The Shop Floor, Top Floor Talk Show: Casual Convos with Manufacturing Pros

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Rich Nave, COO of The Luminous Group and a returning guest with 38 years in manufacturing, to talk about one of the more stubborn problems in the industry: quality. Specifically, why so many manufacturers are still stuck inspecting parts after they're made instead of building quality into the design and process from the start.Rich walks through the difference between what he calls "reactionary quality" and proactive quality. The reactionary version measures parts after production, which means all the material, labor, electricity, and compressed air has already been used before anyone decides whether the part is any good. The alternative is designing a process reliable enough that consistent results are basically guaranteed, so you're checking process parameters like pressure and temperature rather than sorting good parts from bad ones at the end of the line.He makes the case that quality needs to run through design, process engineering, and operations, not sit in a single department acting as a gatekeeper. And the tools for doing this aren't new. FMEAs have been around since the 1980s, LPAs since the early 2000s. The reason manufacturers aren't using them well isn't a missing tool. It's leadership. Rich argues that leaders have to commit time and resources upfront instead of defaulting to firefighting after something goes wrong.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Sainyam Arora, Quality Assurance and Systems Engineer at Johnson Matthey. They explore why quality breaks down when companies treat it as a department instead of a shared responsibility. Sainyam explains how silos weaken ownership and turn quality into policing.He argues that leaders must ask better questions, connect quality to customer impact, and invite operators into the process. He also warns that standard work can slip into complacency when teams stop asking why. To build real improvement, companies need space for curiosity, trust, and shared language.Josh and Sainyam also dig into AI. Sainyam says most plants still run on fragmented systems and mixed data, which limits what AI can do. He argues that manufacturers need a common data language first. The episode ends with a look at workforce change and continuous improvement ahead.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Anne Trobaugh, Vice President of Quality and Customer Experience at American Woodmark. Together, they explore what it takes to move quality beyond a compliance exercise and make it a real driver of customer satisfaction and business results.Anne shares how her team at American Woodmark developed a customer experience dashboard built on direct feedback, focusing on delivery, product quality, and response. She explains why keeping priorities clear, communicating results across all levels, and empowering teams to solve problems make a measurable difference. Anne also discusses the value of seeking diverse perspectives, learning when to end projects that no longer serve their purpose, and using data to drive decisions at the executive level.The conversation closes with Anne’s take on the need for more women in manufacturing, the power of mentorship, and the growing role of artificial intelligence in improving both back office and plant floor operations.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Rajeev Seth, Director of Operational Excellence and Asset Reliability at Mondelez International. Together, they dive into the real meaning of operational excellence on the shop floor, moving beyond checking dashboards and running special projects. Rajeev shares how true excellence starts with a clear purpose and a mindset that ties daily work to culture, leadership behavior, and engagement at every level.Rajeev explains why operational excellence must reach across all functions and up and down the organization. He breaks down the difference between firefighting and real problem solving, showing why consistent leadership, trust, and clear KPIs matter. Rajeev also shares practical ways to spot when teams slip into reactive habits and how leaders can build habits that drive prevention and continuous improvement.Looking ahead, Rajeev discusses how automation and machine learning are changing the landscape. He explains how technology helps lock down process variation, freeing teams to spend more time on meaningful problem solving and less on repetitive fixes. The conversation offers grounded advice for leaders aiming to build lasting improvement, not just quick fixes.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Julie Adkins, Senior Manager of Lean Transformation, Continuous Improvement, and Operational Excellence, to dig into what it takes to drive meaningful change on the plant floor. Julie shares how her team navigated the challenges of merging two manufacturing plants, building new processes from scratch, and setting daily routines that keep everyone focused on progress.Julie explains how daily improvement meetings, clear KPIs, and team alignment form the backbone of a strong operational culture. She highlights why consensus on key metrics matters and how data—while not everything—points to areas for real improvement. Julie also describes how her team moved from firefighting to building sustainable systems, using 5S and practical coaching to help everyone take ownership.Throughout the conversation, Julie stresses that change sticks when leaders invest in people, stay flexible, and set priorities that everyone can rally around. The episode offers a down-to-earth look at building buy-in, making data useful, and growing a culture where continuous improvement becomes part of everyday work.