The Manufacturing Edge - For Ops Leaders

Episode 3: Food and Beverage Safety Management Part 3 - A Five-Step Playbook: Assess, Make Visible, Build, Train, and Sustain

TBM Consulting Group — Mon, 01 Jun 2026 16:31:01 +0000

In Part 3, Will and Nasir shift from “what’s going wrong” to “what to do about it.” They walk through TBM’s five-step food safety management system approach—Assess, Make Visible, Build the Structure, Train and Do, Sustain—and tie each step back to the real-world challenges discussed in Parts 1 and 2.

You’ll hear how an honest diagnostic, clear visibility, defined ownership, frontline engagement, and disciplined sustainment work together to move a safety culture from reactive to proactive to truly interdependent. Nasir shares why most organizations think they’re further along than they are and why closing the gap between policy and behavior takes 2–3 years of consistent effort.

Listen now and explore next steps to turn insight into action on your plant floor.

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Episode 2: Food and Beverage Safety Management Part 2 - From the Floor Up: Fixing Safety Where Product, People, and Suppliers Meet

TBM Consulting Group — Mon, 01 Jun 2026 16:27:22 +0000

In Part 2, Will and Nasir move closer to the action on the plant floor, exploring how safety breaks down across three zones: production processes, the frontline workforce, and your extended supplier network. They show why high turnover, onboarding shortcuts, and weak supplier oversight can undermine even the best-documented safety programs.

You’ll hear what a “living” HACCP system looks like, why new workers are hurt at dramatically higher rates, and how supplier decisions made on cost alone can trigger multimillion-dollar recalls months later. The conversation connects day-to-day realities—line speeds, changeovers, sanitation, labeling, and near-miss reporting—to the brand and financial risk sitting in your safety system.

Tune in to spot vulnerabilities and start closing them in your daily operation.

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Episode 1: Food and Beverage Safety Management Part 1 - Beyond Recalls and Recordables: Seeing the Whole Iceberg

TBM Consulting Group — Mon, 01 Jun 2026 16:24:52 +0000

In Part 1 of this three-part series, host Will Merriman and TBM Senior Management Consultant Nasirali (Nasir) Emadi unpack why food and beverage safety management is about much more than staying off OSHA’s radar or avoiding the next recall headline. They connect the dots between recordables, product recalls, and everyday process decisions on the plant floor, showing how safety prevention consistently delivers a 3–5x ROI versus reactive spending.

Drawing on 30 years in operations and food and beverage packaging, Nasir explains why nearly every “surprise” incident can be traced back to long-standing process gaps and leadership choices. You’ll hear why 300 recalls and 220,000 workplace injuries in 2024 are not random events—and what that tells you about your own safety system.

Listen now and start reshaping how your organization thinks about safety, risk, and performance.

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Episode 1: When SIOP Gets Real: Capacity, Analytics, and Better Decisions

TBM Consulting Group — Fri, 10 Apr 2026 18:18:47 +0000

Modern Sales Inventory and Operations Planning, or SIOP, separates manufacturers who are constantly firefighting from those who can see around the corner and plan with confidence.

If you’re still relying on spreadsheets, siloed systems, and forecasts no one fully trusts, you’re likely paying for it in overtime, expediting, and missed customer commitments.

In this episode of The Manufacturing Edge, our host Will Merriman talks with TBM’s Global Supply Chain leader Brian Cromer about: How to tighten Sales Inventory and Operations Planning discipline, build realistic capacity models, and use analytics to expose true constraints and hidden capacity—before they become crises.

For operations, supply chain, and P&L leaders who want lower working capital, better service levels, and fewer surprises, this is a fast, practical listen.

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Episode 2: Tech Talk - Managing the Human Side of Digital through Change Management

TBM Consulting Group — Thu, 19 Feb 2026 13:58:42 +0000

Many digital management system initiatives fall short — not because of the technology, but because organizations underestimate the human side of the transition. Moving from traditional paper-based boards to digital systems requires more than new tools; it demands changes in leadership behaviors, communication habits, and how teams engage with daily performance. When that change isn’t actively managed, adoption stalls and the expected ROI never materialize.

