Lights Out: Technology and Automation Podcast by MakingChips

Inspiring and teaching Manufacturing Leaders in the areas of automation.

How to Calculate Automation ROI — The Right Way, Ep #31 12/26/2025

How to Calculate Automation ROI — The Right Way, Ep #31 Automation is exploding across the manufacturing world, but the real differentiator isn’t the robot, pallet pool, or software you buy—it’s whether you know how to calculate ROI the right way. In this episode of Lights Out, we break down the financial side of automation in plain language so every shop owner, operator, and leader can make smarter investment decisions with confidence. This is the follow-up to our baseline episode, where we had listeners identify their current spindle utilization, setup times, labor load, and cost per part. Now we take the next step: turning those numbers into an ROI model that actually reflects how automation performs on the shop floor. Instead of guesswork, gut instinct, or “we tried that once,” we show you how to quantify annual savings, increased capacity, reduced scrap, payback period, and more. We simplify the math in a way that works for high-mix job shops, multi-shift production cells, and every workflow in between. Whether you’re evaluating a robotic tending system, a pallet pool, high-density workholding, or a Cobot, understanding the financial impact of your decision is the foundation for long-term, scalable automation success. With real scenarios, honest discussion, and a few holiday-season laughs (including Nick’s mysterious disappearance), this episode gives you the practical tools you need to approach automation with clarity—not confusion. If you want to make 2026 your most efficient year yet, start by calculating ROI the right way You will want to hear this episode if you are interested in... (0:23) How ProShop ERP delivered rapid ROI in Mike Payne’s shop (2:49) Today’s focus on ROI and key metrics (4:15) Review of required baseline data including utilization, setup time, labor load, and cost per part (6:32) Breakdown of the simple ROI formula and the more detailed expanded formula (8:53) ROI Example: Labor savings, increased spindle hours, and scrap reduction (12:39) Method for calculating labor savings using remaining labor percentage (13:45) Why you should use Hire MFG Leaders for your next hire (14:16) Converting increased machine utilization into measurable financial value (15:02) Impact of pallet pools and high-density workholding on cutting setup and changeover time (16:49) Importance of including maintenance, programming, and depreciation in ROI models (19:38) Role of adaptive feed-rate controls in improving uptime and process reliability (21:57) ROI scenarios for robotic tending cells and five-axis pallet pool systems (24:18) Value of redeploying skilled operators to higher-impact work as part of automation ROI (25:16) When Cobots are an appropriate automation choice and when integrators are necessary (27:18) Key homework steps: running a basic ROI estimate and identifying utilization gaps (29:32) Why you need to check out the SMW Autoblok catalog Resources & People Mentioned How delivered rapid ROI in Mike Payne’s shop Why you should use for your next hire Why you need to check out the The Core ROI Formula for Automation Simple version: ROI (%) = (Annual Savings – Annual Costs) ÷ Investment × 100 Expanded version for manufacturing: ROI = [(Labor Savings + Increased Machine Utilization + Scrap Reduction + Overtime Avoided) – Maintenance & Depreciation] ÷ Capital Cost Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/39338705

The Automation Adoption Boom: Why ROI is the 2026 Metric That Matters, Ep #30 12/12/2025

