In this episode of the Operations Science Podcast, host Ed Pound sits down with Stefano Relli, an international leader in continuous improvement at a global precision optical lens manufacturer.

Together, they break down the real-world challenges of running a make-to-order, high-variability production system and how balancing a push-pull system can transform flow, efficiency, and customer responsiveness.

Stefano shares how his multicultural leadership journey shaped his approach to operational excellence, people alignment, and driving change in high-precision environments.

From understanding the complexity of lens manufacturing to managing production capacity, optimizing equipment efficiency, and engaging both frontline teams and senior leadership, this episode dives deep into what it takes to run operations at scale.

Perfect for professionals in manufacturing, operations, Lean systems, continuous improvement, and supply chain, this conversation delivers practical insights backed by global experience.

Topics Covered:

• Handling high-mix, make-to-order challenges
• Implementing push-pull systems
• Cultural intelligence in leadership
• Aligning KPIs with operational goals
• Managing variability and production capacity
• Engaging teams in continuous improvement
• The human side of operational transformation
• Stefano’s personal passion for road cycling

Timestamps -

00:00 Introduction to the Operations Science Podcast

00:49 Meet Stefano Relli: A Leader in Optical Lens Manufacturing

01:57 Stefano's Multicultural Journey and Its Impact on Leadership

08:24 Challenges of Make-to-Order Systems in Lens Manufacturing

12:46 Understanding the Lens Manufacturing Process

19:44 Implementing Push-Pull Systems for Operational Excellence

25:53 Ensuring Equipment Efficiency

26:42 Managing Production Capacity

28:31 Engaging Leadership in Continuous Improvement

34:20 Aligning People and Processes

35:26 Personal Journey and Influences

41:34 The Joy of Road Cycling

43:46 Conclusion and Final Thoughts

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