In this episode of The Manufacturing Edge, TBM experts explore what it really takes to successfully evolve from TBM’s traditional management system to its Digital Management System. They discuss why effective change management — building buy-in, reinforcing new behaviors, and sustaining leadership engagement — is the critical link between digital investment and lasting operational results.

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Episode 1: Tech Talk - From Whiteboards to Real-Time: Why Digital Management Systems Are Now a Manufacturing Imperative

TBM Consulting Group — Tue, 20 Jan 2026 22:06:36 +0000

This episode of The Manufacturing Edge explores how digital management systems have fundamentally transformed what’s possible compared to traditional, physical boards and manual tracking. The discussion highlights how real-time visibility, multi-site connectivity, faster escalation, and data-driven decision-making replace delayed rollups and siloed information—while still preserving the lean disciplines of daily accountability, problem-solving, and leadership engagement. It’s a look at why digital isn’t just a new format for the same boards, but a step-change in speed, scale, and impact for modern manufacturing operations.

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Episode 6: Back to the Basics - Part 6: Final Thoughts: The First Move Every CEO Should Make in 2026

TBM Consulting Group — Tue, 13 Jan 2026 18:48:13 +0000

In a world obsessed with AI, automation, and digital transformation, the manufacturers that will pull ahead this year are doing something far more fundamental: they are mastering operational discipline.

In this special multi-part episode of The Manufacturing Edge, TBM Consulting Group CEO Bill Remy sits down with regional leaders from the U.S., Europe, and Latin America for a candid, executive-level conversation on what truly drives results when markets are uncertain, costs are rising, and talent is scarce.

The message is clear: technology is a force multiplier—but only when the basics are rock-solid. Leadership presence, daily management, problem-solving, standard work, and a bias for action are the real competitive advantages in the new year.

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 6: Final Thoughts: The First Move Every CEO Should Make in 2026

If given the reins for a day, each leader would do the same thing:
Go to the gemba. Lead from the front. Re-establish daily management discipline. Invest in people's capability. Build a culture of standard work, visual control, and relentless problem-solving.

The closing message is powerful:
Technology will accelerate the future—but only operational excellence will sustain it. The companies that hardwire fundamentals in 2026 will move faster, execute better, and outperform in every market condition.

If you want to assess where your organization stands—and how to strengthen the systems, routines, and leadership behaviors that drive results—now is the time to act.

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Episode 5: Back to the Basics - Part 5: Why Doing Nothing Is the Riskiest Strategy

TBM Consulting Group — Tue, 13 Jan 2026 18:47:00 +0000

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 5: Why Doing Nothing Is the Riskiest Strategy

At the executive and board level, the conversation turns to decision paralysis. In complex, uncertain environments, waiting for perfect clarity often results in lost momentum and cultural stagnation.

The leaders reinforce the need for a strong bias for action—testing, learning, adjusting, and moving forward. Progress comes from disciplined experimentation, not endless debate. As one panelist put it: don’t let “best” get in the way of getting better.

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Episode 4: Back to the Basics - Part 4: Leadership at the Point of Impact

TBM Consulting Group — Tue, 13 Jan 2026 18:45:52 +0000

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 4: Leadership at the Point of Impact

Strong technical performers are often promoted without being prepared to lead, resulting in weak supervision, limited coaching, and higher turnover. The team emphasizes that performance and retention start with leaders on the shop floor—building trust, developing skills, and reinforcing standards through daily coaching and problem-solving.

The message is clear: investing in frontline leadership and true capability development is essential to building stable, engaged teams that can execute with discipline and deliver results.

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Episode 3: Back to the Basics - Part 3: The Critical Basics Every Plant Must Start Now

TBM Consulting Group — Tue, 13 Jan 2026 18:44:48 +0000

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 3: The Critical Basics Every Plant Must Start Now

What are the non-negotiables?

