Smart Manufacturing That Works: Tim Stuart on Fixing Digital Chaos in U.S. Factories

Share this episode

In This Episode

In the latest episode of The Disrupted Factory, we hear from Tim Stuart, founder of Visual Decisions and a veteran of American manufacturing. With decades of experience at Black & Decker, Cummins and Toyota, Tim brings a straight-talking, no-nonsense perspective to the challenges of making smart manufacturing stick in real-world factories. He shares how digital tools can power Lean Six Sigma improvements without overwhelming teams with admin work or falling into a checkbox culture. Instead, Tim focuses on building digital strategies that empower thinking employees on the floor and drive meaningful adoption. Drawing on his years spent on the factory floor, Tim unpacks why data alone is not enough, how to avoid vendor-driven chaos, and the importance of practical leadership in digital transformation. We also explore how the U.S. Smart Manufacturing Institute is helping democratise digital adoption and what makes a consultant credible in the eyes of factory workers. If you are involved in operations, continuous improvement or digital transformation, this episode delivers honest, hard-earned insights from someone who has walked the walk.

Episode Guests

Tim Stuart is a recognised expert in Smart Manufacturing and Digital Lean Transformation, with more than 32 years of experience across manufacturing, engineering, consulting and business leadership. As the founder and president of Visual Decisions Inc., Tim has guided numerous organisations in leveraging data-driven strategies to optimise operations, strengthen supply chains and implement Industry 4.0 solutions. With extensive leadership roles at Black & Decker, Cummins and Toyota North America, Tim’s career has been built at the intersection of shop floor experience and digital innovation. His expertise combines Lean Six Sigma, digital transformation, AI-driven analytics and industrial IoT to help companies drive operational excellence. Tim is acknowledged by CESMII, the U.S. Smart Manufacturing Institute, as a leading expert in the field, having led more Smart Manufacturing Roadmap projects than any other external consultant. He is also collaborating with CESMII to define the standard training curriculum for Digital Lean. A sought-after speaker, consultant and educator, Tim has designed and delivered executive training programmes on smart manufacturing, data analytics and digital innovation. He holds a master’s degree in Operations Research from the University of Illinois Urbana-Champaign, along with certifications from Rensselaer, MIT, Stanford and other top institutions. Passionate about bridging the gap between traditional lean principles and modern digital capabilities, Tim empowers companies to achieve sustained competitive advantage in an increasingly connected world.

Related Podcasts