Events

December 12, 2019

DISH Network hosted a plant visit in Spartanburg showcasing Industry 4.0 projects developed largely in-house by their engineering and operations teams. Highlights included vision systems with OCR for automated cosmetic inspection, collaborative robots improving productivity and reducing material costs, and a redesigned returns process that cut floor space by 30% with a sub–two-year payback. The visit also demonstrated how lean principles, IoT sensors, and workforce training are tightly integrated to drive continuous improvement.

January 16, 2020

OpExChange members toured Komatsu America’s Newberry facility last week to see firsthand their industry-leading safety culture and energy improvements. The team shared their six-tiered safety program, including a near-miss reporting system, Safety Dojo, risk assessments, and “Point & Call” practices, resulting in zero lost-time accidents in the past five years and a 67% reduction in recordables. Members also learned how Komatsu reduced their carbon footprint by 55% through data-driven energy management. The visit highlighted Komatsu’s engaged management, lean principles in action, and strong community involvement, offering valuable peer-to-peer insights for attendees.

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.

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 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.

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.

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.

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.

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.

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.

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 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.

September 3, 2020

Bosch Engineering and Production Services shared how they are taking a holistic approach to Industry 4.0 during an OpExChange webinar attended by 94 participants from 47 sites across South Carolina. The session focused on connectivity—linking people, machines, and systems—and emphasized that Industry 4.0 is a cultural transformation, not just a technology or IT initiative. Bosch outlined its five implementation levels, lessons learned from its North American model plants, and the critical role of people and change management. The webinar concluded with practical recommendations and an invitation for future plant visits and continued learning around Industry 4.0 and IoT.

September 9, 2020

Sunland Logistics Solutions hosted an in-person OpExChange event in Simpsonville, sharing their lean journey and continuous improvement culture. Leaders highlighted Sunland’s servant-leadership values, visual daily management, workforce engagement through Two-Second Lean, and investment in a dedicated CI Dojo for hands-on learning. The visit included a full facility tour and interactive discussion, giving members practical examples of how Sunland drives operational excellence across its 3PL operations.

September 22, 2020

A live broadcast highlighted how three manufacturers—Dish Network, FN America, and Rolls-Royce—are approaching Industry 4.0 and IIoT at very different stages of maturity. Dish showcased practical, low-cost predictive maintenance and real-time monitoring to reduce downtime and lost production. FN America outlined a disciplined, architecture-driven digital strategy tightly aligned to business value and operator engagement. Rolls-Royce emphasized that successful digital transformation is ultimately about people and culture, supported by strong partnerships and a clear vision. Delta Bravo reinforced the message with real-world AI case studies, showing that starting small with clean data can deliver rapid, high-ROI results.

October 8, 2020

This broadcast focused on cybersecurity as a critical pillar of Industry 4.0, led by Delano Collins, VP of Corsica Cybersecurity. He emphasized that cybersecurity is not a product, but a continuous process—one that is increasingly vital as manufacturing connectivity and remote access expand. He outlined common intrusion methods targeting manufacturers, noting that most attacks exploit end users through phishing and weak access controls. The session highlighted practical countermeasures including employee training, patching, network segmentation, and continuous monitoring. Additional resources and a follow-up webinar were shared to help members assess and strengthen cybersecurity readiness at their facilities.

November 4, 2020

Dr. Eric Hayler showed how Industry 4.0 technologies can complement Lean Six Sigma without large capital investment. Drawing on his experience at BMW, Amazon, and as president of The Hayler Group, Eric introduced Low-Cost Intelligent Automation (LCIA) and connected it to the House of Lean, particularly the Jidoka pillar. He shared practical examples—such as sensors, scanners, AGVs, and pick-to-light systems—that are now affordable and easily integrated into kaizen activities. The key takeaway: technologies once considered advanced are now accessible tools for everyday lean improvement.

November 12, 2020

Corsica Cybersecurity hosted a webinar focused on new cybersecurity requirements for Department of Defense suppliers. He outlined the Cybersecurity Maturity Model Certification (CMMC), which replaces NIST 800-171 and now requires third-party audits rather than self-attestation. Most suppliers will fall under Level 3 compliance, and organizations already meeting NIST 800-171 have a relatively small gap to close. Robert emphasized that CMMC is an organization-wide responsibility, not just an IT initiative, and shared tools and reference materials to help suppliers prepare.

December 8, 2020

Wikoff Color Corporation shared how leadership development is central to its employee-owned culture. Through tools like stay interviews, individual development plans, and emotional intelligence assessments, Wikoff focuses on engagement, retention, and leader credibility. The session highlighted that strong leadership is built on both results and behaviors, reinforcing continuous improvement through people-focused development.

December 16, 2020

The OpExChange wrapped up 2020 with a virtual Year-in-Review highlighting strong engagement despite pandemic disruptions. A total of 26 events were held, with virtual sessions driving a 112% increase in average attendance during the second half of the year. Membership also grew, with 22 new companies joining—the highest increase since 2011. Looking ahead to 2021, OpExChange shared a robust Q1 schedule, new member tools through the Panorama portal, and recognized companies and individuals for outstanding participation and collaboration.

January 11, 2021

In early 2021, Carolina CoverTech shared how strong leadership and a values-driven culture enabled them to not only withstand the pandemic, but to grow through it. President Rian True and Vice President of Operations Lisa Stuart discussed navigating multiple simultaneous crises by leaning into trust, teamwork, and transparency. Their candid conversation highlighted the power of complementary leadership styles, consistent communication, and visible care for employees. The session reinforced that in times of crisis, it is culture—not circumstance—that determines whether an organization merely survives or truly adapts and overcomes.

January 19, 2021

Bill Bliss of Bliss & Associates led an interactive workshop on candidate selection and interviewing, focused on reducing the high cost of bad hires. With less than 30 participants, the session covered interview preparation, defining job competencies, legal considerations, and using structured decision matrices. Role-playing interviews reinforced key concepts, while data highlighted that nearly half of new hires fail within 18 months, often at a cost exceeding 150% of base salary. The full recording, presentation, and reference materials are available on the OpExChange Portal.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

November 16, 2021

The final 2021 plant visit was at Sulzer Pumps in Easley, SC, where 17 attendees saw their new digital work instruction platform and toured the facility. Sulzer aims to increase production to 5,000 pumps annually by 2025 and has implemented Dozuki to standardize training, capture tribal knowledge, and enable employee suggestions. Early results show improved employee engagement, higher customer net promoter scores, and reduced complaints. Videos, photos, and presentation slides are available on the Portal.