The Automation Adoption Boom: Why ROI is the 2026 Metric That Matters, Ep #30 Before a shop can automate confidently, it has to understand one thing clearly: ROI drives every great automation decision. In this episode of Lights Out, David Vuyk and Eric Nekich kick off a multi-part series on Automation ROI—focusing not on hype or shiny tech, but on the real metrics and methods that determine whether automation will pay off or become an expensive paperweight. With “Jolly St. Nick Goellner” out preparing for the holiday season, David and Eric take the mic to break down a critical truth: you cannot automate an unreliable process, and far too many shops are buying robots before they fix the fundamentals. From workholding to setup reduction to operator loading, the guys lay out the baseline measurements every shop must capture before investing in automation. They also explore why automation adoption surged 30% this year and how reshoring, labor shortages, and rising demand are pushing shops to think differently about their processes. But enthusiasm alone isn’t enough—what separates successful adopters from fence-sitters is the ability to quantify ROI quickly and accurately, not in a vacuum, but across the entire upstream-downstream workflow. This episode serves as the foundation for the ROI model the hosts will build in Part 2. You’ll walk away knowing which numbers matter, how to capture them (even with pen and paper), and how to prepare your shop for real automation readiness. And yes…you’ll also get your homework. You will want to hear this episode if you are interested in... (0:00) Why automation fails when processes and fixturing are unreliable (0:12) Why we love SMW Autoblok for workholding (2:18) Launching the Automation ROI series and framing the conversation (3:42) Industry trends driving a 30% rise in automation adoption (6:31) Fence-sitters, misconceptions, and why ROI must lead decisions (7:29) Step one of ROI: defining the process and the goal behind automation (11:03) Why ROI must include upstream and downstream impacts (13:46) Common automation failures, cobot misuse, and “coat hanger” systems (16:44) Core ROI foundations and costs affected by automation (17:43) Partner with Verdant Commercial Capital for financing (22:35) Metric #1: Measuring spindle utilization accurately (25:22) Metric #2: Understanding setup time and the role of modular workholding (28:50) Metric #3: Operators per machine and multi-machine tending (31:18) Metric #4: Labor cost per part and machine burden calculations (32:18) Metric #5: Remaining Labor Percentage and what “good” looks like (35:34) Homework: identify bottlenecks and capture current-state metrics (38:14) Make your next hire with Hire MFG Leaders Resources & People Mentioned Why we love for workholding Partner with for financing Make your next hire with Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/39338620

Facing the Future: Automation Truths from 40 Years on the Shop Floor with Mike Gamache, Ep #29 11/28/2025

Facing the Future: Automation Truths from 40 Years on the Shop Floor with Mike Gamache, Ep #29 As we dive into this episode of Lights Out, we sit down with someone who’s seen automation evolve from pencil drawings and flame-cut templates to fully integrated robotic systems: our friend and longtime industry leader, Mike Gamache. For decades, Mike has lived at the intersection of machining, fabrication, automation, and continuous improvement, and we couldn’t be more excited to bring his experience to our listeners. We reflect on how we first met Mike—a mix of Germany trips, delayed flights, Delta drink tickets, and a little tough love that eventually turned into friendship and collaboration. But what really makes this conversation valuable is the unfiltered truth Mike brings about automation. We explore what makes it succeed, why it fails, and how shops can avoid the painful mistakes that come from chasing trends instead of defining real problems. Throughout our conversation, we pull back the curtain on how companies like Metalcraft of Mayville use automation to transform throughput, stabilize processes, and eliminate the dirty, dull, dangerous, and demanding work no one wants. Mike walks us through identifying bottlenecks, understanding ROI, choosing between prefab and custom solutions, and overcoming the cultural resistance that keeps shops stuck in the past. We also talk about the mindset behind automation—how lean thinking, stable processes, and leadership alignment create the foundation for truly running lights out. And in a powerful shift, we explore Mike’s “Create Holy Moments” philosophy, a reminder that continuous improvement isn’t just for machines—it’s for people, teams, and communities as well. This episode blends humor, hard-earned wisdom, and practical guidance you can use right away. If you’re serious about improving your shop and moving toward lights-out operations, this is one conversation you don’t want to miss. You will want to hear this episode if you are interested in... (0:22) Partner with Verdant Commercial Capital for a smooth process (1:53) Introducing Mike Gamache (and how Eric met him) (7:24) Mike’s manufacturing and engineering origins (11:07) Growing value-added steel work and machine shops (13:38) Cornerstone Design: sales, marketing, and leadership (16:44) Starting Gamache Systems and eventual acquisition by Metalcraft (18:08) Overview of Metalcraft’s automation investment and Skag product line (20:10) How ROI is measured and how projects are selected (21:27) Case studies: rearranging facilities and implementing robotic processes (23:12) What shops should automate first (and why processes must be stable beforehand) (26:24) Check out the SMW Autoblok catalog (27:40) How to prioritize automation (start at shipping, work upstream) (29:36) Common blockers: legacy thinking, unclear processes, poor flow (31:14) Value of fresh eyes and cross-industry solutions (33:13) Lean foundations as a prerequisite for automation success (34:05) Strategic conviction vs short-term ROI thinking (37:30) Fear of automation and overcoming failed attempts (39:18) Leadership alignment as the key to adoption (40:42) Global competition and why automation is mandatory (44:06) Custom vs prefabricated automation: when to choose each (48:50) Sticker shock, engineering hours, and ROI evaluation (49:58) Mike’s “Create Holy Moments” movement (57:58) Mike’s five-step process for improvement (1:01:36) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Partner with for a smooth process Check out the Connect with Mike Gamache Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/39166300

