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From ROI to Reality — Measuring Success After You Automate, Ep #32

Lights Out: Technology and Automation Podcast by MakingChips

Release Date: 01/16/2026

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More Episodes

Automation doesn’t end when the system is powered on. In fact, that’s often where the real work begins. In the third and final episode of this Lights Out series, the conversation shifts from planning and justification to execution, measurement, and long-term performance.

After covering market forces driving automation adoption and breaking down ROI math in the first two episodes, this installment tackles the question many shop owners wrestle with once automation is live: Is this actually working? Dave Vuyk and Eric Nekich dig into how to validate performance, track meaningful metrics, and avoid leaving ROI on the table after implementation.

Rather than chasing dozens of KPIs, the discussion focuses on practical measurement frameworks that connect directly back to the original business problem automation was meant to solve. From labor efficiency and throughput to OEE and cost per unit, the hosts explain how to create visibility without overwhelming leadership or alienating the shop floor.

This episode also explores the human side of post-automation success. Metrics aren’t meant to be surveillance tools. When used correctly, they become shared scorecards that drive engagement, continuous improvement, and ownership across the organization. For shops serious about lights-out manufacturing, this final chapter reinforces a simple truth: automation only delivers value when outcomes are measured, understood, and continuously improved.

You will want to hear this episode if you are interested in...

  • (0:00) Recap of the three-part automation ROI series
  • (2:03) The risk of flying blind without a measurement framework
  • (3:20) Why tracking everything dilutes ROI visibility
  • (3:58) Tying KPIs back to the original business problem
  • (4:46) Core automation KPIs tied to ROI calculations
  • (6:08) What realistic ROI looks like 90 days after implementation
  • (6:45) Join us at the 2026 IMTS Exhibitor Workshop
  • (8:52) Why labor savings alone don’t tell the full story
  • (10:55) Manufacturing cost as a percentage of revenue
  • (11:44) Translating KPIs into shop-floor language
  • (12:50) Capacity gains, lead times, and customer impact
  • (13:39) Breaking down OEE into availability, performance, and quality
  • (16:36) How fixturing and workholding affect automation ROI
  • (18:46) Process reliability, chip management, and coolant considerations
  • (20:06) Why ROI ownership must extend beyond leadership
  • (21:22) Why we love SMW Autoblok for workholding
  • (22:33) Benchmarking without falling into the comparison trap
  • (25:36) Industry averages for OEE, OTD, and cycle time reduction
  • (27:40) Crawl, walk, run expectations for lights-out automation
  • (29:52) Change management and shop-floor buy-in
  • (34:24) Three post-implementation actions to lock in ROI
  • (38:56) Use Hire MFG Leaders for your next hire

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