December 13, 2021

The 2021 Year-End OpExChange event on December 13 celebrated member growth, recognized award winners, and recapped key learnings from 34 events. The 2022 Q1 schedule and new Portal tools—including templates for development, site visits, and hosting—were also shared with attendees.

January 14, 2022

As Trane Technologies rapidly expanded its Columbia, SC operations, the site accelerated its Industry 4.0 journey by deploying predictive analytics in partnership with IoTco. Starting with a focused pilot on press operations, Trane achieved a roughly 15% improvement in equipment uptime with payback in under a year. The session highlighted a disciplined “think big, start small, scale fast” approach—grounded in people, process, and tools—that is now being scaled across multiple sites.

January 20, 2022

SCMEP introduced its Workforce Development Playbook to help manufacturers address today’s labor challenges through a strategic focus on Recruitment, Retention, and Reputation. During the OpExChange broadcast, Bill Bliss and Susan Whitehead highlighted that engagement and culture—more than compensation alone—are the strongest predictors of retention. The playbook provides practical, short- and long-term actions across 21 workforce topics, reinforced by SCMEP’s “Smart Talent” approach, which applies systematic leadership development to drive engagement and reduce turnover. A full recording, tools, and resources are available on the Portal.

February 10, 2022

Veteran manufacturing leader Mike Ungar shared how Industry 4.0 should be viewed not as a standalone initiative, but as a set of tools that strengthen an existing Lean culture. Lean remains the backbone—focused on flow, waste reduction, and PDCA—while digital technologies can dramatically accelerate improvement cycles. The key message: start with a clearly defined problem, then apply the right Industry 4.0 tools to support Lean, not the other way around.

February 18, 2022

BorgWarner’s Seneca team hosted a plant visit showcasing logistics and inventory improvements at their Shiloh warehouse, featuring drone-based cycle counting from Gather AI and autonomous trailer-loading robots from Slip Robotics. Attendees saw live demonstrations led by warehouse employees, highlighting gains in accuracy, safety, and dock efficiency with rapid implementation timelines. The visit underscored how targeted automation can quickly reduce waste and deliver measurable operational value.

March 10, 2022

Polydeck Screen in Spartanburg hosted a plant visit focused on two critical priorities: caring for employees and safety. The team shared how a deeply rooted caring culture—supported by dedicated Caring roles and a company-funded Caring Fund—drives engagement and supports their goal of zero safety incidents. Attendees experienced hands-on safety practices, including observational audits, onboarding, and employee-led safety programs. Polydeck demonstrated how genuine care for people can translate directly into stronger safety performance.

March 16, 2022

AFL Accessories in Duncan, SC has achieved 22 years without a lost-time accident and more than 6.5 million safe work hours in a machining-intensive environment. The team combines a strong people-first culture with practical technology, including real-time locating systems, 3D printing, robotics, and data analytics. Their focus on flexibility, hands-on learning, and employee engagement supports both retention and operational excellence. AFL’s approach shows how simplicity, leadership, and smart technology can work together on the shop floor.

April 5, 2022

During this visit, VELUX shared how their Greenwood, South Carolina facility is advancing an ambitious commitment to become Lifetime Carbon Neutral by their 100-year anniversary. Through aggressive recycling initiatives, renewable energy investments, and partnerships focused on forest conservation, the site demonstrated how sustainability can be embedded into daily operations while delivering real business value. The visit highlighted VELUX’s belief that responsible manufacturing, continuous improvement, and environmental stewardship are inseparable.

April 19, 2022

Why did dozens of manufacturing leaders travel to a remote site in Abbeville? To see how Stoll Industries combines strong leadership and lean manufacturing to achieve world-class retention. Despite beginning their lean journey only a year ago, Stoll has reduced floor space by 30%, cut hours from 65 to 40 per week, improved flow, and boosted first-pass yield to 80%. Even more impressive is their long-standing culture—anchored in servant leadership—that has sustained roughly 95% retention. Stoll’s focus on people first has created a foundation where continuous improvement thrives.

May 17, 2022

BOMAG Americas shared how they use Hoshin Kanri and the X-Matrix to align long-term strategy with daily execution across the organization. The Ridgeway, SC site demonstrated how safety, standard work, and PDCA turn strategic goals into measurable action on the plant floor.

June 9, 2022

During an OpExChange plant visit, Dish Network’s Spartanburg facility shared how a strong lean foundation and deep trust-based culture enabled a major operational transformation. As the site transitioned from set-top box remanufacturing to supporting Dish’s 5G network buildout, leaders emphasized workforce engagement, visual management, and transparent career pathways as critical success factors. The visit reinforced how disciplined lean practices and intentional people development can help organizations navigate significant change while strengthening culture.

June 29, 2022

IFA Summerville shared its phased Industry 4.0 journey, highlighting how digitizing production orders, implementing an MES, and enabling traceability are driving real operational gains. The team demonstrated how real-time data, FORCAM MES, and Power BI are being used not just to visualize performance, but to drive better decisions on the shop floor. Early results include improvements in WIP, inventory accuracy, and productivity, with traceability and predictive analytics next on the roadmap.

July 8, 2022

South Carolina continues to see strong momentum in manufacturing expansions, driven by reshoring, workforce shifts, and capital investment. A panel of industry experts shared practical guidance on navigating site selection, real estate trends, workforce strategies, automation decisions, incentives, and construction planning. A consistent theme emerged: early planning and cross-functional collaboration are critical to controlling cost, schedule, and long-term performance during expansion projects.

August 23, 2022

This visitvisit to Allied Air Enterprises drew one of the largest turnouts of the year, with thirty-five participants from fourteen member companies. The team shared how standard work, visual management, and PDCA-driven execution have significantly improved performance on their air handler lines. The visit highlighted strong alignment from Hoshin strategy deployment to shop-floor execution, with visible results in safety, quality, delivery, cost, and people metrics. Attendees were particularly impressed by the visual factory, takt discipline, and measurable gains achieved through focused kaizen activity.

September 8, 2022

Harsco Rail is driving a lean transformation at its West Columbia facility by empowering employees as problem solvers. Through disciplined A3 problem-solving and daily management, the team has delivered nearly $3 million in improvements without capital investment. The focus is simple and effective—build capability, follow the process, and sustain results.