From SWAT to Spindles: How Johnny Goode Led MSP Manufacturing’s Lights-Out Transformation, Ep #28 11/14/2025

From SWAT to Spindles: How Johnny Goode Led MSP Manufacturing’s Lights-Out Transformation, Ep #28 What do law enforcement, SWAT operations, and CNC machining have in common? More than you’d think. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and Dave Vuyk welcome Johnny Goode, President and Co-owner of MSP Manufacturing in Bloomington, Indiana—a precision aerospace manufacturer that’s rapidly transforming its operations with automation and digital processes. Johnny’s journey is anything but typical. From police officer and SWAT team member to Army National Guard sergeant, his story is packed with grit, discipline, and leadership under pressure. When he traded in his badge for a badge of a different kind—the MSP logo—he brought with him the tactical mindset and resilience that now define his company’s culture and growth. Today, MSP is running 24/5, leveraging modular workholding, five-axis machining, and ProShop ERP to deliver quality aerospace parts on time, every time. In this conversation, Johnny opens up about the leadership lessons he carried from the field to the factory floor, how he earned the trust of veteran machinists, and why he believes that culture, values, and integrity are the real foundation for successful automation. From implementing five-axis technology to reducing stress on his shop floor, Johnny proves that the human element still drives even the most automated operations. If you’ve ever wondered what it takes to modernize a legacy manufacturer without losing its soul—or how to build trust and innovation into every shift—this episode is one you won’t forget. You will want to hear this episode if you are interested in… (0:22) Achieve on-time delivery with ProShop ERP (2:13) Johnny Goode of MSP Manufacturing’s origin story (6:00) Life on the SWAT team: Lessons in pressure, discipline, and adaptability (11:15) How law enforcement and military experiences shaped Johnny’s leadership style (14:24) Early challenges as a next-generation leader and implementing a new ERP system (18:27) Lessons from crisis: How COVID forced diversification and sparked innovation (20:13) Enter automation: Partnering with consultants and leveraging state grants (23:14) Get a true partner in your corner with Verdant Commercial Capital (25:00) Overcoming obstacles in automation and standardizing for success (27:38) Shop floor efficiency: 5S, tool management, and the value of observation (31:51) MSP’s core values: Integrity, efficiency, resilience, precision, respect, and innovation (36:30) Managing change and getting buy-in from the team (38:03) Tracking progress: Using ProShop ERP for traceability, scheduling, and visibility (42:36) The next frontier: Expanding capacity and eliminating new bottlenecks (45:30) Balancing growth with sustainability and employee well-being (49:02) Lessons learned and what Johnny would (and wouldn’t) do differently (53:33) Closing reflections and takeaway for manufacturers ready to evolve (55:40) Why you need to check out Hire MFG Leaders for your next hire Resources & People Mentioned Achieve on-time delivery with Get a true partner in your corner with Why you need to check out for your next hire Connect with Johnny Goode Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/39028795

The Real Takeaways from EMO: Monitoring, AI, and the Changing Face of Automation, Ep #27 10/31/2025

