Israeli Steel Manufacturer Reinvents Production Management Under Alexander Stone’s Leadership

“The manufacturing sector is under immense pressure to innovate and modernize its operations,” according to Info-Tech Research Group, an IT service management firm.

At the forefront of the innovation and modernization of the manufacturing sector is Alexander Stone, a production manager at Hod Assaf Industries Ltd., an Israeli steel fabricator. His leadership and strategic vision in production management, including the management of a diverse team of up to 50 people, provide valuable insights that can benefit executives at all levels.He has been instrumental in redesigning production systems and fostering team efforts among employees, making him an invaluable resource for anyone interested in the future of manufacturing.

As he shares his story, strategies for dealing with challenges, and the characteristics of a good production manager,  anyone, regardless of whether you are a seasoned professional or just starting your career in production, will gain from his valuable insights and inspiration.

Alexander, you’ve overseen some groundbreaking advancements at Hod Assaf, such as the complete overhaul of the control system of the electric arc furnace. Can you tell us about what exactly you did there? 

As a shift/production manager, I am responsible for the entire process cycle at Hod Assaf, which includes ensuring that quality control is top-notch while maintaining a safe working environment and minimizing our environmental footprint. But my interest lies mainly in the technical areas, where I am heavily involved in identifying and implementing state-of-the-art technologies and programs that transform our business processes.

One of my greatest achievements was when we did a complete overhaul of the control system of the electric arc furnace, starting from scratch with its integration with hundreds of sensors, making sure it runs almost seamlessly. This resulted in a significant boost in efficiency and production output. We have also successfully introduced gas purification systems that drastically decrease our environmental impact. These projects involved close collaboration with international specialists from around the world. Apart from that, my ability to adjust these technologies for our particular needs has played a vital role in their success.

It sounds like you thrive on challenges. What aspect of your job do you find most demanding? 

The hardest part is staying ahead of the game. Once a process has been optimized, there is no incentive to change anything. For me, it means always looking for new challenges and pushing the boundaries of production management. So basically, I test myself by coming up with new management problems and solving them using innovative solutions. A well-oiled operation is good, but when continued long-term stagnation sets in, professional regression may come about.

Can you elaborate on a specific technological hurdle you’ve overcome, such as the launch of a new electric arc furnace control system at Hod Assaf? 

The introduction of a new program for controlling an electric arc furnace, as well as additional systems and stations, was very challenging. We completely adapted it from scratch to all production processes, connecting each of the systems step by step; detecting and eliminating various problems; synchronizing various high-precision instruments such as the operation of electrodes; controlling water air pressure and electrical voltage; controlling electrode movements and gas purification; controlling valve systems and pressure flow intake air from the furnace of various kinds of compressors; and controlling electric trolleys, an oxygen supply robot, hundreds of secondary sensors of thermal cables, and secondary systems. This was mind-boggling and it took months of hard work and collaboration with engineers and programmers from different parts of the globe. But through overcoming those challenges bit by bit, we were able to have a fully operational system, which greatly enhanced our production capabilities.

You talked about being very strong in managing people. For example, your team includes about 40-50 people from different countries around the world. So, hHow do you create a thriving work environment with such a diverse team? 

Balance is very important. I aim to have a friendly atmosphere where people feel supported and take an active role in their jobs. It’s more than just being the boss; it’s about being the leader who motivates and inspires his team members. My team includes about 40-50 people of different nationalities. Hence, fostering comradeship among the members is extremely critical. To boost teamwork and communication, I participate actively in organizing corporate events and team-building exercises. This has been a major contributor to our success.

As you look back at your remarkable career with Hod Assaf, can you say you’re most proud of launching the new electric arc furnace control system, a ground-up system that incorporated hundreds of sensors to ensure uninterrupted operation? 

That’s a good one. It’s hard to pick out just one achievement. Completely renovating the control system for the electric arc furnace was something else. However, it increased the efficiency of our operations significantly, thus raising our manufacturing output considerably. The technical challenges were many, but I am grateful for the team’s commitment and dedication towards the implementation of such a sophisticated initiative.

Moreover, I have also taken pride in building an internal management structure that is effective at Hod Assaf. This included creating a comprehensive reward system that motivates employees to perform highly on a regular basis. We have also implemented a strong personnel control system that ensures that each person fits into his or her position with the right skills and knowledge. These have had major impacts on overall productivity and success at the company.

Nonetheless, it is crucial to note that my wonderful team made this all possible. I derive immense satisfaction from having established a workplace where people feel appreciated, empowered, and motivated enough to give their best as far as they are concerned. Finally, it is very rewarding watching my team work together seamlessly, overcome challenges together, and still manage to deliver outstanding results consistently; these are indicators of the strong team culture we’ve nurtured at Hod Assaf.

The world of production management keeps changing. In your opinion, what future trends do you see? 

Digitalization and automation are key drivers here. New technologies offer great potential for optimizing processes and simplifying production procedures. Another trend is a growing emphasis on environmentally friendly practices, which is reflected in such advancements as cleaner gas purification systems, and I’ve been actively involved in introducing them myself lately.

However, these changes will not be enough because we expect an even broader consolidation of these trends into one concept. Imagine production lines supported by artificial intelligence capable of self-optimization, identification of maintenance problems before they occur, or minimization of waste generation during industrial processing stages. Additionally, sustainability will become an absolute requirement, requiring expertise in environmentally friendly technologies and regulations.

Why is the role of a production manager so crucial? 

Production managers are the unseen conductors in any manufacturing operation. Their obligations are numerous, including supervising technical processes, running divisions, managing finances, and ensuring safety. It’s a tough job that requires a range of different skills and the capacity to adjust to an ever-changing context. This adaptability will be even more important in the future. They will have to keep on upskilling themselves throughout their careers so that they can stay ahead of technological advancements and also through the regulatory monitoring maze.

What advice would you give to companies looking to improve their production processes, considering your extensive experience in production management? 

Continuous improvement is essential for competing in today’s market environment. Therefore, my primary suggestion would be to embrace innovation. One must not shy away from investing in new technologies and systems that enhance efficiency within operations, thus simplifying them. Automation and digitalization, among others, are always continuously evolving; hence, new techniques emerge all the time, which can change how things are done at factories or processing plants.

However, it is worth mentioning that technology alone is not everything. A solid team must be in place to effectively initiate and manage such changes. Invest in your people, create new training opportunities aimed at developing their skills, and stay updated with the latest advancements. Foster a culture of continuous learning where team members are encouraged to experiment with new ideas and engage in improvement processes. This way, you can have a more committed workforce that will eventually lead to long-term success.

Any advice for anyone wanting to be a production manager? 

Be well-rounded. You must possess strong technical knowledge while also being good with people. Don’t shy away from taking on challenges, embracing new projects, or even actively looking for ways through which you can learn and improve yourself further. Initiative and the willingness to step out of one’s comfort zone should never be substituted by anything else. In the years ahead, these will be more significant traits than ever before. Furthermore, aspiring production managers should also foster an openness towards new technologies and a commitment to sustainability.

What do you think your future holds? 

It’s always an opportunity for me to step out of my comfort zone and take up new projects. I see myself climbing the corporate ladder to higher management roles, possibly within other organizations or even in other industries. These are also possibilities: educating people and possibly founding my own company to transform production methods in various industries. Therefore, my long-term vision is to be among the pioneers bringing about these exciting changes in the field of production management.

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