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Powering the Process℠ is a podcast for engineers, plant managers, and operations leaders focused on industrial systems, plant optimization, and manufacturing efficiency. Hosted by ProcessBarron experts, each episode delivers practical insights on material handling, air and gas systems, industrial equipment, and reducing downtime.
Jen Little:
This podcast is brought to you by ProcessBarron. Handle everything better. Welcome to Powering the Process℠, the podcast focused on the real work behind industrial manufacturing. Each week, we explore the systems, equipment, and strategies that keep plants running efficiently, from everyday operational challenges to emerging engineering solutions. Our goal is to share practical insights that help keep your process moving.
Let’s get started.
Welcome to Powering the Process℠, where we share the stories behind the people and processes that keep America’s industries moving. Today’s episode is all about manufacturing excellence, what it means, how it’s achieved, and why it matters.
At ProcessBarron, manufacturing excellence isn’t just a goal; it’s a standard we live by every day. Recently, we were honored with the Birmingham Business Journal’s Excellence in Manufacturing Award, a recognition that reflects the hard work, innovation, and dedication of our entire team.
So what does manufacturing excellence really look like? It’s precision at every step, reliability in every system, and a culture that never settles for “good enough.” In this episode, we’ll explore what drives our commitment to excellence, how our people make it happen, and why it’s the foundation of everything we do.
Joining me today is Michael Stewart, Vice President of Manufacturing at ProcessBarron. Michael has been with the company for nearly nine years. Michael, thanks for being here.
Michael Stewart:
Thanks for having me, Jen. I’m excited to be here and part of the conversation.
Managing Large-Scale Manufacturing Operations
Jen Little:
I want to start with the scope of our operations. We have more than 120,000 square feet of manufacturing space. What is it like managing that day to day?
Michael Stewart:
It really comes down to organization and structure. We operate across two facilities, each led by a plant manager, with clear leadership and accountability beneath them. We use a cellular manufacturing approach, with lead personnel assigned to specific areas.
From scheduling and order entry to engineering and production, alignment across the organization is critical. Every day, everyone needs to understand the goals, not just for that shift, but for the week and the month. Consistent communication across departments is what keeps everything moving smoothly.
Jen Little:
That sounds like a lot to manage.
Michael Stewart:
It can be. Every day brings new challenges, but we rely heavily on daily shift huddles to keep everyone aligned. Those huddles ensure each team member knows what’s expected and how their work contributes to meeting customer expectations, which is ultimately what matters most.
Defining Manufacturing Excellence
Jen Little:
So what does manufacturing excellence mean to you personally?
Michael Stewart:
It starts with alignment between people, processes, and purpose. In manufacturing, that means precision at every step. My team picks up after order entry, beginning with detailed engineering. If the engineering isn’t right, everything downstream is affected.
Excellence also means reliability, delivering high-quality products on time, every time. Quality is non-negotiable. It’s built into every step of the process, not something we check at the end. And it’s driven by pride. Our team understands that the equipment we build is critical to our customers’ operations, and that responsibility matters.
Recognition and What It Represents
Jen Little:
What did winning the Birmingham Business Journal’s Excellence in Manufacturing Award mean for the team?
Michael Stewart:
It was a tremendous validation of the work done across the entire organization. While it’s labeled a manufacturing award, it reflects the efforts of the whole company, from engineering and sales to pricing, execution, and communication.
Having an external organization recognize our commitment to quality and reliability is an honor. It motivates us to keep improving and to build on what we’ve already accomplished.
Robotic Welding and Automation
Jen Little:
One major innovation over the last few years has been robotic welding. Can you talk about that?
Michael Stewart:
Absolutely. Robotic welding has had a very positive impact. We’ve also upgraded manual welding equipment with advanced controls and feedback systems, but robotics has brought greater consistency to certain applications.
The challenge for us is that we operate in an engineer-to-order environment, not a high-volume production line. Traditional robotic programming doesn’t always make sense. That’s why we adopted no-code robotic systems, where the robot learns directly from the operator instead of requiring hours of programming.
This allows us to quickly deploy robots for custom work, improving speed, repeatability, and in many cases, weld quality.
Cobots, Flexibility, and Workforce Impact
Jen Little:
Are the robots used for specific products, or do they vary?
Michael Stewart:
Both. We use two types of robots: industrial robots for more repetitive, moderate-volume work, and collaborative robots, or cobots, that are portable and flexible. Cobots can be moved to large components like ductwork or fan housings and programmed right on the shop floor.
There was some initial concern from employees that robots might replace jobs. But that wasn’t the case. Over time, the team saw that robots are simply another tool, one that adds capacity and frees skilled welders to focus on more complex, technical work.
Quality, Safety, and Accountability
Jen Little:
How do you ensure quality standards stay consistent with automation?
Michael Stewart:
All welds, robotic or manual, are held to the same standards. Our inspectors are Certified Welding Inspectors (CWIs), trained to evaluate penetration, adhesion, and overall weld integrity. Quality expectations never change.
We also emphasize quality at the source. Fixing an issue in engineering is far more efficient than fixing it after fabrication. We empower employees to speak up if something doesn’t look right, rather than passing problems downstream.
Jen Little:
And safety plays a big role as well.
Michael Stewart:
Safety is our top priority. It’s one of our core values. We reinforce it through daily and monthly safety meetings and by giving every employee stop-work authority. Anyone from a new hire to the CEO can stop work if something isn’t safe.
That empowerment, along with mentoring and coaching, especially for newer team members, is critical in an environment where we’re handling large, heavy equipment.
Developing the Next Generation
Jen Little:
It sounds like mentorship is a big part of your culture.
Michael Stewart:
It is. Mentorship happens across the organization, not just for safety, but for quality and craftsmanship. We pair experienced employees with newer team members and invest heavily in training and development.
We also partner with local community colleges and run apprenticeship programs in welding and machining. Some are formal Department of Labor programs, others are internal, including tuition support with long-term commitments. Developing skilled talent is essential to our future.
Continuous Improvement and What’s Next
Jen Little:
What innovation has had the biggest impact on manufacturing performance?
Michael Stewart:
Beyond automation, it’s been process discipline. Over the last few years, we’ve focused heavily on improving process flow, eliminating waste, and driving continuous improvement. That focus has improved quality, efficiency, and our ability to deliver on time.
Jen Little:
As we wrap up, what’s next after the Excellence in Manufacturing Award?
Michael Stewart:
The award is a milestone, not a finish line. Excellence means continuous improvement, reducing waste, improving processes, and staying competitive. Our goal is to remain a trusted partner for customers by delivering reliable, high-quality equipment they can depend on for decades.
Jen Little:
Michael, thank you for joining us and for everything you do.
Michael Stewart:
Thank you. I really enjoyed it.