The Real Takeaways from EMO: Monitoring, AI, and the Changing Face of Automation, Ep #27 In this episode of Lights Out, we debrief from one of the largest manufacturing technology shows in the world—EMO Hannover. From automation and adaptive controls to AI-driven machining and the evolving economics of shop ownership, the team unpacks what’s really changing in manufacturing and what’s just noise. As the hosts reflect on trends like the shift from horizontal to 5-axis machining centers, the rise of machine monitoring and IoT integrations, and the reality of underused OEM technology, they dig into what these patterns mean for modern shops aiming to run smarter—not just harder. The conversation covers more than just new gadgets on the trade-show floor—it’s about how cultural adoption, change management, and continuous improvement determine whether those technologies actually deliver ROI. We explore the parallels between software as a service and machine tool ownership models, the challenge of aligning shop-floor teams around innovation, and why data-driven manufacturing will define the next generation of top shops. Whether you’re a shop owner wondering which investments will truly pay off, or a manufacturing leader preparing your business for the next wave of automation, this episode offers practical insights drawn straight from the global stage. You will want to hear this episode if you are interested in... (0:22) Achieve RASRAM with SMW Autoblok (1:58) IMTS vs. EMO: Comparing global manufacturing events (6:52) Eric’s three major takeaways from EMO (8:23) What’s driving the shift from Horizontal to 5-axis? (10:10) The acquisition of Heller (and what it signals about market dynamics) (11:52) Why one-and-done machining is critical in today’s talent-scarce environment (14:30) OEM strategy shift: Removing underused tech to lower sticker prices (16:00) Adoption gaps: Why built-in monitoring often goes unused (18:16) Investing in your business is an investment in ProShop ERP (19:52) Lessons from CRM and SaaS adoption (22:05) How technology should be offered and priced to match real shop behavior (25:18) The argument for offering advanced tech as optional—not standard—to increase real adoption (26:18) Lights-Out intermission: Eric’s unexpected award-winning hobby (28:56) Monitoring explosion: Using data to drive continuous improvement (32:40) The case for hiring a dedicated integrator or continuous improvement lead in every modern shop (36:27) Why offering monitoring and condition-control tools lowers risk and improves adoption (39:30) Debating whether machine builders are truly adapting their business models (42:52) Three practical tips to takeaway from this episode of Lights Out (44:48) Join us at Top Shops 2025 (Get 20% off with code MAK20) Resources & People Mentioned Achieve RASRAM with Join us at (Get 20% off with code MAK20) Investing in your business is an investment in Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/38825810

Coached—Not Just Monitored: How the Best Shops Turn Data into Action, Ep #26 10/17/2025

Coached—Not Just Monitored: How the Best Shops Turn Data into Action, Ep #26 You can collect data all day—but if you’re not using it to coach your team, you’re missing the point. In this episode of Lights Out, hosts Nick Goellner and Dave Vuyk wrap up their “Mindset Shifts for Lights Out Legends” series with one final transformation: moving from a monitored shop to a coached one. Drawing on lessons from Nick’s recent talk at the Automated Shop Conference, the hosts unpack how to turn dashboards into decisions and metrics into motivation. They explain why dashboards don’t make chips, how to turn OEE from a vanity metric into a coaching tool, and how to align both machines and people toward a shared goal of improvement. Nick also introduces the idea of the “other OEE”—Overall Employee Engagement—and explores how the best shops connect coaching, culture, and continuous improvement into measurable performance. From building the right tech stack (ERP, MES, and machine monitoring) to running better daily standups, this conversation breaks down what it really takes to lead a high-performance, data-driven manufacturing team. Whether you’re running one shift or lights out, this episode will challenge how you think about data, leadership, and what it means to truly coach your people toward operational excellence. You will want to hear this episode if you are interested in... (0:24) Why Verdant Commercial Capital is a partner in your business (2:50) Highlights from Nick’s trip to EMO (and global trends about machine monitoring) (7:30) Recap of previous Lights Out mindset shifts (8:25) “Dashboards don’t make chips” — why data without action is waste (9:14) The difference between a head coach and a head monitor in manufacturing (13:11) How cadenced meetings and daily standups drive accountability (14:30) Why starting manual helps validate processes before investing in tech (15:45) Breaking down ERP, MES, and machine monitoring (and how they work together) (20:33) Check out the SMW Autoblok catalog (21:13) Defining OEE: availability × performance × quality as the shop’s north star metric (23:05) Adaptive vs. accelerated performance—why slowing down can speed you up (27:09) What world-class OEE looks like and why most shops start around 20% (29:13) Coaching strategies to improve machine availability and uptime (32:00) How capturing downtime reasons reveals the real improvement opportunities (33:46) Dissecting the other OEE: Overall Employee Engagement (38:09) Turning OEE into a coaching tool rather than a vanity metric (40:12) Football and manufacturing: how coaching and data awareness drive success (42:21) Use Hire MFG Leaders for your next hire Resources & People Mentioned Why is a partner in your business Check out the catalog Use for your next hire Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/38564515