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Ishant Gajbhiye, Quality Manager at an automotive manufacturer. They explore how the role of quality shifts from being the “firefighting” team to becoming a true partner across manufacturing operations. Ishant shares how his day is a mix of plant-floor walks, cross-functional teamwork, and strategy—always focused on moving from reactive problem-solving to building long-term discipline and accountability.Ishant explains why quality isn’t just about finding defects or delivering bad news. Instead, he sees quality as the glue that connects production, engineering, and logistics. By involving quality early, sharing actionable data, and closing the loop on non-conformances, teams can turn audits and metrics into tools for growth rather than paperwork. He emphasizes that every dollar invested in quality pays back in risk reduction, process improvement, and real financial savings—making quality a value center, not a cost center.The conversation closes with practical advice for leaders who want to attract and keep younger talent. Ishant highlights the need for clear growth paths, high-tech tools, and a flexible, modern culture. He urges manufacturers to treat mentorship as a daily practice and to focus on communication that brings people together, not just checks boxes.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Dr. Rebecca Teeters, Senior Vice President of Business Supply Chain at 3M. They explore how real accountability and improvement take root on the shop floor and in leadership circles.Rebecca shares how daily standard work meetings drive her teams to reflect, learn, and act. She explains how “winning the day” depends on tracking the right metrics—ones that let operators and managers adjust in real time, not just measure after the fact. For Rebecca, true accountability comes when people see and own problems, and when leaders create systems that make this possible.The conversation digs into the balance between autonomy and standardization, the discipline it takes to coach instead of firefight, and why good systems—not heroic fixes—lead to lasting results. Rebecca leaves listeners with clear tools to help teams learn, adapt, and sustain progress in a demanding environment.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Ed Rocha, Quality Director at Schaeffler. They explore the practical realities of leading quality in manufacturing, from handling major escalated issues to organizing teams for better results. Ed shares how his job means finding strategy in the chaos—whether that’s breaking down big problems or making sure the right people own the work.Ed explains why quality teams succeed when they balance the voice of the customer with the needs of the business. He describes how a leader can set the tone by being the toughest critic in the room, but also by preparing teams to anticipate customer needs. Ed also dives into the importance of process audits and actionable ownership, using stories from his own experience to show how small lessons drive ongoing improvement.The conversation closes with a look at how quality leaders can avoid repeating the same year, and why adapting your language for executives makes your message land. Ed leaves listeners with a leadership lesson: focus less on having all the answers and more on building teams that learn to solve problems together.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Attrayee Chakraborty, Quality Systems Engineer at Analog Devices. They explore how quality teams can shift from a reactive, “firefighting” mode to a proactive, problem-solving mindset. Attrayee shares how she balanced urgent daily demands with long-term process improvements, using tools like quality plans and the Eisenhower Matrix to prioritize and get buy-in across teams.Attrayee describes her approach to building strong quality plans rooted in real user feedback, not just compliance. She explains how involving stakeholders early and often helps maintain engagement, even as priorities shift. The conversation covers the challenge of keeping people invested, the importance of making everyone feel heard, and the payoff of moving toward a culture where issues are solved before they grow.Attrayee also discusses the role of corrective and preventive actions (CAPA) and the need for clear problem statements, critical thinking, and accountability. She reflects on how AI can support documentation but can’t replace the human judgment needed for real quality improvements. Throughout, Attrayee offers practical advice for creating lasting change and building quality into every part of the process.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Bruce Gane, Safety Manager at Morrow Steel. Together, they explore the realities of managing safety in manufacturing, where production pressures often push safety down the list of priorities. Bruce shares his approach to creating a strong safety culture—one built on open conversations with employees, careful audits, and a focus on finding and fixing root causes before they become serious issues.Bruce explains why most injuries are preventable and why he avoids calling them accidents. He describes how real change starts when teams look beyond compliance and invite frontline workers to share ideas and concerns. Through stories from his career, Bruce highlights the challenges of balancing productivity, quality, and safety, emphasizing that companies often value output over worker well-being until it’s too late.Throughout the conversation, Bruce offers practical advice on building trust, recognizing warning signs of poor culture, and keeping safety at the table alongside quality and productivity. His philosophy centers on listening, acting on every concern—no matter how small—and making sure everyone goes home safe at the end of the day.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Rick Davis, Chief Manufacturing and R&D Officer at Morgan Foods. They explore how true culture and leadership shape daily life and long-term success in manufacturing. Rick explains why he focuses on people, quality, safety, and cost, but always starts by building trust and understanding what “winning” means for the whole team.Rick shares why culture is not just a slogan or a set of KPIs, but the foundation for sustained results. He describes the danger of “false culture” — where surface-level engagement masks deeper issues — and how real progress comes from empowering everyone to improve. He argues that leaders must listen, act on feedback, and involve people at every level to define success and drive change that lasts.Through stories from his own career, Rick highlights the value of mentorship, accountability, and making work easier for others. He closes with practical advice for leaders and frontline teams alike: invest in people, stay connected, and never underestimate the power of small actions to shift culture.

