Events

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.

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.