Adaptive Over Aggressive: Redefining Lights-Out Manufacturing with Camoren Schley, Ep #25 09/26/2025

Adaptive Over Aggressive: Redefining Lights-Out Manufacturing with Camoren Schley, Ep #25 Lights-out manufacturing isn’t just about adding robots or running machines overnight — it’s about creating a culture and a system where your shop can perform at its peak without constant human intervention. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and David Vuyk sit down with innovator and entrepreneur Camoren Schley of Slytek to explore the technologies and mindsets making true lights-out operations possible. Camoren’s story begins in his grandfather’s Denver manufacturing shop and evolves into a journey of building and selling high-pressure coolant systems, developing machine monitoring technology, and launching Slytek’s advanced adaptive control solutions. He’s not just creating products—he’s redefining how small and mid-sized shops can compete with enterprise-level operations. This episode dives into the mindset shift from being aggressive to adaptive and reactive to predictive—a crucial transformation for any shop looking to scale its production, reduce tool wear, and embrace automation. Camoren explains how adaptive controls, process monitoring, and integrated machine intelligence can help shops run longer, safer, and smarter while dramatically cutting costs. Listeners will also hear real-world examples of shops that implemented Slytek technology to move from constant babysitting and tool breakage to fully unattended overnight production. Whether you’re running five machines or 150, this conversation shows how measuring, monitoring, and coaching can unlock the next level of performance. Finally, the hosts discuss how Slytek’s holistic approach—from machine monitoring to process control to coaching—bridges the gap between data and decision-making. It’s a blueprint for any manufacturer looking to shift from firefighting to future-proofing. You will want to hear this episode if you are interested in... (0:20) Invest in your business by investing in ProShop ERP (2:48) Why we get to record this episode in person (6:12) Camoren’s family manufacturing legacy and how it shaped his approach to problem-solving (8:44) From repairing high-pressure coolant systems to designing his own solutions (11:10) Early machine monitoring experiments and the surprising boost in operator productivity (13:03) Founding Slytek and expanding into tool optimization and adaptive control technology (16:08) Adaptive controls—what they are and why small and mid-size shops need them (17:54) How Slytek’s adaptive controls mimic an expert machinist adjusting feed rates in real time (20:23) Shifting from aggressive to adaptive mindsets (A case study on tool breakage) (26:33) Beyond the spindle: Coolant concentration, chip management, and process monitoring (29:37) Grow your top and bottom-line with CliftonLarsonAllen (CLA) (30:35) Slytek’s process monitoring in graphite electrode manufacturing (33:43) The “villains” of lights-out manufacturing and how to measure before you manage (38:53) Understanding ROI: tailoring technology to solve the right problem for your shop (43:30) Coaching, accountability, and helping shops turn data into action (46:38) Why Slytek technology is built for small and mid-sized shops as well as big players (48:35) Your Lights Out “Plan of Action” to implement immediately (53:05) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Invest in your business by investing in Grow your top and bottom-line with Why you need to listen to Connect with Camoren Schley Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/38361935

From Fixed to Mixed: Mindset Shifts That Power Lights-Out Manufacturing, Ep #24 09/12/2025

