosted an educational webinar with Gemba Systems demonstrating how Real-Time Locating Systems (RTLS) enable Industry 4.0 decision-making by providing accurate, real-time visibility on the shop floor. Presenters highlighted ultra-wideband technology, which delivers tracking accuracy within inches at lower cost than traditional RFID or Bluetooth, unlocking a wide range of use cases. Practical examples showed how small OEE gains can translate into meaningful financial impact, supported by ROI and use-case tools shared on the Portal. A one-week RTLS demo was awarded to T&S Brass and Bronze Works, with additional demos available through Gemba Systems or SCMEP.

June 22, 2021

Mike Ungar, business coach with FocalPoint, led an interactive virtual session on building a sustainable lean culture, drawing on his 36 years at Michelin. He outlined five essential culture points: customer-defined value, employee engagement, respect for standards, waste elimination, and visual management. Discussion centered on engaging employees in problem-solving and giving them time and structure to improve their work. Mike emphasized that shaping culture is a core management responsibility and the foundation of lasting continuous improvement.

June 9, 2021

Shaw Industries’ Columbia plant demonstrated how virtual reality is driving measurable cost and training improvements. The team shared how VR reduced operator training waste and cut training costs by at least 25%, while also improving safety and proficiency. Participants also saw innovative uses of QR codes for safety reporting, Gemba walks, and continuous improvement, reinforcing how digital tools can strengthen daily operations when applied with purpose.

May 4, 2021

Sunland Logistics Solutions in Simpsonville hosted a hands-on Lean simulation that immersed participants in core concepts such as continuous flow, standard work, takt time, and cycle time. CEO Arch Thomason shared how lean became central to Sunland’s strategy after a major business setback, emphasizing a people- and process-centered management system. The company’s approach includes belt training for all employees and strong visual daily management to make problems visible and drive learning. The visit concluded with a live simulation that demonstrated how lean thinking improves quality, delivery, and cost across the operation.

March 16, 2021

A sustainability-focused session featured four presenters sharing practical strategies manufacturers can apply immediately. Komatsu detailed a team-based PDCA approach that reduced electricity usage by 44% in two years. Clemson University’s Industrial Assessment Center highlighted no-cost energy assessments that have delivered millions in savings while significantly reducing CO₂ emissions. Southpoint Solutions explained how total lifecycle cost—not just simple payback—should guide LED lighting decisions, while the South Carolina Department of Commerce showcased tools and services to help manufacturers reduce waste, improve recycling, and even create new revenue streams.

March 16, 2021

Savannah River Nuclear Solutions shared how a well-designed employee suggestion system can unlock frontline knowledge while driving measurable results. SRNS operates the 310-square-mile Savannah River Site and runs what is believed to be the longest continuously operating suggestion program in the U.S., dating back to 1952. The program has generated more than $250 million in savings and continues to deliver roughly $1 million annually, while boosting employee engagement and morale. Blake focused not just on results, but on the practical fundamentals needed to launch, sustain, and scale a successful suggestion system at organizations of any size.

March 9, 2021

AstenJohnson shared how they use Hoshin Kanri to align strategic priorities with daily execution. The session highlighted practical approaches to policy deployment, clear goal alignment, and disciplined follow-up to drive accountability and results across the organization.

February 16, 2021

This webinar on Virtual Product and Process Development (VPPD) explored how companies can use digital tools to streamline product and process development. VPPD allows design, manufacturing, and serviceability considerations to be evaluated concurrently, reducing late-stage changes, lowering costs, and improving efficiency. The team highlighted software tools like Siemens Teamcenter, Dassault 3D Experience, and FlexSim, which enable virtual prototyping, ergonomic analysis, and process simulation. Case studies demonstrated significant time and cost savings, improved assembly processes, and optimized plant layouts. Overall, VPPD helps companies bring products to market faster while ensuring quality and operational readiness.

February 9, 2021

Jim Benson, co-author of Personal Kanban, led an interactive session on applying visual management to knowledge work. Using Turner Construction’s $922M Coney Island hospital rebuild as a case study, Jim demonstrated how visual tools support communication, collaboration, and flow in complex projects. Participants then experienced a live “Lean Coffee” exercise, showing how personal Kanban can democratize meetings and improve decision-making. The session reinforced a core takeaway: effective collaboration consistently drives higher quality, better delivery, and stronger outcomes.

January 26, 2021

Shaw Industries’ Aiken plant shared insights from its corporate co-op and Operations Management Training (OMT) programs, highlighting practical steps for launching a successful co-op model. College recruiter Bradley Townsend outlined the program structure, which supports 30–50 students per semester, with 47% returning for additional terms and 75% receiving job offers upon graduation. Claudia Paulson, a former co-op and now Quality Engineering Manager, emphasized the value of assigning real-world projects that drive measurable improvements while engaging students. Shaw also discussed virtual recruiting tools and concluded with clear “how-to-start” guidance for OpExChange members. Event recordings and resources are available on the Portal.