Events

August 28, 2024

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. This people-first approach is simply the next step in Sargent Metal’s long-standing commitment to safety, innovation, and operational excellence.

August 26, 2024

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. The session highlighted practical methods used across the state, from SafeStart programs to “concern report” competitions, reflecting a shared commitment to making South Carolina’s workplaces safer and more resilient.

July 25, 2024

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.

June 27, 2024

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.

June 13, 2024

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. Mactac’s journey is still underway, but their results—and their willingness to share and learn—demonstrate a commitment to operational excellence that truly sticks.

June 11, 2024

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. The visit highlighted a company deeply rooted in Florence County and committed to building world-class vehicles with safety, quality, and teamwork at the core.

May 14, 2024

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.”

April 30, 2024

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.

April 9, 2024

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. The tour made one message clear: at BW Flexible Systems, culture isn’t a slogan—it’s the engine behind continuous improvement and long-term success.

March 26, 2024

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.