Events

November 2, 2021

Savannah River Remediation (SRR) in Aiken, SC, presented to OpExChange on November 2, 2021, highlighting their mission to safely disposition liquid radioactive waste at the 310-square-mile site. Rodney Blackmon shared their hazardous operations and strong safety culture, emphasizing learning from even small mistakes. Phil Breidenbach introduced the RAVE employee recognition program, which reinforces desired behaviors through quick, peer-to-peer recognition. Jessica Bricker showcased the “Baseball Card” process, summarizing CI successes for the Department of Energy, including projects saving hundreds of millions. Videos, slides, and templates are available on the Portal.

October 19, 2021

OpExChange visited AMBAC International in Elgin, SC, hosted by CEO Robert Isherwood and team. The plant highlighted its adoption of the Great Game of Business® (GGOB), which boosted profit 851%, improved productivity 21%, and enhanced engagement. Key practices include MiniGames™, a Gate Review process, and open-book management that empowers employees with ownership of results. The 47-employee plant emphasizes building people alongside profits, fostering a culture of collaboration and financial awareness. Photos, videos, and presentation materials are available on the Portal.

October 13, 2021

David Lynn, President of Peak Safety, led a session on the science of decision-making and its impact on workplace safety. Drawing on his experience with OSHA and manufacturing, David explained how thousands of daily decisions carry safety implications and why people take risks. He introduced practical human performance principles and the SAFE conversation tool to help leaders drive better safety decisions on the floor.

September 30, 2021

Stanley Black & Decker hosted a visit to its Fort Mill, SC connected factory, showcasing how Industry 4.0 and lean principles are driving operational gains while creating U.S. jobs. The 350,000-sq-ft facility combines automation, real-time performance management, and digital connectivity to support production of more than 3 million tools annually and employ roughly 750 associates. A centralized Command Center using real-time OEE data enables rapid decision-making, while collaborative and mobile robots improve safety, ergonomics, and productivity. Leaders emphasized starting simple, building a lean foundation, and scaling automation and data use thoughtfully as part of a long-term strategy.

August 11, 2021

The “Turnover Tsunami” webinar addressed the workforce crisis facing South Carolina manufacturers, with Dr. Rebecca Battle-Bryant sharing research and practical guidance drawn from her work with SCMEP. With record job openings and rising attrition, the session emphasized that workforce challenges require an all-hands approach built around the three “R’s”: Recruitment, Retention, and Reputation. Key takeaways included shortening hiring cycles, leveraging employee referrals, improving frontline leadership, and better engaging five distinct workforce generations. The session also highlighted state and federal incentives available to support hiring and retention, with additional tools and resources available on the Portal.

August 4, 2021

Sleep Number hosted OpExChange at its Irmo facility and shared how value stream mapping (VSM) drove a 75% productivity increase in the sewing department with zero capital investment. In just one year, the site also reduced work-in-process by nearly 40% and significantly cut overtime—despite a surge in pandemic-driven demand. The team credited these gains to their Sleep Number Daily Management System and strong operator engagement, with visual controls and problem-solving owned on the floor. Plant tours and manager testimonials reinforced how VSM improved employee well-being, eliminated Saturday work, and strengthened daily execution. Resources, recordings, and tools from the visit are available on the OpExChange Portal.

July 22, 2021

Belimed shared how they are building an OpEx/CI culture with limited resources, showing that meaningful progress doesn’t require a large budget. About two years into their journey, the Charleston-based team focused on practical problem solving, leadership development, and small, “just do it” improvements alongside larger CI and radical change events. Real-world examples in quoting and shipping demonstrated significant gains in quality, time, and cost using A3 and DMAIC methods. The session reinforced that continuous improvement is a never-ending journey—and that even small teams can make big gains by learning from others and applying the fundamentals consistently.

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.