Events

August 25, 2020

BOMAG shared how its Ridgeway, SC team uses the SCAT (Systematic Cause Analysis Technique) to thoroughly investigate every safety incident. Rather than stopping at surface-level causes, the process helps uncover deeper systemic issues such as communication gaps and compliance weaknesses. Through a real-world case example, BOMAG demonstrated how disciplined root-cause analysis strengthens safety culture and drives more effective corrective actions.

August 13, 2020

This webinar explored collaborative robots (cobots) and their growing role in small and mid-sized manufacturing. Bob Goosen of Purdue MEP outlined how cobots differ from traditional robots, where they fit best, and how to evaluate ROI. With lower costs, quick payback, and the ability to work safely alongside people, cobots are a flexible automation option for low-to-medium volume, high-mix operations.

August 6, 2020

A webinar on additive manufacturing explored how 3D printing complements traditional manufacturing by enabling greater design flexibility, faster prototyping, and new production possibilities. Justin Hopkins reviewed key additive technologies and where they add value across the product life cycle—from rapid prototyping and production ramp-up to tooling, spare parts, and end-of-life support. Real-world case studies showed how manufacturers are using additive methods to reduce lead times, improve performance, and gain economic advantages. While not a replacement for conventional processes, additive manufacturing is an increasingly important tool to include in a modern manufacturing toolkit.

July 29, 2020

Jeff Gossett of Tailwinds Consulting led a 90-minute session on the critical role culture plays in successful organizational change, drawing more than 80 participants from across South Carolina. He highlighted that while infrastructure enables improvement, culture ultimately determines whether change is sustained. Using the “Lone Nut and First Follower” concept, Jeff emphasized how leaders must intentionally shape norms and tailor communication to different styles to build momentum. The session reinforced that meaningful change happens one person at a time—until the tipping point is reached.

July 1, 2020

OpExChange hosted a 75-minute virtual session featuring AHT Cooling Systems (Ladson, SC) and SeeDaten, Inc., focused on employee training and emerging software technology. The webinar drew 65 participants from 36 South Carolina companies. AHT shared how its pay-for-skills and cross-training program—built on TWI principles—has increased workforce flexibility, engagement, and operational continuity. SeeDaten demonstrated how reality, augmented reality, and mixed-reality tools can accelerate training, improve retention, and simplify learning infrastructure. The session reinforced a core continuous-improvement message: start somewhere, learn, and keep building.

June 1, 2020

Dantherm Cooling hosted a plant visit highlighting its transformation in both performance and culture. Leaders Greg Kaye and Kevin Lanford showcased the Dantherm Cooling Arena—a hockey-themed visual management hub that reinforces servant leadership, accountability, and team recognition. Built around Personal Kanban and clear shop-floor communication, the approach has driven strong results, including on-time delivery improving from 30% to 80% and a 40% reduction in turnover. The visit reinforced how people-focused leadership and visual systems can accelerate operational excellence.

May 1, 2020

A week-long webinar on Leading Through a Crisis brought leaders together for daily one-hour sessions focused on navigating the challenges of Covid-19. Led by Chris Stoeklein and based on John Maxwell’s teachings, the series emphasized calm, people-first leadership and concluded with the interactive John Maxwell Leadership Game. The sessions offered practical perspective and encouragement for leading effectively during times of crisis.

February 27, 2020

KION North America hosted a benchmarking visit at its Summerville, SC headquarters, showcasing practical, low-cost improvements in digital work instructions, 6S, and logistics. The team demonstrated how they created fully electronic work instructions using common tools like Excel, PDFs, and smartphone video—cutting labor costs by roughly 22%. Attendees also saw strong visual management, improved FIFO controls, smart battery charging, and employee-driven improvements through KION’s VOICES program. The visit concluded with an interactive plant tour and peer discussion around lean, logistics flow, and Industry 4.0 initiatives.

February 25, 2020

OpExChange members recently visited Woodward’s Greenville plant, hosted by Dee Kalata, Operations Director, and Joe Conway, Lean Six Sigma Master Black Belt. Woodward shared how they are expanding into remanufacturing fuel system components using Systematic Layout Planning (SLP), along with a walkthrough of their “True North” vision, daily management system, and leader standard work. The team demonstrated how visual management, operator involvement, and disciplined problem-solving support both new business development and existing operations. The visit concluded with a peer benchmarking discussion, reinforcing the value of OpExChange collaboration and shared manufacturing expertise.

February 6, 2020

PCI Group delivers mission-critical communications from its Fort Mill, SC and Dallas, TX facilities, processing more than one million secure documents daily for highly regulated industries. Following rapid growth in 2015, PCI recognized the need to rethink how production, quality, and training were managed at scale. By implementing standard work as a foundation of their lean journey, PCI reduced variation, improved training and onboarding, and strengthened employee engagement through operator-driven documentation and visual standards. These efforts enabled PCI to sustain growth, improve quality and service levels, and even launch a new facility in just three months—demonstrating the powerful business impact of disciplined standard work and servant leadership.