September 23, 2022

Digital transformation continues to deliver real results for manufacturers—but only when it is tied to a clear business case. Industry examples show strong ROI from automation, analytics, and connectivity, yet many companies remain stuck in “pilot purgatory.” A key takeaway from this session was the importance of thinking big, starting small, and scaling fast, while aligning people, process, and technology. Conducting a structured Industry 4.0 assessment can help organizations identify high-value pilot opportunities, manage change effectively, and build a scalable roadmap for long-term success.

October 3, 2022

Phoenix Specialty Manufacturing is a fourth-generation, family-owned precision stamper in Bamberg County with a strong national presence. Their success is built on in-house tool and die capability, customer-focused flexibility, and a deeply engaged workforce. At the heart of it all is a leadership culture that prioritizes people and long-term performance.

November 8, 2022

Campbell’s Snacks hosted a plant tour in Charlotte highlighting a long-standing robotics culture across baking, packaging, and palletizing operations. Attendees saw multiple generations of ABB and Syntegon robots, including high-speed pick-and-place systems and newer technology that combines carton forming and packing to save space. The visit also showcased high-volume cracker production, flexible automation in the warehouse, and a strong emphasis on safety, benchmarking, and workforce engagement as key enablers of sustained automation success.

November 15, 2022

As hiring and retention challenges continue across manufacturing, many companies are partnering with workforce providers like MAU Workforce Solutions for support. MAU shared a lean, data-driven framework for building effective contract workforce partnerships, emphasizing upfront discovery, optimization of the hiring funnel, and ongoing collaboration. The key takeaway: treating the relationship as a true partnership—grounded in data and continuous improvement—drives better retention and performance.

December 6, 2022

The year-end review highlighted strong growth, with membership increasing 64% since mid-2020, despite pandemic disruptions. In 2022, 33 events were delivered through a mix of in-person plant visits, virtual sessions, and half-day workshops, engaging more than 1,000 participants statewide. Several companies and individuals were recognized for outstanding engagement, collaboration, and employee development, including a renamed collaboration award honoring a long-time industry contributor. The update also outlined board leadership activity and previewed a robust slate of plant visits, workshops, and virtual events planned for the first quarter of 2023.

January 12, 2023

Dodge Industrial in Greenville, SC hosted an OpExChange plant visit that highlighted its long-standing commitment to operational excellence. As a founding and active OpExChange member, the site demonstrated its capabilities in manufacturing heavy-duty industrial gearboxes, supported by a strong Lean and Six Sigma infrastructure. Visitors observed multiple Kaizen initiatives, a structured tiered performance management process, and a dedicated lean laboratory. The visit also emphasized Dodge Industrial’s exceptional safety culture, including the SafeStart Now program, which has driven significant and sustained improvements in safety performance.

January 24, 2023

PCI Group in Fort Mill hosted an OpExChange plant visit focused on sharing progress in its lean journey and innovative approaches to employee development and engagement. The transactional mail provider demonstrated how lean principles, executive commitment, and standard work have supported significant growth while maintaining high-volume, high-security operations. Highlights included a highly automated production flow with minimal work-in-process, strong visual management tied to service-level agreements, and a robust onboarding and career progression program. The visit concluded with an engaging peer discussion centered on retention, training, and building a sustainable lean culture.

February 6, 2023

Boeing South Carolina has been “building the dream” since establishing 787 Dreamliner final assembly operations in North Charleston in 2010. The site showcases advanced manufacturing through highly automated assembly, extensive use of carbon fiber composites, and innovative safety technologies such as ergonomic exoskeletons. Beyond production, Boeing has played a major role in strengthening South Carolina’s manufacturing ecosystem by expanding its supplier base and investing heavily in workforce development. Through statewide STEM outreach and programs like DreamLearners, Boeing is helping build a skilled talent pipeline that benefits both the aerospace industry and the broader South Carolina economy.

March 2, 2023

ZF Transmissions showcased its Gray Court facility to highlight its rapid growth in e-Mobility and the use of Industry 4.0 technologies. The visit featured collaborative robots, data-driven condition monitoring, and an interactive e-Mobility Expo demonstrating how innovation is improving safety, productivity, and workforce engagement. Together, these initiatives underscore ZF’s role in advancing electric vehicle manufacturing in South Carolina.

March 7, 2023

Cascades Tissue Group recently welcomed OpExChange members to share how they are strengthening employee engagement across their operations. The team highlighted practical approaches to communication, leadership involvement, and creating ownership at the front line. Rather than focusing solely on tools or programs, Cascades emphasized building trust and connection with their workforce. Attendees gained real-world insights into how engagement improvements can drive culture, performance, and retention.

March 14, 2023

Chris Wayne, VP of Business Development & Growth at SCMEP, led a one-hour OpExChange webinar on Value Analysis/Value Engineering (VAVE). He explained how VAVE can increase customer value and reduce manufacturing costs by making strategic design decisions early, using cross-functional teams to explore cost “knobs” and levers. Examples ranged from a simple pencil to the Apollo 11 Lander, showing that while the process is straightforward, it requires diverse perspectives and openness to new ideas. The full recording, presentation deck, and Excel templates are available on the OpExChange Portal.

March 21, 2023

Carolina Food Service in Loris, SC, has grown rapidly since 2009 by focusing on superior customer service. During an OpExChange visit, President Juan Serrato shared how the company leveraged SCMEP resources to develop a five-year strategic plan, boosting sales, refining marketing, and building a culture of continuous improvement. Initiatives like TalentClick assessments, Enterprise Café analytics, and lean-inspired warehouse practices have helped CFS expand market share and improve operational efficiency.

April 13, 2023

Cybersecurity is no longer optional for manufacturers. In this virtual session, Wes Knight outlined the risks SMEs face, from potential losses of $100K to $1.5M to the threat of business closure following an attack. Beyond risk mitigation, implementing standards such as CMMC or TISAX can provide a competitive advantage, streamline audits, and help attract new clients. The session also emphasized the importance of maintaining standards, documenting processes, and fostering a culture of compliance.

April 28, 2023

During an OpExChange tour, RASCO highlighted their successful plant-wide implementation of Training Within Industry (TWI). The six-year initiative standardized job instruction, trained over 100 employees, and enhanced operational performance. Using structured scripts, reflection meetings, and technology-enabled tracking, RASCO ensures employees perform tasks safely, correctly, and efficiently while fostering engagement and continuous improvement.

