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Podcast Summary
In this episode of the Better Batch Podcast, hosts Alex Koves and Peter Suddard sit down with process improvement expert, Katie Gezon, to discuss how businesses—especially batch process manufacturers—can optimize their operations and transition effectively from small to medium, and medium to large.
Katie explains the importance of establishing a sustainable foundation, embracing a culture change, and moving away from reliance on “tribal knowledge.” She also offers practical advice for leveraging data, setting KPIs, and building processes that empower employees to work smarter, not harder.
Key Takeaways
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Culture Shift Fuels Growth
Moving from a “mom and pop” mentality to a structured, process-driven mindset is crucial for scaling. This pivot requires buy-in at every level of the organization. -
Document & Standardize
Writing down processes (SOPs) and converting “tribal knowledge” into standard procedures ensures consistency, reduces errors, and enables easy cross-training. -
Empower Your Workforce
Operators on the floor hold the key to continuous improvement. Involving them in creating or refining SOPs and encouraging knowledge-sharing fosters ownership and engagement. -
Set Meaningful KPIs & PIs
Your core Key Performance Indicators should be few and tied to top-level goals (cost, time, quality, safety). Let those KPIs cascade into specific Process Indicators owned by mid-level managers and operators. -
ERP Systems: Not Always First
While an ERP can revolutionize data collection and decision-making, it’s only helpful when you’re ready—i.e., when you have sufficient team size and established processes. -
Continuous Improvement & MCRS
A Management Control Reporting System (MCRS) provides a clear cadence of meetings and accountability. Consistent check-ins on KPIs and PIs keep your improvement efforts on track.
Actionable Tips
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List Out Your Core Processes
Identify the top 5–10 operational processes in your facility. Start standardizing them in collaboration with the operators who know them best. -
Pick 3–5 KPIs
Work with leadership to clarify the top-level goals (e.g., cost reduction, reduced downtime, improved throughput). Then determine which KPIs directly measure those goals. -
Create a Meeting Cadence
Establish regular intervals (daily, weekly, monthly) for discussing and acting on KPI/PIs data. Assign clear ownership to keep teams accountable. -
Plan for Cross-Training
Make sure no single individual holds all the knowledge. Map out coverage plans so operations continue smoothly during vacations or unplanned absences. -
Assess Your Readiness for ERP
If you’re still small, master the fundamentals first (e.g., consistent SOPs, base-level data). If you’re medium or larger and drowning in spreadsheets, explore ERP solutions to unlock advanced data insights.
About the Guest
Katie Gezon is a seasoned expert in alcoholic beverage operations, known for streamlining processes and boosting efficiency in distilleries, breweries, and beyond. With hands-on leadership roles at industry giants like Anheuser-Busch, Kraft Heinz, DöhlerGroup, and Joolies, Katie has mastered lean manufacturing, preventive maintenance, and clear communication practices.
Her deep experience in large-scale beverage manufacturing makes her the perfect guest to tackle complex production challenges. In this episode, Katie shares practical insights on managing operational efficiency—from the production floor up—while prioritizing quality and continuous improvement.
📧 Email: [email protected]
🔗 LinkedIn: Connect with Katie
About the Hosts
Alex Koves: As the President and CEO of Mar-Kov, Alex leads the charge in delivering purpose-built software tools that simplify complex manufacturing challenges. His background in operations management fuels his passion for helping businesses optimize their processes. Connect with Alex on LinkedIn.
Peter Suddard: Peter has worked with batch process manufacturers for years, helping them scale and improve their business. He has extensive experience ensuring customer success and driving product enhancements, making him an invaluable resource for manufacturers seeking to scale. Connect with Peter on LinkedIn.