Episode 24

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Published on:

31st Aug 2026

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

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About the Podcast

The Manufacturers Network
Real conversations with leaders in manufacturing, automation, and workforce retention.
The Manufacturers’ Network is where manufacturing leaders, plant managers, and industry innovators come to talk straight about what’s working and what’s not, on the shop floor and beyond.

Each week, host Lisa Ryan sits down with people who live and breathe this business: operations executives, HR directors, engineers, and founders who are building stronger teams and smarter systems in the face of nonstop change.

Listeners gain real-world insights on:
• Employee retention and workforce engagement
• Automation, AI, and the future of skilled trades
• Supply chain and operations leadership
• Safety, sustainability, and company culture that lasts

If you’re tired of generic “leadership talk” and want practical conversations from people who get it, this podcast is for you.

New episodes drop every Monday and are short enough for your commute, sharp enough to shape your week.

Subscribe and be part of the conversation that’s connecting manufacturers across industries, one story at a time.

About your host

Profile picture for Lisa Ryan

Lisa Ryan

As a Certified Speaking Professional (CSP), an award-winning speaker and author of ten books, Lisa Ryan, CSP, works with her clients to develop employee and client engagement initiatives and strategies that keep their top talent and best clients from becoming someone else’s.
Lisa’s expertise includes: strengthening workplace culture, improving employee engagement, increasing customer retention, and initiating gratitude strategies (“Grategies”) for personal and professional benefit. Lisa’s participants enjoy her high energy, enthusiastic delivery and quick wit and they leave the session with ideas they are committed to acting on immediately to make positive workplace culture changes.
Lisa costars in two films with other experts including Jack Canfield of “Chicken Soup for the Soul.” She is the Past-President of the National Speakers Association, Ohio Chapter and holds an MBA from Cleveland State University.

Relevant Experience

• Keynote, breakout or workshop speaker at more than 100 national and international conferences
• Thirteen years of industrial marketing and sales experience, including seven years in the welding industry – and yes, she does weld
• Host of “Elevate Your Engagement Levels: What You Need to Know” on the Elite Expert Network and the C-Suite Network
• Creator of “The Seven Mistakes Managers Make to Crush Company Culture” video series
• Best-selling author of ten books, including “Manufacturing Engagement: 98 Proven Strategies to Attract and Retain Your Industry’s Top Talent”
• Award-winning speaker