May 2, 2023

OpExChange members toured Otis Elevator’s Florence plant, exploring three years of automation and Industry 4.0 initiatives. Fourteen robots have been deployed, reducing labor needs, eliminating errors, and boosting safety. Visitors also learned about connected equipment dashboards, a digital twin for process simulation, and plans for a fully SMART factory by 2025. Lean practices, visual management, and workforce engagement were highlighted throughout the tour.

May 16, 2023

AFL Conductor Accessories showcased how practical analytics and a strong, people-centered culture can drive exceptional results during an OpExChange plant tour in Duncan. By leveraging Microsoft Power BI, the team achieved dramatic gains in on-time delivery, revenue growth, and operating profit—without significant capital investment. Just as impressive is their culture, reflected in world-class safety performance and employee retention. The visit highlighted how accessible data, empowered teams, and collaboration fuel sustained operational excellence.

May 16, 2023

SixAxis demonstrated that lean manufacturing delivers real, measurable results when it is deeply embedded in daily operations and culture. During this OpExChange visit, the team openly shared how disciplined lean deployment, standard work, and employee engagement drove dramatic improvements in safety, quality, delivery, and cost. Just as important, they showed how sustaining lean success depends on leadership, transparency, and making continuous improvement everyone’s responsibility.

June 6, 2023

Lean Manufacturing remains one of the most effective ways to improve productivity and profitability in U.S. manufacturing, yet most companies have yet to fully embrace it. In a record-attended OpExChange virtual session, Doug Berger of Industry Reimagined 2030 shared research showing that manufacturers who treat Lean as a people-centered, continuous improvement system achieve dramatically better results. The path forward is clear: make Lean practical, relevant, and focused on execution.

June 20, 2023

T&S Brass and Bronze Works has built its reputation on reliability—both in the products it delivers and the culture it sustains. During an OpExChange plant visit, participants gained insight into how respect, flexibility, and humanity are intentionally woven into daily operations, driving exceptional employee retention and engagement. Leaders shared how a family-oriented culture, reinforced over decades, empowers employees to take ownership of both quality and community. This people-first mindset is matched by rigorous quality systems, hands-on testing, and continuous investment in safety and automation. Together, these elements reflect a company where “Reliability Built In” is more than a tagline—it’s a lived experience.

July 18, 2023

Michelin has developed a world-class maintenance training program focused on building critical technical skills and strengthening long-term workforce retention. Through a partnership with SCMEP and the South Carolina Department of Commerce, this “Talents for Manufacturing” program is now available to manufacturers across the state. Recently, OpExChange participants from twenty companies experienced the program firsthand through in-depth overviews and hands-on workshop tours at Michelin. The training emphasizes real-world scenarios, with nearly 75% of the time spent applying skills at the workbench. This practical approach equips maintenance professionals with the confidence and capability to perform when it matters most.

August 8, 2023

This OpExChange session featured practical supply chain insights from Sunland Logistics Solutions, alongside SCMEP’s introduction of CONNEX SC. Amy Sartain of Sunland shared real-world logistics strategies manufacturers can apply immediately, from supplier identification to transportation and storage decisions. Together, the discussion highlighted how strong logistics partners and smart digital tools can strengthen South Carolina’s manufacturing ecosystem.

August 15, 2023

BMW Spartanburg hosted one of OpExChange’s marquee plant visits, welcoming 48 participants from 33 manufacturing and distribution companies across South Carolina. Attendees toured the highly automated body shop and engaged directly with BMW leaders on Lean Six Sigma and daily management. The visit offered rare insight into how a global OEM aligns people, technology, and systems to drive consistency, quality, and continuous improvement at scale.

August 29, 2023

During an OpExChange visit to Timken’s Honea Path facility, members saw firsthand how leadership development and disciplined problem-solving shape the shop floor. The site’s Timken Manufacturing Operating System (TMOS) embeds safety, quality, and delivery into daily management through leader standard work, visual controls, and a robust andon response system. The visit reinforced a core lean principle: a strong operating system, led consistently by people, is what sustains culture and continuous improvement.

September 19, 2023

DeepHow and Beyond: AI Is Reshaping Workforce Training at Stanley Black & Decker During an OpExChange visit to Stanley Black & Decker’s Fort Mill facility, members explored how the site is using AI to capture tribal knowledge and strengthen workforce training amid ongoing skilled labor challenges. The team showcased DeepHow, a video-centric platform that preserves expert know-how and delivers standardized, multilingual training at the point of need. The visit reinforced how digital tools, when grounded in lean principles and people development, can drive safer, more consistent operations.

October 3, 2023

Schaeffler’s Fort Mill 1 facility demonstrated how digitalization, automation, and connectivity are being woven into daily manufacturing operations. Rather than treating digital tools as standalone initiatives, the team emphasized using digitalization as a practical extension of continuous improvement. From autonomous material handling and condition monitoring to real-time production visibility, the visit showcased how Schaeffler is turning data into actionable insight while improving safety, efficiency, and sustainability.

October 24, 2023

Often called South Carolina’s “best-kept secret,” the Vocational Rehabilitation Department (VR) is a powerful workforce development and retention resource for employers across the state. During an OpExChange visit to VR’s West Columbia campus, participants gained new insight into a large, motivated talent pool and saw firsthand how disability does not limit ability. VR is helping businesses meet workforce needs while creating meaningful employment opportunities.

October 31, 2023

Sumter Packaging showcased its latest Manufacturing 4.0 investment during a recent OpExChange plant visit, demonstrating how advanced automation is elevating quality, efficiency, and flexibility. The new Göpfert High Board Line delivers 100% inspection, faster changeovers, and world-class print quality—reinforcing Sumter Packaging’s commitment to continuous improvement and customer excellence.

November 14, 2023

Autokiniton’s Fountain Inn plant showcases one of the most highly automated operations OpExChange has visited to date—where robots outnumber associates on the shop floor. Designed to support BMW Spartanburg, the facility combines high-capacity stamping, robotic assembly, and smart material flow with a relentless focus on uptime and quality.

December 4, 2023

Ingevity’s Charleston plant demonstrates how sustainability and safety can go hand in hand. During an OpExChange visit, members saw how the site converts industrial waste into valuable products while maintaining an exceptional safety record driven by strong engagement and accountability. It’s a powerful example of operational discipline in action.

December 12, 2023

OpExChange added 41 sites in 2023, reaching 191 members across SC, NC, and GA. The year featured 34 events, including site visits and workshops on analytics, Kaizen, and employee development. Awards recognized standout companies and individuals for engagement, collaboration, and promoting the OpExChange mission. The 2024 schedule is already underway with plant visits, workshops, and virtual sessions across the region.