Leaders must be present on the floor, not managing from spreadsheets and offices.
Hour-by-hour, plan-versus-actual visibility must drive fast response.
Standard work, short-interval control, and simple KPIs must replace data overload.
Trust in frontline teams and structured problem-solving must become daily habits.

Execution speed is built through routine, clarity, and accountability—not heroic firefighting.

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Episode 2: Back to the Basics - Part 2: Technology Only Works When the Fundamentals Are Right

TBM Consulting Group — Tue, 13 Jan 2026 18:32:51 +0000

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 2: Technology Only Works When the Fundamentals Are Right

AI, automation, and digital tools dominate headlines—but the panel warns against confusing investment with improvement.

Without standard work, visual management, closed-loop problem solving, and trained leaders at the gemba, technology often automates waste, increases complexity, and overwhelms the workforce. The group emphasizes “creativity before CapEx,” aligning people, processes, and management systems first so that digital investments actually deliver sustainable results.

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Episode 1: Back to the Basics - Part 1: Getting Back to the Basics to Tackle Uncertainty

TBM Consulting Group — Tue, 13 Jan 2026 18:31:48 +0000

Listen to this 6‑part series to sharpen your focus and reinforce the fundamental disciplines that drive sustained manufacturing performance.

Part 1: Getting Back to the Basics to Tackle Uncertainty

The discussion opens with the global reality facing manufacturers: geopolitical instability, tariffs, inflation, labor shortages, and cautious capital spending. Across regions, executives are prioritizing cash, resilience, and predictable execution.
The leaders agree that in times of uncertainty, the companies that win are those that double down on fundamentals—stabilizing processes, making performance visible, standardizing work, and building daily problem-solving routines. Operational discipline, not bold bets on “shiny objects,” is what creates control, confidence, and speed.

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Episode 9: The 80’s Called and They Want Their Management System Back - Part 3

TBM Consulting Group — Mon, 11 Aug 2025 14:47:48 +0000

Getting It Right – How to Succeed (and Why Many Don’t)

In the final episode, Will, Bill Remy, and Paul Culling tackle the real-world challenges of implementation. From overcoming resistance to change to avoiding common pitfalls, they share best practices that ensure your digital management system doesn’t just launch—it lasts.

You’ll hear practical advice on how to build buy-in across all levels of the organization, why starting small leads to bigger success, and how the TBM–iObeya partnership helps manufacturers scale without adding unnecessary complexity.

If you're ready to modernize but unsure where to start, this episode will give you the roadmap.

For more information about the TBM Digital Management System, click here →

Episode 8: The 80’s Called and They Want Their Management System Back - Part 2

TBM Consulting Group — Mon, 11 Aug 2025 14:45:04 +0000

Why Digitizing a Management System Is a Force Multiplier

In this second part of the series, Will, Bill Remy, and Paul Culling dive deeper into why digitizing your management system is more than a tech upgrade—it’s a catalyst for transformation. They explore how integrating TBM’s tiered management system with iObeya’s digital capabilities boosts speed, visibility, and collaboration, sharing real-world examples of faster decision-making, stronger problem-solving, and more aligned execution across teams and sites. If you're still stuck in siloed communication and collaboration on ops processes and , this episode will change how you think about what’s possible.

Episode 7: The 80’s Called and They Want Their Management System Back - Part 1

TBM Consulting Group — Mon, 11 Aug 2025 14:42:18 +0000

In this three-part series on The Manufacturing Edge Podcast, the host Will Merriman sits down with TBM CEO Bill Remy and Paul Culling, Territory Director for the Americas and Head of Global Alliances at iObeya, to tackle a challenge that’s holding too many manufacturers back: outdated, disconnected management systems.

In this part one of the series, Will sits down with Bill and Paul to discuss the new TBM–iObeya partnership and how it’s propelling TBM’s Management System into the digital era. They explore why this collaboration is so critical for manufacturers navigating today’s fast-paced environment—and why sticking with paper-based systems could leave you trailing behind the competition.

