In early June, something remarkable happened in Columbia, South Carolina. FN America, one of the world’s premier firearm manufacturers, opened its doors not just for a typical plant tour – but for a first-of-its-kind, multi-day Kaizen event hosted through the OpExChange. It marked an exciting new chapter for this South Carolina manufacturing network that, for the past twenty-three years, has connected peer manufacturers to share best practices, benchmark operations, and help drive continuous improvement.
The OpExChange is a unique program under the South Carolina Manufacturing Extension Partnership (SCMEP), built on the simple but powerful idea that manufacturers learn best from one another. For over two decades, the program has been fostering collaboration among manufacturers of all sizes and industries – helping them grow through operational excellence, lean manufacturing, and leadership development.
This four-day event at FN America was the first Kaizen event organized under the OpExChange banner. Unlike typical OpExChange visits, which are three-to-four-hour benchmarking events, this initiative was immersive and hands-on. FN America, an active OpExChange member for nearly fifteen years and a two-time “Most Engaged Company of the Year” recipient, was the perfect host for this groundbreaking event.
An Opportunity to Learn – and See
The event, led by SCMEP Process Improvement Coach David Woods, aimed to do two things:
- Train participants to identify waste using Lean manufacturing principles – particularly the eight wastes – and implement standard work.
- Identify improvement opportunities within FN America’s M240 machine gun assembly operation.
It was not a classroom exercise. After a brief introduction to Lean fundamentals, teams of participants – made up of FN America associates and OpExChange members from companies including Alimex Precision in Aluminum, BOMAG, Champion Aerospace, Ebara Pumps, Polydeck Screen, Southern Fabricators, and Ulbrich Specialty Wire Products – hit the shop floor. They studied the assembly processes, observed operator workflows, and practiced “learning to see” waste and inefficiencies.
“Learning to see,” as David emphasized, is the cornerstone of building a Lean culture. It means training your eyes to recognize non-value-added activity – the waiting, excess motion, overproduction, and other forms of waste that silently erode operational performance. David Woods, a process improvement coach with the SCMEP for the past thirteen years, brought more than three decades of lean manufacturing expertise to this event. His background includes time with industry leaders Toyota and Danaher, two organizations widely recognized for shaping and advancing lean manufacturing principles. David skillfully guided the team through the Kaizen process, sharing his deep knowledge and practical experience every step of the way.
Culture That Resonates
What struck participants most was not just the impressive machinery or the exacting standards of precision – it was the culture. Throughout the week, visitors consistently commented on the pride, professionalism, and camaraderie of FN America’s workforce.
John Benenhaley, a 14-year production supervisor with FN America, summed up that passion in an emotional moment during the final presentations. “I’ve got the best job in the world,” he said, holding back tears. “We take a lot of pride in what we do. Every day, we help protect the world.”
This deeply ingrained sense of purpose was evident not just on the production line, but among leadership as well. During the closing session, FN America Chief Operating Officer Mark Hoosier thanked the Kaizen teams for their input. “It’s really not hard for us to open our doors and let you bring critique,” he shared. “Being comfortable with critique and processing it is what helps all of us grow as individuals and as leaders.”
One of the participants asked Mark how they could return to their own plants and positively influence the culture there. In response, he left the group with a powerful message: “Culture is the sum of our individual behaviors. Every one of us shapes the culture in our workplaces and in our homes. Go home, treat people with that same mindset, and use these tools as opportunities to help others grow.”
Impact Beyond the Factory
The event was a win on all fronts. FN America received actionable recommendations to improve efficiency in its M240 assembly process. Participants gained valuable, transferable skills in Lean thinking, identifying waste, and implementing standard work – lessons they could immediately take back to their own operations.
One participant noted how unique it was to practice these skills in an unfamiliar industry yet still be able to apply Lean fundamentals effectively. Another said it was one of the most valuable learning experiences of their career.
Kaitlyn Leduc, Continuous Improvement Manager for FN America, said she could talk for hours about how much she learned during the week. She praised David Woods’ instruction and was already messaging colleagues by day two about what she was learning.
The Bigger Picture
This event also highlighted the vital role of standard work in manufacturing. As David Woods taught, standard work is more than a set of instructions – it is the foundation for stability, safety, and continuous improvement. It minimizes process variation, ensures consistent product quality, and serves as the baseline for any future improvement efforts.
In South Carolina where manufacturing is a leading economic driver, these Lean fundamentals have relevance for every manufacturer – regardless of size, industry, or current culture.
The OpExChange and SCMEP remain committed to supporting that mission to help South Carolina manufacturers grow. As David Woods reminded the group, opportunities for improvement exist everywhere – if you learn to see them.
Final Thoughts
Perhaps the most inspiring takeaway from the week was not a Lean tool or a manufacturing insight, but a simple philosophy: the pursuit of excellence and the humility to recognize there’s always room to grow. FN America, one of the best at what they do, proved that greatness is not about perfection – it is about the courage to keep getting better.
For South Carolina manufacturers interested in embarking on their own Lean journey, David Woods and SCMEP stand ready to assist. And for those who have yet to experience the OpExChange, events like this prove just how transformative collaborative learning can be.
About FN America
FN America, LLC is a leading U.S.-based firearms manufacturer with a proud history of supplying high-quality, precision-engineered weapon systems to military, law enforcement, and commercial markets. A subsidiary of the globally respected FN Herstal of Belgium, FN America operates its primary manufacturing facility in Columbia, South Carolina, where it produces some of the most trusted firearms in the world.
Best known for iconic products like the M240 and M249 machine guns, the FN SCAR® series, and the FN 509® family of pistols, FN America has earned a reputation for uncompromising performance, innovation, and craftsmanship. Their weapons are relied upon by U.S. military forces and allied agencies around the globe.
Committed to continuous improvement and operational excellence, FN America combines advanced manufacturing technology with a highly skilled workforce to uphold the highest standards of quality and reliability. Beyond its manufacturing leadership, the company fosters a culture of pride, respect, and continuous learning – qualities that were evident to all who participated in the recent OpExChange Kaizen event.
About the OpExChange
The OpExChange, a program of the South Carolina Manufacturing Extension Partnership (SCMEP), is a dynamic peer-to-peer network of manufacturers and distributors across South Carolina. For over 23 years, this collaborative group has helped member companies improve performance through benchmarking, best practice sharing, and collective learning. Member companies regularly host site visits and events, offering real-world examples of industrial automation, lean manufacturing initiatives, workforce engagement, and leadership development. It is an invaluable resource for South Carolina manufacturers seeking to learn from others on similar operational excellence journeys.
If your company is interested in joining this collaborative effort to strengthen both your operation and South Carolina’s manufacturing community, reach out to Mike Demos at mdemos@scmep.org. Visit www.OpExChange.com for more information on joining and a list of upcoming plant visits.
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