January 23, 2024
1:00 pm - 3:45 pm

The OpExChange conducted its inaugural plant visit of 2024 on January 23 at Sealevel Systems, located in Liberty, SC. Established in 1986, Sealevel has witnessed substantial growth in the past four years, with a nearly doubled sales figure, an expanded market share in critical communications industries, and the achievement of their largest-ever energy design contract.

February 7, 2024
1:00 pm - 3:45 pm

The OpExChange thrives on success stories, driven by a collective "how-did-they-do-it" spirit. This thirst for knowledge fueled our 2024 plant visit to RX Industries (RXI) on Hilton Head Island. The visit brought together OpExChange peer manufacturers from across the state who sought not just inspiration from Tom's story and recommendations, but also the opportunity to offer their own insights.

February 20, 2024
1:00 pm - 3:45 pm

In mid-February, the OpExChange peer networking group paid a visit to Current Lighting, located in Hendersonville, NC, a member of the OpExChange for 16 years. A total of forty-four peers from twenty-nine companies participated in the plant tour and collaborative discussions.

March 5, 2024
1:00 pm - 3:45 pm

The OpExChange visit to Starbucks’ Sandy Run Roasting Plant highlighted a world-class operation grounded in people, craftsmanship, and continuous improvement. Producing over 70 million pounds of coffee each year, the site combines a unique cellular layout with a strong CI culture built on 5S, daily management, and hands-on A3 problem solving. Partners shared tangible wins—including major downtime reductions—and the team’s enthusiasm for learning was unmistakable. Though their CI journey is still young, Sandy Run is already setting the pace in safety, quality, and performance across the Starbucks network.

March 26, 2024
10:30 am - 12:00 pm

This virtual event showcased how Matterport Scanning brings affordable digital twin technology to manufacturers of all sizes. David Woods of SCMEP demonstrated how quick 3D facility scans can streamline layout improvements, support relocations, and enhance training and maintenance. This simple, cost-effective tool gives teams clearer insight into their operations and faster paths to efficiency.

April 9, 2024
1:00 pm - 3:45 pm

BW Flexible Systems in Duncan offered a powerful look at what happens when a manufacturing organization truly puts people first. Guests saw how the company’s culture—rooted in Barry-Wehmiller’s “Everybody Matters” philosophy—drives both leadership development and daily operations. From their no-layoff commitment and employee “University” to a growing tiered lean reporting system, the site demonstrates how caring for people and pursuing performance can work in harmony.

April 30, 2024
1:00 pm - 4:00 pm

Sargent Metal Fabricators in Anderson, SC showcased how a family-owned company can blend cutting-edge automation with deeply rooted values. Nearing its 50-year milestone, Sargent has transformed from a small sheet-metal shop into a highly advanced, 160,000-square-foot operation powered by robotic bending cells, fiber-laser cutting, modern welding technology, and in-house powder coating. During the OpExChange visit, guests saw firsthand how innovation, continuous investment, and a commitment to people have positioned Sargent Metal as a leader in precision fabrication. Their message was clear: automation isn’t just their future—it’s in their DNA.

May 7, 2024
1:00 pm - 3:45 pm

Rolls-Royce’s Aiken facility showcases precision, innovation, and sustainability in engine manufacturing. Visitors to the OpExChange tour saw advanced machining, assembly, predictive analytics, and the new Remanufacturing & Overhaul Center, supporting a circular economy. The plant features a solar-powered microgrid, strong safety programs, and a nationally recognized high school apprenticeship, reflecting Rolls-Royce’s commitment to people, technology, and delivering “power that matters to everyone.”

May 21, 2024
12:30 pm - 2:45 pm

Honda South Carolina Manufacturing welcomed the OpExChange for its first plant visit, offering a behind-the-scenes look at the world’s leading Honda side-by-side production facility. The Timmonsville plant—now 840,000 square feet and over 1,000 associates strong—showcased its award-winning manufacturing of the Honda Talon and its shift to advanced AGV and AGC technology. Visitors toured the high-speed assembly line, saw smart carts in action, and learned how Honda’s blend of innovation, ergonomics, and continuous improvement keeps production running at impressive efficiency.

June 4, 2024
1:00 pm - 3:45 pm

Mactac’s Moore, SC facility showcased an impressive blend of automation, continuous improvement, and team-driven problem solving during their first OpExChange plant visit. Over the past two years, the site has transformed operations through proactive maintenance, laser-guided vehicles, a fully automated Ferretto warehouse, and a strong focus on waste reduction. Their shift from reactive to preventive maintenance, supported by Power BI analytics, has boosted uptime and efficiency, while waste levels have dropped dramatically. Most notable was the culture: a leadership team empowering talent, engaging employees, and embracing lean principles.

June 27, 2024
11:00 am - 12:00 pm

This webinar explored the vast potential of E-learning in today's manufacturing landscape. We were fortunate to have Adrienne Temple, Vice President of Training Programs for the South Carolina Manufacturers' Extension Partnership (SCMEP), and Greg Surtman, Workforce Development Manager of Tooling U-SME, share their valuable insights. There were 131 participants from 68 companies from 25 counties in South Carolina.

July 16, 2024
1:00 pm - 3:45 pm

Dish Network’s Spartanburg facility showcases how a strong lean culture can drive transformation. The 317,000-square-foot plant has shifted from high-volume operations to producing custom 5G cabinet enclosures and now complex cable and wire-harness assemblies. With an experienced team and a “Do It SomeHow!” mindset, the site blends engineering expertise with practical lean tools, from visual operations to hands-on simulations for every new hire. Their first external harness project highlights how this culture of innovation and continuous improvement is opening new opportunities for the Spartanburg team.

August 20, 2024
8:00 am - 12:00 pm

Wabtec’s Greenville plant recently hosted a safety “workout” with OpExChange peers, drawing participants from fifteen South Carolina manufacturers. Site Director Jason Williams and EH&S Manager Todd Davis shared how the team has been steadily building a stronger safety culture over the past three years, embedding safety into daily Gemba walks, performance objectives, and digital reporting tools like Gensuite. After touring the facility, participants collaborated on the key elements of a deep safety culture—leadership commitment, robust safety infrastructure, engagement at all levels, and behavior-based safety.

