Connected Shopfloor

En este episodio de Connected Shopfloor Podcast, conversamos con David Molina, COO y Copropietario de Plásticos Benito (PLASBESA), para explorar cómo una empresa familiar con 40 años de historia se reinventa a través de la tecnología, la ingeniería y la agilidad industrial. Con formación en Ingeniería Técnica Industrial (especialidad Mecánica) y experiencia previa internacional en Martifer, David lidera la fábrica junto a su hermana, equilibrando la gestión financiera con el desarrollo de producto, moldes y producción.La conversación se centra en la transición generacional y en la evolución del modelo de negocio: de producciones masivas y estandarizadas a proyectos a medida, prototipado rápido y series más cortas con impresión 3D e inyección de termoplásticos. David aborda abiertamente los desafíos de gestionar una fábrica en familia, la importancia de la alineación entre ventas y la capacidad real de la planta de producción, así como la diversificación de cartera frente a un mercado fuertemente dependiente de la automoción.El episodio analiza también el papel del plástico reciclado ante las nuevas regulaciones y la urgencia de la digitalización en las pymes industriales. David detalla cómo la sustitución de registros manuales por la captura de datos y el análisis en tiempo real con proGrow transformó la productividad en la fábrica, permitiendo detectar paradas invisibles, optimizar costes y tomar decisiones más rápidas y precisas.

Neste episódio do Connected Shopfloor Podcast, conversamos com Francisco Ferro, Diretor de Business Development e Melhoria Contínua na INCOMPOL, para explorar os desafios da gestão industrial, da digitalização e da melhoria contínua em setores de elevada exigência, como o automóvel e o aeroespacial. Com formação em Engenharia Electrotécnica e Licenciatura em Engenharia Mecânica pelo Instituto Superior Técnico, Francisco acumula uma sólida bagagem internacional, destacando-se a sua passagem de quase uma década pela Rolls-Royce na Alemanha.A conversa mergulha no choque cultural ao regressar a Portugal e na transição do rigor alemão para a realidade das fábricas nacionais, abordando como introduzir processos exigentes sem perder a agilidade. Francisco partilha reflexões fundamentais sobre a fiabilidade dos dados na tomada de decisão, o nível de visibilidade que se deve dar aos operadores no chão de fábrica e a constante arbitragem entre os objetivos de Produção e o rigor da Qualidade para proteger as margens num mercado altamente competitivo.Ao longo do episódio, debate-se ainda a caça à eficiência, a eliminação de paragens invisíveis e a resistência humana ao processo de digitalização. O episódio culmina num debate sobre a Inteligência Artificial no chão de fábrica: estará a tecnologia a facilitar a gestão ou a afastar os líderes do contacto direto com a equipa e da realidade do Gemba?

No primeiro episódio da 3.ª temporada do Connected Shopfloor Podcast, conversamos com Pedro Pinto, CEO e fundador da Padrão Determinado, para explorar os bastidores da gestão industrial num dos setores mais competitivos e tradicionais do país: o têxtil. Com uma formação sólida em Gestão de Empresas e um percurso com forte pendor financeiro, Pedro traz uma visão analítica e pragmática à liderança de uma fábrica têxtil sediada em Marco de Canaveses.A conversa mergulha na sua jornada profissional, desde o desafio de erguer uma fábrica do zero — num ecossistema hiper-competitivo — até à transição de "homem dos números" a líder que gere equipas com objetivos antagónicos, equilibrando a visão comercial, o volume de produção, a precisão da qualidade e a margem financeira.Ao longo do episódio, Pedro partilha perspetivas valiosas sobre o impacto real da tecnologia no chão de fábrica. Debate de forma honesta se a Inteligência Artificial, a visão artificial para deteção de defeitos e os algoritmos de corte são otimizações reais com ROI mensurável ou apenas conceitos teóricos. O episódio aborda ainda o combate aos desperdícios visíveis e invisíveis, a gestão da falta de mão de obra qualificada e as exigências da concorrência global, desde as metas de sustentabilidade até ao desafio iminente do Passaporte Digital do Produto na União Europeia.📌 Timestamps00:10 - Do zero ao têxtil: criar uma fábrica num mercado tradicional05:20 - Gestão de equipas e resolução de conflitos entre departamentos10:01 - Produção e amostras no Têxtil17:08 - Digitalização e desafios no chão de fábrica20:16 - Mão de obra vs. Tecnologia24:03 - Day One Shopfloor25:11 - Onde se perde dinheiro na fábrica e o valor invisível da poupança26:42 - Posicionamento global, sustentabilidade e o Passaporte Digital do Produto28:13 - A evolução do fundador: da execução à delegação32:32 - Desligar da fábricaGostaste deste episódio? 🎧Deixa o teu gosto e subscreve o podcast para não perderes os próximos episódios sobre a transformação do chão de fábrica!Descobre mais sobre a proGrow em: www.progrow.aiQueres falar coma nossa equipa? Manda um email para [email protected]

