PHP E8 - Continuous Improvement and Leadership in Manufacturing

In this episode of The Pulse of High Performance, hosts Seth Davies and Paul Campbell sit down with Brian Vance, Senior Continuous Improvement Manager at Rust-Oleum. 

Brian discusses his journey from a nontraditional start in the Air Force and various roles in manufacturing to becoming a key leader in continuous improvement (CI). 

Emphasizing data-driven CI practices, Brian shares how Rust-Oleum’s MS-168 system—a version of the Toyota Production System—has been instrumental in streamlining operations, minimizing downtime, and enhancing safety. 

• Continuous Improvement as a Core Practice:

Continuous improvement, rooted in Lean Six Sigma and the MS-168 system, helps Rust-Oleum increase efficiency, resolve recurring issues, and enhance safety. 

Brian shared a case where CI practices eliminated major downtime on a key machine, showcasing the lasting impact of structured problem-solving.

• Operator Engagement:

Operators are critical to CI success at Rust-Oleum. 

Their involvement in problem-solving builds ownership and accountability, turning initially resisted tools like hourly boards into essential aids that track and resolve top issues.

• Effective Leadership:

Good leaders drive alignment by communicating clear goals and empowering their teams. 

Brian highlights the value of “momentum” in leadership, where a unified focus propels progress, and contrasts it with the limitations of micromanagement.

• Data-Driven Decision Making:

Data visibility is crucial for Rust-Oleum, allowing the team to focus on high-impact problems through “brutal prioritization.” 

A tiered communication model ensures everyone from operators to executives stays aligned on metrics and goals.

• Preparing for the Future with Skills and AI:

Skilled trades are in short supply, pushing Rust-Oleum to prioritize training and retention. 

Additionally, Brian sees AI as a future tool to improve quality and efficiency in production, specifically in achieving consistency in paint batching.

Brian’s insights underscore the importance of investing in continuous improvement, empowering team members, and using data as a foundation for operational excellence. 

From managing people to leveraging advanced CI systems, Rust-Oleum’s success showcases the power of structured leadership and rigorous process optimization. 

Join Competitive Solutions Leaders as they delve into the core of high-performing organizations on The Pulse of High Performance.

This show is sponsored by Visuant, your partner in driving operational excellence through data-driven insights.

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