August 28, 2024
10:30 am - 11:30 am

The workers’ compensation process is often slow, costly, and full of waste—and Sargent Metal is proving it doesn’t have to be. In an OpExChange session, CEO Tim Hayden shared how his team is applying lean thinking and automation to fix a broken system. By partnering with Zenjuries, Sargent Metal has streamlined communication, reduced claim lag time, and taken control of the 70% of the process manufacturers can directly influence. The result: faster claim closure, lower reserves, and meaningful savings—while getting injured employees back to work sooner.

September 6, 2024
12:15 pm - 4:30 pm

Michelin opened its doors to OpExChange members for a rare look at how digital innovation is reshaping tire manufacturing. During a visit to the US7 plant in Lexington, teams from US5 and US7 showcased major projects—from Automated Guided Forklifts and augmented-reality work instructions to autonomous inspections performed by Spot, the robot dog. Members also toured the facility, witnessing production of some of the world’s largest tires. Beyond technology, Michelin highlighted its people-focused culture through the “Spark Team,” a design-thinking initiative that enhances the employee experience.

October 22, 2024
1:00 pm - 3:30 pm

On October 22nd, OpExChange had the privilege of touring their impressive water heater plant in McBee, SC. The focus of this visit was to share the development of the AO Smith Operating System (AOSos). The company's pioneering work in advanced welding techniques and glass-to-steel fusion revolutionized the manufacturing of products like pressure vessels, large-diameter pipes, and glass-lined water heaters. This innovation led to their prominence as a leading water heater manufacturer, introducing the first glass-lined water heater in 1936.

October 23, 2024
11:00 am - 12:15 pm

Stephen Deas, Process Improvement Coach for SCMEP, hosted an insightful webinar in October of 2024 focused on AS9100. With extensive experience in helping South Carolina companies implement Quality Management Systems (QMS), Stephen provided a comprehensive, hour-long overview of this aerospace and defense industry standard.

November 14, 2024
9:00 am - 10:15 am

David Woods delivered a clear, practical introduction to Lean—covering its origins, the eight wastes, and core tools like 5S and standardized work. Drawing on his Toyota and Danaher experience, he emphasized one central message: Lean starts with people. SCMEP offers coaches and training to support any manufacturer beginning or advancing their Lean journey.

December 5, 2024
8:00 am - 4:30 pm

In early December 2024, I had the privilege of moderating a panel discussion with leaders from three exceptional OpExChange companies during the South Carolina Manufacturing Summit. The focus of our session was a topic of critical importance to manufacturers across the state: achieving and sustaining high employee retention rates.

December 10, 2024
11:00 am - 12:00 pm

This virtual meeting highlighted the 2024 OpExChange year, celebrating the most engaged individuals and companies. Special recognition was also given to those who demonstrated collaboration and support for others throughout the year.

December 17, 2024
11:00 am - 12:15 pm

This webinar provided an overview of SCMEP’s Advanced Manufacturing Guide, available for download. It highlighted how SCMEP supports manufacturers of all sizes in adopting technologies that reduce cost, improve quality, and enhance safety. Key focus areas include AI/ML, VR/AR, cybersecurity and CMMC, network penetration testing, digital twins, robotics and automation, and Power BI.

January 14, 2025
1:00 pm - 3:45 pm

In January, AstenJohnson’s Clinton, SC facility hosted OpExChange members for an exclusive visit, providing a firsthand look at the company’s unique culture and operations. The event spotlighted AstenJohnson’s core focus on safety, employee retention, and operational excellence, drawing attention to its longstanding dedication to continuous improvement and collaboration.

January 22, 2025
10:30 am - 11:30 am

In January, Jason Merschat, founder of Advanced Process Automation, led a thought-provoking webinar on the use of simulation to create effective Digital Twins for manufacturing operations. Jason, who partners with SCMEP to teach Lean Six Sigma classes and provide consulting services to manufacturers, shared his expertise in leveraging simulation techniques alongside Lean Six Sigma principles, positioning this approach as the next evolution of Lean Six Sigma.

February 18, 2025
1:00 pm - 3:45 pm

In February, FujiFilm’s Greenwood, SC facility opened its doors for the first time to the OpExChange, welcoming 21 companies from eleven counties in South Carolina and one from North Carolina. The visit provided an in-depth look at FujiFilm’s transformation from a traditional film photography company to a diversified technology leader. With a sharp focus on lean manufacturing and Industry 4.0 integration, FujiFilm highlighted how continuous improvement has kept them at the forefront of their industry.

March 20, 2025
12:00 pm - 3:30 pm

OpExChange members explored Atlas Copco’s Rock Hill facility, gaining insight into advanced manufacturing, workforce development, and cutting-edge automation. The tour highlighted medical gas system production, lean practices, VR training, and drone-based warehouse scanning. With strong engagement, sustainability leadership, and a culture that values diversity, Atlas Copco delivered an impressive first hosting event that set a new benchmark for excellence.

April 1, 2025
11:30 am - 3:00 pm

In April, TICO Manufacturing opened its doors to the OpExChange network for a powerful benchmarking event. TICO (Terminal Investment Corporation), headquartered in Savannah, Georgia, is a leading manufacturer of terminal tractors—commonly referred to as yard trucks or spotters. What sets TICO apart is its unique dual role as both a manufacturer and operator of these vehicles, giving it a practical understanding of what makes equipment reliable, efficient, and user-friendly.

April 15, 2025
12:45 pm - 3:45 pm

Bausch + Lomb’s Greenville facility showcased its impressive digital transformation journey, revealing how modern tools are boosting performance in a highly regulated, high-volume environment. Visitors saw real-time inventory tracking, predictive maintenance, digital validation, advanced vision inspection, and Power BI–driven performance management. The site’s measurable gains in uptime, yield, and efficiency highlight how digital innovation and strong culture can drive sustainable operational excellence.

May 6, 2025
12:00 pm - 3:45 pm

The OpExChange community had the privilege of touring one of the most advanced manufacturing sites in the flooring industry last week, as Shaw Industries welcomed us to their Aiken, South Carolina plant – known internally as Plant 78. What we witnessed was not just a testament to operational excellence, but a glimpse into the future of manufacturing in South Carolina and beyond.

June 2, 2025 @ 7:00 am — June 5, 2025 @ 3:30 pm

In early June, something remarkable happened in Columbia, South Carolina. FN America opened its doors not just for a typical plant tour – but for a first-of-its-kind, multi-day Kaizen event hosted through the OpExChange. It marked an exciting new chapter for this South Carolina manufacturing network that, for the past twenty-three years, has connected peer manufacturers to share best practices, benchmark operations, and help drive continuous improvement.