In the 14th and last episode of the Connected Shopfloor Podcast, we sit down with Laurens van den Berg, Chief Operations Officer at Läderach, to explore the high-stakes world of luxury chocolate manufacturing. With a background that spans electromechanical engineering, global management, and an INSEAD MBA, Laurens brings a uniquely analytical perspective to one of the world’s most coveted Swiss chocolate brands.The conversation dives deep into his professional journey, from his early career steps in heavy production at Barry Callebaut across Indonesia, France, and Belgium, to his current role managing a fully vertically integrated supply chain that controls everything from the cocoa bean to the retail counter across more than 260 global boutiques.Throughout the episode, Laurens shares invaluable insights into the daily realities of global operations. He breaks down the "chocolate butterfly effect"—how a minor shipping delay in West Africa can directly impact a customer walking into a boutique in Zurich—and discusses the delicate balance between high-tech automation and preserving the handcrafted soul of a family business founded in 1962.From bridging the communication gap between shopfloor engineers and boardroom executives to managing cultural shock absorbers when leading diverse international teams, this conversation is a masterclass in operational excellence. Laurens also tackles the future of the industry, sharing his take on next-generation talent, real-time data integration, and whether trends like lab-grown cocoa are actual future realities or just industry hype.

Nuno Silva joins us on the Connected Shopfloor podcast to break down the strategies behind managing a global industrial group with seven distinct business units. He explains why management principles are universal and why technical expertise matters less than accountability, rigor and a deep obsession with client delivery.We explore the concept of structural resilience and how diversifying into sectors like mining and naval operations provides the necessary breathing room to survive automotive market volatility. Nuno also reveals his approach to the shopfloor, emphasizing that a leader must feel the raw reality of production to truly understand the business.From the challenges of localized management in Brazil and Mexico to the strategic shift required to compete with China through precision instead of price, this conversation offers a masterclass in industrial leadership. We conclude with a forward-looking discussion on how to attract new talent by making the industry emotionally engaging and how AI will augment human judgment without replacing the essential intuition that defines successful managers.

In this episode of the Connected Shopfloor Podcast, we welcome Robert Moak, a veteran who truly understands the meaning of "command and control" in both a literal and industrial sense. Bob spent 22 years in the US Navy before transitioning into the trenches of manufacturing, bringing a unique perspective on leadership, discipline, and the high-stakes reality of shopfloor operations.The conversation dives deep into the "hard truths" of industrial management, starting with a provocative comparison: Is managing a ship's crew the same as managing a production line? Bob shares his journey from the structured hierarchy of the Navy, where rules are absolute and responsibility can land you in jail, to the complex, often messy world of civilian manufacturing where respect must be earned, not just commanded.As the episode unfolds, Marco and Bob tackle the critical gaps in modern production. They discuss the "lies" of perfect OEE figures, the vital (and often neglected) ritual of the Shift Handover, and Bob's battle-tested strategy for neutralizing "Bad Actors", those persistent equipment failures that drain a plant's profitability. This episode is a masterclass in operational accountability. It concludes with a forward-looking reflection on AI and Industry 4.0, questioning if we are losing our human curiosity to the machines we build.

In this episode, Marco Tschan sits down with Júlio Leite, Operations Manager at WEDRONE, a company that is redefining the intersection of tradition and innovation. Established in 2020 as an R&D powerhouse, WEDRONE made waves in 2022 by acquiring a legacy firm with 70 years of aluminum die-casting expertise.Julio brings a fascinating "full-circle" perspective to the table: from starting his career as a machine operator in his father’s shop and teaching informatics, to holding leadership roles at global giants like Lear Corporation, Coindu, and Molaflex.We dive deep into the WEDRONE story and how a modern R&D-focused company is breathing new digital life into 70 years of die-casting know-how while navigating the high-stakes "gold standard" pressure of supplying Porsche, VW, and Bentley, where non-quality costs are measured in tens of thousands of Euros per minute. Julio shares the reality of their digital transformation, moving from paper and fax to 60+ IoT devices and computer vision on the path toward AI-driven root cause analysis. We also explore the human factor of manufacturing, discussing why Julio spends his day on the shop floor instead of behind a desk and how he uses "Birthday Coffee" meetings to build a culture of trust.Whether you're interested in the technicalities of one-piece flow in aluminum machining or the leadership philosophy of a man who values white wine as much as industrial efficiency, this episode is packed with veteran insights.