Many companies struggle with quality because they try to run before they can walk. They jump to sophisticated tools and systems before mastering the basics. This often fails to solve the root cause of their problems.In this episode of Shop Floor, Top Floor Talk Show, Josh Santo speaks with Thiago Roveri, Director of Quality at RR Donnelley. Thiago explains why a strong foundation is essential for any quality initiative. He outlines the "walking" basics all manufacturers should have in place. These include clear process mapping, disciplined root cause analysis, 5S programs, and creating a visual factory that speaks for itself.Thiago shares a powerful story about improving a factory's productivity from 60% to 90%. The team achieved this not by adding technology, but by addressing the operators' fundamental needs. Listen to learn how to assess your operation and build a quality culture from the shop floor to the top floor.

Quality departments often get viewed as the company police force, creating tension and conflict across manufacturing organizations. In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo speaks with Steve Povenz, former Director of Quality at Shape, who breaks down why this perception develops and how to fix it.Steve explains the root causes behind adversarial quality relationships. Competing metrics between departments create natural conflicts. When manufacturing gets measured solely on throughput while quality focuses on corrective actions, teams work against each other instead of together. Poor engagement from quality professionals who stay at their desks rather than on the shop floor makes the problem worse.Steve demonstrates how vulnerability creates partnership. He transformed a struggling plant by telling the operations manager that her problems became his problems. Steve joined every safety investigation and improvement effort, proving quality adds value beyond finding problems. The partnership delivered a 60% drop in customer incidents and major cost reductions.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with manufacturing executive JD Marhevko. They discuss the link between shop floor activities and business results. JD explains how process changes affect scrap rate, warranty, and efficiency. These factors directly translate into a company's margin and capacity.JD shares leadership lessons from her grandfather, a union tool and die maker. She explains why leaders must respect the expertise of frontline workers—the people with "chips in their shoes." This philosophy shapes her servant leadership approach. She identifies natural leaders within a facility and collaborates with them to solve problems systemically.To gain support for new initiatives, JD stresses the need to speak the language of business. She details her strategy of partnering with the finance team to prove the value of quality improvements. By presenting a clear, one-page proposal that shows financial impact, teams can secure the buy-in needed for change.