June 18, 2025
10:30 am - 11:30 am

The OpExChange community gathered virtually for a webinar introducing a valuable new tool designed to help manufacturers navigate the increasingly complex world of sustainability. This event spotlighted the recently launched Sustainability Resource Guide – a comprehensive, easy-to-use reference developed specifically for small and mid-sized manufacturers.

June 26, 2025
1:00 pm - 3:45 pm

IFA’s Summerville plant is transforming to meet the rapid shifts in the automotive industry. During a recent site visit, guests saw how the team is investing $40 million in advanced automation, expanding half-shaft production, and strengthening problem-solving systems. From fully automated assembly lines to skilled workforce development, IFA is redefining modern automotive manufacturing in South Carolina.

July 15, 2025
12:00 pm - 3:45 pm

In the quiet town of Bamberg, South Carolina, Phoenix Specialty Manufacturing stands as a shining example of American manufacturing resilience. A fourth-generation, family-owned company with roots dating back to 1907, Phoenix was recently honored by the National Institute of Standards and Technology (NIST) as a Hero of American Manufacturing.

August 5, 2025
1:00 pm - 5:00 pm

In the nearly 24-year history of the OpExChange, no plant tour has been larger than the recent visit to SEW-Eurodrive’s Lyman, South Carolina campus. More than one hundred guests from forty-seven organizations, representing 17 counties, gathered to experience one of the more advanced manufacturing operations in the Southeast.

August 19, 2025
12:45 pm - 4:00 pm

The August visit to BMW Spartanburg offered a powerful look inside Assembly Hall 52, where automation, digital twins, and AI are transforming automotive production. Guided by Brad Stone and BMW’s Innovation team, attendees saw how advanced robotics, data-driven decision-making, and human-centered ergonomics come together. The experience showcased BMW’s vision for the factory of the future—and practical ideas for today.

September 8, 2025

A perfect day on the course became something far more meaningful: the inaugural OpExChange Golf Tournament brought together manufacturers from across South Carolina and raised $28,900 for Upstate Warrior Solution. Beyond the friendly competition, the event reflected the true spirit of the OpExChange community—people coming together not only to strengthen their companies, but to support veterans, first responders, and families who have served.

September 9, 2025
12:45 pm - 3:45 pm

Itron’s West Union facility offered a compelling look into the future of energy, water, and smart city management. As the company centralizes North American operations, the site is driving a renewed lean transformation supported by advanced automation, real-time analytics, and a strong culture of engagement. Attendees saw high-speed meter assembly, innovative gas meter technology, and battery-powered device production—all underscoring Itron’s role as a global leader in grid modernization and resource efficiency.

September 23, 2025
10:30 am - 12:00 pm

South Carolina is experiencing a surge in data center growth, reshaping opportunities for manufacturers. In a recent webinar, industry experts highlighted the forces driving this expansion—from fiber and power availability to automation, controls, and AI. Local manufacturers like AFL and Daedalus Industrial are already supplying critical infrastructure, positioning the state to play a major role in the global digital economy.

October 21, 2025
11:45 am - 3:45 pm

OpExChange members visited Northern Tool + Equipment’s Fort Mill distribution center to explore “Smart Distribution.” The tour showcased advanced automation—AutoStore and Packsize—paired with a people-first culture, long-tenured employees, and workforce development initiatives like Tools for the Trades™. NTE demonstrated that operational excellence thrives when technology and human talent work together.

October 29, 2025
10:00 am - 2:30 pm

OpExChange members explored digital twin simulation modeling in a hands-on workshop led by Jason Merschat. Participants built virtual models of their own processes, testing scenarios and identifying constraints before making real-world changes. The session highlighted how digital twins combine Lean principles, data, and visualization to drive smarter, safer, and more efficient operations.

November 4, 2025
1:00 pm - 5:00 pm

A tour of KION North America’s Summerville campus showcased world-class manufacturing in action. From custom forklift assembly and mast fabrication to smart logistics and robotic welding, the visit highlighted how automation, precision, and people-driven innovation come together. KION’s Home Turf initiative demonstrates the value of local production, workforce development, and operational excellence.

November 18, 2025
1:00 pm - 3:45 pm

In November, the OpExChange traveled to Florence for a visit to one of South Carolina’s most quietly influential manufacturing institutions – the Southeastern Institute of Manufacturing Technology, or SiMT. Although SiMT joined the OpExChange just over a year ago, their impact on the state’s manufacturing landscape stretches back much further. For nearly two decades, they have played a dual role that few organizations can claim: they are both a manufacturing services provider and a workforce engine.

December 16, 2025
11:00 am - 12:00 pm

2025 marked the strongest year in OpExchange history. In this recorded webinar, Mike Demos reflects on a year of record participation, statewide growth, and meaningful collaboration across South Carolina manufacturing. The session includes a recap of key milestones, member growth, portal enhancements, a look ahead to 2026, and the presentation of our annual Engagement Awards — recognizing companies and individuals who exemplify the spirit of sharing, learning, and continuous improvement that defines OpExchange.

January 6, 2026
10:00 am - 2:30 pm

Are utility costs cutting into your margins? Has your company been receiving more inquiries about sustainability performance? This half-day workshop will explore actionable steps to meet these increasing requirements in ways that are practical and relevant to your business. We’ll share strategies for smarter energy, water, and waste management, and guide you through calculating your Scope 1 and 2 greenhouse gas emissions.

January 13, 2026
1:00 pm - 3:45 pm

At Timken’s Tyger River plant, operational excellence is not theoretical—it’s visible, measurable, and deeply embedded. During an OpExChange visit focused on TMOS 2, participants saw how a 125-year-old company is redefining flow, quality, and responsiveness in a highly complex, make-to-order job shop. Through disciplined systems, real-time data connectivity, and a workforce with extraordinary tenure, the team has turned material flow into a true competitive advantage—cutting lead times to levels competitors cannot match while maintaining the performance standards Timken is known for worldwide.

February 3, 2026
10:30 am - 11:30 am

Artificial Intelligence is no longer confined to tech companies—it’s quickly becoming a practical tool for manufacturers looking to work smarter and stay competitive. In this one-hour OpExChange webinar, Cameron Duncan, Co-Founder of Hallian Technologies, breaks down Generative AI in plain language and shows how organizations can begin applying it safely and effectively. From Large Language Models to Retrieval Augmented Generation, this session focused on what AI really is, how it works, and how to start small without the hype.