After 30 years as a high-level executive for global giants like Unilever, Barry Callebaut, and Bunge, Maurizio decided to take a leap of faith during a global pandemic. In this episode, we dive deep into his decision to acquire Alojas, a potato starch and pulse processing factory in Latvia, and how he transformed a company on the brink of bankruptcy into a thriving business.Maurizio shares invaluable insights on strategic acquisition, explaining why buying distressed assets can be the smartest move for an entrepreneur. He also discusses the 80/20 rule of profit, detailing how to use commodities to pay the bills while simultaneously building high-margin specialty products. Drawing lessons from industry leaders like Ferrero, he touches on the importance of vertical integration and controlling the supply chain from the ground up.Furthermore, the conversation explores modern leadership, specifically why engineers need a business mindset and how to foster a culture that values disagreement and synthesis. Maurizio concludes by discussing growth and resilience, using his experiences running marathons and moving a family across Europe during a lockdown to explain why discomfort is the ultimate catalyst for professional and personal development.Whether you are an aspiring entrepreneur, a business student, or a corporate professional, Maurizio’s methodical approach to strategy, operational efficiency, and innovation offers a roadmap to success in any industry.

In this episode of the Connected Shopfloor Podcast, host Marco Tschan welcomes a specialist who truly understands what happens when the high-level theory of the boardroom meets the gritty reality of the machine.Mike Lane is a veteran of the manufacturing world with over 17 years spent in the trenches of management consulting. Having optimized operations for global giants like Accenture and Hitachi, Mike’s expertise spans across aerospace foundries, paper mills, and international food and beverage plants. While he is a master of the "nuts and bolts" of performance, focusing on OEE, Lean, and Root Cause Analysis, his secret weapon is actually his background in HR and Sales. This unique combination gives him a distinct edge in tackling the most difficult part of any industrial transformation: changing human behavior.The conversation dives deep into the "hard truths" of operational change, beginning with a provocative look at why so many "perfect" Lean systems eventually fail. Mike shares his perspective on whether manufacturing actually suffers from technical problems, or if these are simply leadership issues disguised as technical ones. Drawing from his extensive experience conducting DILO (Day In The Life Of) studies, Mike reveals the most common "lies" we tell ourselves about how we spend our time on the shop floor and discusses how much an employee’s behavior truly changes the moment they know they are being observed.As the episode unfolds, Marco and Mike explore the sensory side of consulting, discussing how a seasoned expert can judge the health of a factory by sound alone. They also tackle the tension between traditional methods and the digital frontier, questioning if the psychological power of a physical whiteboard is being lost in the era of iPads and "Smart Factories." This episode is a masterclass in practical manufacturing wisdom. It concludes with a powerful reflection on Industry 4.0, examining why, even 20 years into the future, we might still be struggling with the same basic human communication issues despite our advanced AI.

In this episode, we sit down with Miguel Félix, Production Director at Prenso-Metal, to explore the front lines of industrial transformation. From its roots in 1992 to becoming a Tier 1/Tier 2 powerhouse in the automotive sector, Prenso-Metal represents the pinnacle of Portuguese precision engineering.With a background in International Trade and a Master’s in Business Management, Miguel brings a strategic perspective to the technical world of metal forming. He plays a pivotal role at Prenso-Metal, a company specializing in fine blanking, progressive stamping, and high-speed welding for the global automotive industry.We dive into how AI and IoT are moving from buzzwords to the factory floor, revolutionizing the way production is managed in real-time. Miguel breaks down how digital tools are the secret to cutting delays and costs, providing a practical roadmap for innovation in an industry that’s traditionally been a bit more conservative. We also talk about the "balancing act"— keeping quality and speed high while navigating the red tape and cultural barriers that often slow down new tech.But it’s not just about the machines. We get into the human side of manufacturing, with Miguel sharing raw insights on leadership, resilience, and staying authentic. We explore what it’s really like to manage generational shifts and family dynamics in a 100% Portuguese-capital business, and how European manufacturers can stay ahead of the curve when competing with Asian markets through smart innovation and vertical integration.