Episode 6: Much Ado About Sourcing - Global Sourcing Strategy

TBM Consulting Group — Mon, 23 Jun 2025 17:41:54 +0000

Is Your Global Sourcing Strategy Still Fit for Purpose?

In this episode of The Manufacturing Edge, host Daniel Bobik sits down with TBM experts Brian Cromer and Nasir Emadi to tackle the urgent need for manufacturers to rethink their sourcing strategies. With rising geopolitical tensions, supply chain disruptions, and cost pressures, relying on yesterday’s playbook is no longer an option.

What You’ll Learn:

How to proactively manage sourcing risks
Real-world examples of successful onshoring and diversification
The role of SIOP (Sales, Inventory, and Operations Planning), analytics, and supplier collaboration
Top 3 actions to future-proof your supply chain

Whether you're in supply chain, operations, or procurement, this episode offers practical insights to help you build resilience and agility into your sourcing strategy.

Learn More About TBM Consulting Solutions →

Episode 5: Lean and Focused: How to achieve your AOP with tight budgets

TBM Consulting Group — Mon, 02 Jun 2025 16:09:45 +0000

Even as global tariffs surge, supply chains strain, and costs climb, the pressure on manufacturers to deliver on Annual Operating Plan (AOP) goals remain a priority—often with fewer people and tighter budgets. In this episode of The Manufacturing Edge, TBM experts David Pate and Brian Cromer share how manufacturers can shift from survival mode to rapid progress—advancing confidently toward their AOP targets. Tune in to learn the bold moves that drive results fast—without sacrificing agility, efficiency, or competitiveness.

What You’ll Learn in This Episode:

Smarter Sourcing & Supply Chain Agility: How to reassess your sourcing strategy to navigate tariffs, reduce inventory costs, and build resilient supplier partnerships that support long-term success.
People & Process Optimization: Explore how cross-training, employee engagement, and continuous improvement can drive agility and reduce human capital costs—without increasing headcount or overtime.
Operational Cost Control Tactics: From waste elimination to process standardization, discover how small changes can lead to significant savings and help you stay on track with your AOP.

Whether you're a plant manager, supply chain leader, or executive decision-maker, this episode offers practical insights you can apply immediately. Hear real-world examples, expert advice, and actionable strategies to help your organization thrive—even when budgets are tight.

Learn More About TBM Consulting Group Solutions here.

Keep pushing the Manufacturing Edge.

Episode 4: The Lean Comeback: Why Manufacturers Are Reinvesting in Lean

TBM Consulting Group — Tue, 25 Mar 2025 17:14:10 +0000

In this episode of The Manufacturing Edge podcast, host Daniel Bobik sits down with Bill Remy, CEO of TBM Consulting Group, to explore the evolving role of Lean Manufacturing in a digital world. The discussion highlights how lean principles remain a powerful tool for driving efficiency, eliminating waste, and fostering agility.
Bill shares insights on overcoming implementation challenges, integrating AI and automation while staying true to lean fundamentals, and how companies can leverage lean as a strategic enabler for revenue growth—beyond operational efficiencies, it unlocks new sales opportunities by freeing up capacity and improving service levels.

Whether you're a manufacturing leader or a continuous improvement professional, this episode provides practical takeaways on sustaining lean transformations, optimizing capacity, and staying competitive in an ever-changing and uncertain market.

Listen now to gain expert insights on the future of Lean Manufacturing!

Episode 3: Network Optimization for Growth

TBM Consulting Group — Mon, 10 Mar 2025 14:21:29 +0000

In this episode of The Manufacturing Edge podcast, "Beyond Cost Savings: How Network Optimization Drives Growth in Manufacturing," host Daniel Bobik sits down with Brian Cromer, Managing Director of Global Supply Chain Practice, and Dave Hicks, VP of Maintenance Excellence Practice at TBM Consulting Group. Together, they explore how network optimization goes beyond just cutting costs—it’s a powerful strategy for boosting both efficiency and profitability.