February 10, 2026
10:00 am - 2:00 pm

OpExChange is launching a new event designed by plant managers, for plant managers. This Plant Manager Exchange will offer a confidential setting where leaders can share challenges, exchange ideas, and collaborate on solutions that drive operational excellence. The session will be moderated by Dale McClelland, Plant Manager at Timken – Union. This isn’t a presentation – it’s an exchange of insight and experience among those leading the manufacturing teams.

February 17, 2026
12:30 pm - 3:45 pm

Harsco Rail opened its West Columbia facility to manufacturing peers across South Carolina for a candid look at what it takes to rebuild operational excellence in a complex, low-volume, high-mix environment. From stabilizing material flow and redefining daily accountability to aligning every initiative with measurable business impact, the message was clear: Lean is not a program. It is a path. What attendees saw was not a finished product — but a business deliberately, visibly, and methodically changing how work gets done.

February 25, 2026
10:00 am - 2:30 pm

In this workshop in Columbia, Master Black Belt David Woods led participants through a hands-on SMED (Single Minute Exchange of Dies) simulation — demonstrating how significant performance gains are often achieved not through capital investment, but through disciplined observation and application of Lean principles. Working in teams, participants analyzed a live changeover process, separating internal and external tasks, improving preparation, and eliminating waste. The results were immediate and measurable: the group achieved an average 89% reduction in changeover time. The exercise reinforced a core Lean truth: meaningful operational improvements are driven by people — their engagement, preparation, and ability to see and improve the work.

March 2, 2026 @ 7:00 am — March 5, 2026 @ 4:00 pm

Join us for an exclusive, four-day Kaizen event hosted at Leidos in North Charleston. This is not a classroom exercise – this is hands-on learning in a real factory, assembling sophisticated people-screening systems. This is a rare opportunity to sharpen your Lean skills while making a meaningful impact at a high-performance operation. Take what you learn back to your own facility and drive measurable change.

March 3, 2026
11:45 am - 2:30 pm

OpExChange members visited ITW Hartness in Greenville for an inside look at how the company applies the 80/20 philosophy to simplify operations, improve flow, and build high-performance packaging automation systems.

March 11, 2026
10:00 am - 2:30 pm

Manufacturing leaders from across South Carolina gathered for a hands-on OpExChange workshop exploring how Generative AI can be applied inside manufacturing organizations. Cameron Duncan of Hallian Technologies demystified the technology and shared practical frameworks for identifying AI opportunities that increase productivity, reduce costs, and unlock new business value.

March 24, 2026
1:00 pm - 3:45 pm

Join this plant visit to see how Isringhausen utilizes a Quick Kaizen culture to continuously improve flexibility, customer responsiveness, quality and cost. “Two Plants in One” describes Isringhausen USA. Established in Ladson to be adjacent to the Mercedes Benz Van assembly operation, the high-volume seat manufacturing operation is a model of synchronized production.

April 7, 2026 @ 8:00 am — April 8, 2026 @ 5:00 pm

The premier event is dedicated to advancing digital transformation in manufacturing. This unique conference is led by manufacturers, for manufacturers, and features insightful case studies and presentations from industry leaders. Several OpExChange member companies will be presenting and will also share their expertise during the event.

April 21, 2026
10:00 am - 2:00 pm

HR leaders today are navigating one of the most complex workforce environments in decades. The HR Leader Exchange provides a confidential, peer-driven forum where manufacturing HR leaders can step away from day-to-day demands and engage in honest conversation with others who understand the challenges. Through facilitated small-group discussions, participants will share successes, compare approaches, and gain practical insight on attracting and retaining talent, strengthening culture, and developing the leaders who drive their organizations forward.

April 22, 2026
10:00 am - 2:30 pm

Are utility costs cutting into your margins? Has your company been receiving more inquiries about sustainability performance? This half-day workshop will explore actionable steps to meet these increasing requirements in ways that are practical and relevant to your business. We’ll share strategies for smarter energy, water, and waste management, and guide you through calculating your Scope 1 and 2 greenhouse gas emissions.

April 28, 2026
1:00 pm - 3:45 pm

A third-generation family company owned by Markel Ventures, Metromont has built a strong reputation for innovation, quality, and a culture of safety. This visit will explore how Metromont integrates Lean principles into precast operations and leverages technology in production to meet the demands of large-scale, complex construction projects.

May 12, 2026
1:00 pm - 4:00 pm

Tuffaloy Products has spent nearly 90 years manufacturing precision resistance welding consumables, supplying the current that powers modern manufacturing. Today, this fourth-generation, family-owned company is also conducting change on the shop floor. During this OpExChange visit, you’ll see how Tuffaloy has integrated MachineMetrics with its ERP system to create real-time operational visibility. From downtime tagging to Pareto analysis, the team is turning production data into actionable improvement. This tour offers a practical look at how a legacy manufacturer is combining technology, process, and people to drive measurable results.

May 20, 2026
10:00 am - 2:30 pm

Reduce downtime. Boost productivity. Gain a competitive edge. Discover how SMED (Single Minute Exchange of Dies) can revolutionize your operations in this hands-on, half-day workshop. This session will show you how to dramatically cut equipment changeover times using a proven Lean manufacturing approach.

June 10, 2026
10:00 am - 2:30 pm

In this hands-on workshop, you’ll get no-nonsense, actionable insights on how to leverage generative AI tools securely and effectively. Learn what matters most to your business and prepare your company for the future... without the buzzwords. Walk away with practical workflows you can implement in months, not years.

June 24, 2026
10:30 am - 11:30 am

Allegiance Flag Supply will share how they used ChatGPT and production time-study data to rebalance work across an eight-station sewing line—achieving a 10–20% productivity improvement without additional capital investment. This webinar provides a practical look at how generative AI can support real manufacturing operations.

August 3, 2026
9:00 am - 3:00 pm

🏌️‍♂️ Calling All OpExChange Members! Grab your clubs and get ready to hit the greens for a great cause! The OpExChange Charity Golf Tournament is happening at The Carolina Country Club in Spartanburg, SC, and we’re teeing off to support local veterans, first responders, and their families through Upstate Warrior Solution.

September 23, 2026
10:30 am - 11:30 am

Hammer-IMS will share a real-world implementation of AI-driven quality inspection, showing how their team dramatically reduced programming time and automated complex defect detection. For OpExChange members eager to see practical examples of AI in manufacturing, this session will highlight lessons learned and insights from a successful integration.