In this episode of the Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Gary Jing, Site Quality Manager at nVent, to discuss practical approaches to quality management in manufacturing. Gary shares his unique perspective, shaped by his experience in continuous improvement, operations, and quality roles. He emphasizes the importance of balancing stakeholder expectations with specifications, particularly in high-tech environments where rapidly changing technology can lead to misaligned goals.Gary introduces the concept of viewing quality through a "stakeholder lens," expanding the traditional customer focus to encompass everyone impacted by a product or process. He champions the combined use of Lean and Six Sigma methodologies as a powerful "one-two punch" for process improvement. Gary explains how Lean's straightforward approach, combined with Six Sigma's data-driven analysis, can create positive synergy.Finally, Gary highlights a common oversight in root cause analysis: the lack of consideration for return on investment. He suggests incorporating ROI assessment into root cause analysis and FMEA processes to better prioritize actions and align teams. This practical advice helps drive effective problem-solving and ensures that quality efforts contribute to overall business success.

Quality is often misunderstood. Many view quality control as a cost center, limited to inspections and reactive problem-solving. On this episode of the Shop Floor, Top Floor Talk Show, Mike Fank, quality manager at Wisconsin Metal Parts, challenges this narrow perspective with host Josh Santo. Mike argues for a broader view of quality, encompassing the entire organization, from the shop floor to the top floor.Mike emphasizes that quality should be a way of operating, not just a set of tools. He encourages a proactive approach where production teams own quality and use data-driven methods to improve processes. This shift requires clear communication and shared goals between quality and production. Instead of focusing on checking boxes, quality professionals should strive to build a quality culture.Mike highlights the importance of leadership support and continual improvement. He advocates for making quality easy and using tools like checklists to reinforce positive behaviors. By embracing these principles, organizations can transform quality from a burden into a driver of performance and a source of competitive advantage.

In this episode of Shop Floor, Top Floor Talk Show, host Josh Santo sits down with Daniel Castilla to discuss a mechatronics approach to quality management in manufacturing. Daniel, (Former) Director, Powertrain Quality & Customer Satisfaction, explains mechatronics as the intersection of multiple engineering disciplines, including mechanical, electrical, and software engineering, with a focus on systems thinking. He emphasizes the importance of considering the human element in these systems.Daniel highlights how quality management can benefit from a mechatronics perspective, advocating for a systemic approach that embeds quality throughout the entire process. He challenges the traditional view of quality as a separate function, suggesting it should be an integral part of the input, not just an attribute of the output. This holistic view promotes collaboration between different teams and specializations, breaking down silos and fostering a more integrated approach to problem-solving.The conversation also explores the common misperceptions about quality management and the role of technology in improving quality processes. Daniel touches on the importance of adapting communication to different stakeholders and overcoming the tendency to oversimplify complex challenges. He expresses excitement about the future of quality, particularly the advancements in Quality 4.0 and the potential of AI and digital twin technology.

What’s the difference between leadership and management—and why does it matter on the manufacturing floor?In this episode of Shop Floor, Top Floor Talk Show, Josh Santo sits down with Rich Nave, Chief Operations Officer at The Luminous Group, to break down how these two functions play very different roles in driving team performance. Rich shares why promoting strong managers isn’t enough, and how missing leadership skills can quietly stall improvement.Rich explains why leadership is about direction and inspiration, while management is about structure and execution. You’ll hear how lack of leadership can kill risk-taking, reduce team accountability, and lead to “check-the-box” behavior. Through real-world examples, he shows how leaders can inspire ownership—whether you’re tightening bolts or leading a design team.This episode is packed with practical takeaways for manufacturing leaders looking to create stronger teams and better results, from the shop floor to the top floor.

Welcome to the Shop Floor, Top Floor Talk Show! In this kickoff episode, host Josh Santo introduces what you can expect from the show—real conversations with manufacturing leaders who share hard-earned lessons, practical advice, and no-fluff insights to help you improve operations continuously. Whether you're on the shop floor or in the boardroom, this show is built to bridge the gap with tips you can actually use. Tune in to hear why we created the podcast, what’s coming up, and how you can get involved in the community.