In this episode of The Allied Advisors Podcast, Justin sits down with Rob Tykal—former President, COO, and VP of Global Operations at organizations like Danaher, GM, Daimler, and Superior Industries—for a deep, practical conversation on supply chain, materials management, and leadership.

While the video recording unfortunately cuts out around the 29-minute mark (lesson learned on DSLR limits), the insights captured are pure gold. Rob breaks down why forecast-driven systems consistently fail manufacturers, how consumption-based replenishment actually works in practice, and why great operational leaders must live at the gemba—not just in spreadsheets.

From Kanban design levels and safety stock logic to humility in executive leadership, this episode is a masterclass for mid-market manufacturers looking to improve flow, reduce inventory risk, and build sustainable operational cultures.

🎧 Full audio is intact, and Rob will be back for a follow-up episode.

⏱️ Episode Highlights

• Why all forecasts are wrong—and why companies still rely on them
• The grocery store analogy that perfectly explains pull-based replenishment
• How Kanban design levels eliminate the “cut inventory” debate
• Why excess inventory and stockouts usually coexist
• The real cost of expiration dates, obsolete material, and long lead times
• What executives must learn to see on the shop floor
• Why humility is the most underrated leadership trait
• How smaller manufacturers can outperform large enterprises operationally
• The difference between tools, systems, and culture—and why culture wins

🧠 Key Takeaways

• Forecasts are necessary but unreliable—consumption should drive replenishment
• Properly designed pull systems self-regulate inventory levels
• Leaders must understand materials deeply; intelligence cannot be delegated
• Inventory problems are rarely downstream issues—they’re leadership issues
• Smaller companies have agility advantages if they execute correctly

👤 About the Guest

Rob Tykal is a seasoned operational executive with decades of experience leading global manufacturing organizations. He has held senior leadership roles across automotive, industrial, and life sciences sectors and is widely respected for his ability to pair rigorous lean systems with people-centered leadership. Rob is known not just for improving processes—but for building cultures that sustain them.

📌 About the Podcast

The Allied Advisors Podcast is for mid-market manufacturers focused on scaling operations, improving material flow, and driving measurable bottom-line results. Hosted by Justin Goethe, each episode features operators, executives, and investors who’ve been in the trenches—and know what actually works.

🔔 Call to Action

If this episode resonated with you:

• Follow The Allied Advisors Podcast on your favorite platform
• Share this episode with a fellow operator or supply-chain leader
• Reach out to Allied Advisors if you’re ready to rethink inventory, flow, and execution