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Guest: Brian Vance

In this episode of The Pulse of High Performance, hosts Seth Davies and Paul Campbell explore the intersection of leadership, data, and continuous improvement with Brian Vance from Rust-Oleum.

From Air Force to Manufacturing Excellence

Brian Vance's journey to becoming a Senior Continuous Improvement Manager at Rust-Oleum began unconventionally in the Air Force. His path through various manufacturing roles has shaped his unique perspective on leadership and process optimization.

The Power of Systematic Improvement

At the heart of Rust-Oleum's success lies the MS-168 system—their adaptation of the Toyota Production System. This structured approach to continuous improvement has revolutionized their operations by:

Streamlining production processes
Minimizing costly downtime
Enhancing workplace safety
Driving sustainable efficiency gains

Key Insights from the Conversation

1. Continuous Improvement as a Core Practice

The implementation of Lean Six Sigma principles and the MS-168 system has transformed Rust-Oleum's operational efficiency. Brian shared a compelling example where structured problem-solving eliminated significant downtime on critical equipment, demonstrating the lasting impact of these methodologies.

2. The Critical Role of Operator Engagement

Success in continuous improvement hinges on operator involvement. At Rust-Oleum:

Operators actively participate in problem-solving initiatives
Initially resistant tools, like hourly boards, have become essential
Enhanced ownership and accountability drive sustained improvements

3. Leadership That Drives Results

Brian emphasizes that effective leadership:

Creates clear alignment through transparent communication
Empowers teams to take ownership
Builds momentum through unified focus
Avoids the pitfalls of micromanagement

4. Data as the Foundation for Success

Rust-Oleum's approach to data management includes:

Enhanced visibility across all levels
"Brutal prioritization" of high-impact issues
Tiered communication ensuring alignment from operators to executives
Metrics-driven goal setting and tracking

5. Preparing for Future Challenges

The conversation highlighted two critical future-focused initiatives:

Addressing skilled trades shortages through targeted training and retention programs
Exploring AI applications in production, particularly for paint batching consistency

Looking Ahead

Brian's insights reveal how Rust-Oleum's commitment to continuous improvement, strong leadership, and data-driven decision-making create operational excellence. Their success story demonstrates the power of structured approaches to process optimization and team empowerment.

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EP 8: Continuous Improvement and Leadership in Manufacturing