AI That Actually Works on the Factory Floor with Mike Fedorov

Artificial intelligence is everywhere. Unfortunately, so is AI hype.

Manufacturers are hearing promises about smarter factories, automated planning, and AI-powered decision making. But what actually works inside a real manufacturing operation where data is messy, production schedules change hourly, and experienced employees solve problems machines never see coming?

In this episode of The Manufacturers Network Podcast, Lisa Ryan talks with Mike Fedorov, Co-CEO and COO of Applied AI Labs and former manufacturing leader at Mars and Accenture. Together, they cut through the AI buzzwords and focus on practical strategies manufacturers can implement today.

Instead of chasing shiny technology, Mike explains why successful AI projects begin with operational pain points, involve frontline employees from day one, and focus on delivering measurable business value quickly.

If you're wondering how artificial intelligence fits into manufacturing without replacing your workforce or sacrificing human judgment, this conversation is a must-listen.

What You'll Learn

• Why more than 80% of AI projects fail before delivering meaningful results
• How manufacturers can identify the best first AI project
• Why employee buy-in matters more than software selection
• The difference between AI demonstrations and real factory floor solutions
• How AI can improve production planning and sequencing
• Why dirty manufacturing data shouldn't stop your AI journey
• How experienced employees and AI create stronger decisions together
• The biggest mistakes companies make when implementing AI
• Why resilience still matters even in highly automated operations
• How manufacturers can begin using AI without a massive technology budget

Key Takeaways Solve Real Problems First

The best AI projects don't begin with technology.

They begin with the biggest frustrations employees experience every day.

Instead of asking, "Where can we use AI?" ask:

• What's slowing us down?
• What's costing us money?
• What repetitive work frustrates our people?

Those answers often reveal the highest-return automation opportunities.

Human Judgment Still Wins

AI is remarkably good at processing data.

Experienced people are remarkably good at recognizing when something doesn't feel right.

The future of manufacturing isn't AI replacing people. It's AI helping experienced employees make faster, better decisions while preserving the judgment developed over decades on the plant floor.

Don't Wait for Perfect Data

Many organizations delay AI because they believe their data isn't clean enough.

Mike argues that's the wrong approach.

Real manufacturing environments always contain incomplete, inconsistent, or messy data. The goal isn't perfection. It's building AI systems that can operate successfully in the real world.

Start Small. Win Early.

Manufacturers don't need million-dollar AI initiatives.

Choose projects that are:

• Easy to implement
• Highly valuable
• Capable of delivering measurable ROI quickly

Early wins build confidence throughout the organization and create momentum for larger AI initiatives.

AI Should Strengthen Your Workforce

The strongest manufacturing organizations combine:

• Experienced people
• Practical AI tools
• Operational expertise
• Continuous improvement

Technology doesn't replace great employees.

It helps them spend less time fighting systems and more time solving problems that matter.

Featured Guest

Mike Fedorov is the Co-CEO and COO of Applied AI Labs, helping mid-market manufacturers deploy practical AI solutions that improve operations, production planning, and business performance. Before founding Applied AI Labs, Mike spent 25 years leading manufacturing, supply chain, and consulting initiatives at Mars and Accenture.

Connect with Mike Fedorov

LinkedIn: Mike Fedorov

Applied AI Labs

Email: mike@aalc.ai

About The Manufacturers Network Podcast

Hosted by Lisa Ryan, CSP, founder of Grategy and author of Smart Plant: Aligning AI, Automation, and People, The Manufacturers Network Podcast features conversations with manufacturing leaders, innovators, and experts who are helping organizations build stronger cultures, improve employee retention, develop frontline leaders, and prepare for the future of manufacturing.

Whether you're a manufacturer, plant manager, operations leader, HR professional, or executive, each episode delivers practical strategies you can apply immediately to improve workforce performance and business results.

Keywords: AI in manufacturing, manufacturing AI, artificial intelligence for manufacturers, factory automation, manufacturing leadership, AI adoption, manufacturing operations, production planning, production scheduling, AI agents, manufacturing technology, digital transformation, frontline leadership, employee retention, manufacturing culture, operational excellence, Industry 4.0, smart manufacturing, production optimization, manufacturing workforce, manufacturing podcast, manufacturing innovation, manufacturing productivity, human judgment, manufacturing efficiency