Key discussion points include:

- Optimizing Assets: Strategic equipment placement to enhance efficiency and productivity.

- Reducing Changeovers: Faster changeovers and optimized sequencing to lower costs and increase output.

- Holistic Optimization: Evaluating the entire manufacturing and distribution network for maximum efficiency.

- Cost vs. Service: Finding the right balance between cost savings and maintaining high service levels.

- Expert Insights: How external consultants bring fresh perspectives and industry best practices.

- Ongoing Improvement: The importance of continuous review to stay competitive in a shifting market.

This episode highlights why strategic planning and continuous evaluation are essential for manufacturers looking to improve efficiency, control costs, and enhance service levels—all while driving sustainable growth and profitability.

Episode 2: Navigating Tariffs and the Reshoring Opportunity with Guests David Pate and Harry Moser - PART 2

TBM Consulting Group — Mon, 10 Feb 2025 16:33:20 +0000

In this two-part podcast episode, Daniel Bobik speaks with experts Harry Moser, Founder of the Reshoring Initiative and David Pate, VP of TBMs Operational Excellence Practice, about the pressing issue of tariffs and their wide-ranging impacts on the US manufacturing sector, the financial benefits of reshoring by assessing total cost of ownership, and the short-term tactics and long-term strategies leaders must start now.

This podcast is essential for manufacturing executives looking to understand the strategic implications of tariffs and the growing movement towards reshoring.

Episode 1: Navigating Tariffs and the Reshoring Opportunity with Guests David Pate and Harry Moser - PART 1

TBM Consulting Group — Fri, 07 Feb 2025 15:21:15 +0000

Episode 5: Lean Blog Interviews - Transforming Operations with Lean Leadership: Driving Growth Through Continuous Improvement

TBM Consulting Group — Tue, 03 Dec 2024 15:47:35 +0000

In this episode our CEO, Bill Remy talks with the host of Lean Blog, Mark Graban, about the transformative power of Lean leadership and operational excellence.

Bill shares insights from his extensive career, including how he first encountered Lean principles at Allied Signal and the dramatic improvements achieved through lead time reduction and flow. They explore the critical role of communication and employee involvement in overcoming resistance to change, the deep connection between safety and quality, and the importance of leadership in both driving transformation and sustaining long-term improvement. The podcast concludes with Bill’s and Mark’s reflection on how organizations can leverage Lean as a strategic advantage to drive growth and profitability while fostering a culture of continuous improvement.

Episode 4: With inflation rising, what do you think the impact on demand will be for manufacturers?

TBM Consulting Group — Tue, 11 Oct 2022 19:01:26 +0000

While high inflation will drive down demand and allow supply to catch up, companies will need to shift to a more competitive mind-set to win in this environment. This means improving lead times and consistently meeting service promises compared to the competition. Dan Sullivan explains how traditional operational excellence practices is the smartest, fastest, and most efficient way to win.

Episode 3: Addressing the Rising Costs of Employment and the Talent Shortage

TBM Consulting Group — Fri, 16 Sep 2022 15:49:00 +0000

Shannon shares her perspective on the labor market over the next 6-12 months amid inflation and potential recession and how manufacturers should address the rising costs of employment and talent shortage.

Episode 2: How inflation is impacting suppliers, material costs, transportation costs and customer demand in the next 6-12 months

TBM Consulting Group — Thu, 11 Aug 2022 19:09:09 +0000

Ken Koenemann, Vice President of Supply Chain and Technology practices at TBM Consulting Group, explains how inflation is impacting suppliers, material costs, transportation costs and customer demand in the next 6-12 months. Listen to his perspective on better supply chain planning in the short and long term that can withstand tough economic conditions.

Episode 1: How inflation can impact operations and production planning

TBM Consulting Group — Thu, 11 Aug 2022 18:56:16 +0000

John Ferguson, CEO of TBM Consulting, talks about how inflation can impact operations and production planning and what companies should be doing in the short term to find efficiencies in operations and reduce costs.