Todd Kassal of Illinois: Bringing Quantum-Inspired Thinking to CK RubberTrack
How a Grounded Project Manager Is Leading Operational Innovation in Manufacturing
In Illinois, where production floors hum and time-sensitive deadlines shape every shift, Todd Kassal, Project Manager at CK RubberTrack, has quietly begun to redefine what it means to run an industrial operation. His secret weapon? Not machinery—but quantum-inspired thinking: using computational models born from quantum principles to improve forecasting, logistics, scheduling, and product development within a conventional manufacturing environment.
The Quantum Approach—Without a Quantum Computer
Quantum computing remains emerging and expensive—but Kassal doesn’t wait. Instead, he uses quantum-inspired algorithms: models that mimic quantum logic (e.g., combinatorial optimization and probabilistic scenario analysis) on classical hardware. By embracing these tools, CK RubberTrack can simulate thousands of variables, weigh trade-offs fast, and optimize real-time decisions: from inventory to workflows.
These aren’t theoretical experiments—they've replaced guesswork with data-driven agility.
From Static Forecasts to Probabilistic Planning
Historically, CK RubberTrack relied heavily on past sales data to set inventory targets. But in sectors like agriculture, construction, and municipal equipment, demand is increasingly influenced by unpredictable factors: commodity prices, weather patterns, infrastructure spending, and global supply disruptions.
Kassal's team introduced a quantum-style forecasting engine that evaluates dozens of real-world factors—seasonality patterns, macroeconomic conditions, raw-material lead times, and weather cycles—and outputs a range of possible demand scenarios (not just a single estimate). This probabilistic insight has:
• Improved forecast accuracy by 30–35%
• Reduced urgent purchasing events
• Lowered inventory carrying costs by ~25%
The shift helped CK RubberTrack avoid both overstock and stockouts, smoothing cash flow and improving production continuity.
Real-Time Supply Chain Resilience
Sourcing rubber, steel, adhesives, and reinforced materials from suppliers across Europe, Asia, and North America meant constant exposure to volatility. Shipping delays, regional disruptions, tariff changes—even port congestion—could derail production.
Kassal introduced a quantum-inspired supply chain model that forecasts supplier risk and evaluates route alternatives instantly. During a sudden global shipping slowdown, the system rerouted critical components through alternate sourcing hubs—reducing expected delays and costs. By proactively adjusting logistics, CK RubberTrack avoided over $200,000 in expedited fees while maintaining delivery commitments.
Optimizing Shop-Floor Scheduling with Quantum Logic
Production scheduling at CK RubberTrack is complex: multiple product types, machine changeovers, labor shift variability, and maintenance requirements. Traditional ERP systems offer rigidity—not flexibility.
Kassal deployed quantum-annealing-style schedulers that re-optimize production routines when parameters change—like late delivery, machine downtime, or labor shift updates. These systems calculate optimal sequencing for tasks, minimizing idle time and maximizing throughput.
After implementing this dynamic scheduling:
• Machine utilization increased by 20–25%
• Rescheduling incidents dropped 40%
• Rush job fulfillment speed improved significantly
Production runs became more reliable, with fewer bottlenecks and clearer coordination between teams.
Bringing Intelligence to Every Shift
A highlight of Kassal’s leadership is making complex logic accessible. Rather than dashboards loaded with charts, frontline staff receive clear, actionable prompts, such as:
• “Delay Job A to optimize shipping and save $2,500—approve?”
• “Swap job order to avoid tooling conflict—yes or no?”
• “Switch supplier based on availability changes—recommended?”
This human-centered design keeps workers informed, engaged, and in control, rather than overwhelmed. It builds trust and ensures the quantum models become a tool—not a burden—to the team.
Quantum Chemistry: Smarter Product Design
Kassal’s vision extends beyond operations to product innovation. CK RubberTrack is experimenting with quantum-inspired molecular simulations to model new rubber compounds for durability, wear resistance, and environmental variation—before blending materials in a lab.
This digital experimentation has:
• Cut R&D cycles by 50%
• Produced a new compound with 20% better abrasion resistance
• Generated custom formulas for different deployment climates
It’s material science accelerated: smarter rubber designed with insight rather than trial-and-error.
Fostering a Culture of Informed Innovation
Despite advanced tools, Kassal emphasizes culture over code. He led cross-department workshops, paired engineers with production staff for live pilots, and gathered feedback at every stage. Visual tools show outcomes—not probabilities—helping the whole organization engage with technical logic in an intuitive way.
The pause for understanding led to strong adoption: teams across procurement, forecasting, production, and R&D talk openly about “simulation scenarios,” “cost-versus-speed trade-offs,” and “schedule optimizations”—solid evidence of a data-driven mindset.
Tangible Benefits That Add Up
The impact has been measurable and meaningful:
• Inventory costs down ~30%
• Annual logistics savings exceeding $400K
• Production throughput gains of 18–25%
• On-time delivery consistently above 95%
• R&D lead times cut in half
These gains align directly with Kassal’s practical goals: higher efficiency, stronger margins, and improved customer reliability.