From Fixed to Mixed: Mindset Shifts That Power Lights-Out Manufacturing, Ep #24 In this episode of Lights Out, Nick Goellner, Eric Nekich, and Dave Vuyk take listeners inside the mindset shifts powering the next wave of lights-out manufacturing. Forget just “working harder” — this conversation is about working smarter, breaking out of fixed thinking, and unlocking massive gains without adding headcount or square footage. The trio opens by sharing the personal routines and disciplines that keep them at peak performance, then pivots to the real topic: transforming machine shops from fixed to mixed mindsets. By rethinking workholding, machine real estate, and cycle times, they reveal how shops can multiply throughput, free up operators, and set the stage for full automation. Drawing on real-world examples — from Swiss shops running uninterrupted for 15 years to small teams like Imago Manufacturing using “time freedom” as a business model — Nick, Eric, and Dave show how modular workholding and extended cycles aren’t just efficiency hacks. They’re the foundation of the automated mindset that drives profitability, sustainability, and freedom. Whether you run five spindles or fifty, this episode gives you the blueprint to shift your thinking, increase ROI, and build a shop that runs at its best even when you’re not there. You will want to hear this episode if you are interested in... (0:28) Invest in your shop by investing in ProShop ERP (3:11) Our morning routines and personal disciplines — how we build leadership habits (6:38) The 3 pillars of health: mental, physical, and spiritual wellness (8:00) How we’re building communication and speaking skills (10:34) The five key mindset shifts we’re making (11:52) Breaking down fixed vs. mixed mindset (14:47) The ROI of self-centering vises and zero-point systems (19:59) Mixing parts, programs, and setups for longer unattended runs (21:21) Partner with CLA to improve profitability and efficiency (23:05) Change management tips: How to get your team on board (26:00) Lessons from Swiss manufacturing and 15 years of lights-out performance (28:45) Moving from operated to automated: Implementing pallet systems and external setups (31:14) Running a growth experiment starting with our existing machines and vises (33:22) Covering the case study of Feinberg Machining (36:15) Imago Manufacturing: Why we think small shops can win big (39:04) Mega shops vs. networks of high-performing small shops (40:48) Next episode: adaptive vs. aggressive and predictive vs. reactive mindsets (41:20) Listen to the Machine Shop Mastery podcast to level up your shop Resources Mentioned Invest in your shop by investing in Partner with to improve profitability and efficiency Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/38192180

Carrying the Legacy Forward: Yuto Matsuura on Family, Precision, and the Future of Automation, Ep #23 08/29/2025

Carrying the Legacy Forward: Yuto Matsuura on Family, Precision, and the Future of Automation, Ep #23 In this episode of Lights Out, we sit down with a special guest who embodies both tradition and innovation: Yuto Matsuura, fourth-generation leader of Matsuura Machinery. His story is one of legacy, expectation, and transformation—from the weight of inheriting a century-old family business to finding his own passion for manufacturing and automation. We talk openly about the realities of stepping into leadership at a young age. Yuto shares how making a life-changing decision at just fifteen felt more like an obligation than a choice—and how, over time, he turned that responsibility into a genuine calling. His journey, marked by international education, personal turning points, and the influence of his grandfather’s legacy, highlights what it really means to steward a family company into the future. From there, we dive into what makes Matsuura unique in the world of automation. Yuto explains why build quality is the foundation of true “lights out” reliability, why five-axis machines aren’t just for complex aerospace parts, and why standardization is the hidden key to successful unattended machining. His insights into precision, trust, and process reliability reveal why Matsuura has earned its reputation as one of the world’s most respected automation leaders. Yuto opens up about his vision for the next decade—focusing on people, processes, and ERP-driven efficiency in the face of labor shortages. He reflects on what he’s most proud of so far, both personally and for the company, and why building relationships has always been at the heart of Matsuura’s success. This conversation goes beyond machine tools—it’s about carrying a legacy, honoring sacrifice, and shaping the future of manufacturing. You will want to hear this episode if you are interested in... (0:27) Investing in ProShop is an investment in your shop (2:56) Learn about Yuto Matsuura and his family’s four-generation legacy (6:26) Making the decision at 15 to commit to Matsuura during Japan’s recession (8:43) Feeling obligation versus genuine passion in carrying on the legacy (11:30) Outside expectations—from classmates to relatives—about his future role (13:13) Why his father limited family involvement to one successor (14:44) Yuto’s education abroad (earning a master’s degree in Canada in one year) (18:38) The influence of his grandfather’s legacy and the promise to honor it through work (21:33) Grow your top and bottom line with CLA (23:16) Why Matsuura has become synonymous with automation and precision (27:38) Real-world examples of reliability: Matsuura machines running 15 years straight (30:49) Why five-axis with pallet changers is the foundation of flexible automation (34:28) Standardization as the milestone for successful automation adoption (37:47) Yuto’s vision for the next 10–20 years: ERP, processes, and overcoming labor shortages (40:35) Why people and recruiting are as important as technology in manufacturing (41:54) What Yuto is most proud of: dealership networks, global partnerships, and digital transformation (44:26) How online marketing transformed both Matsuura’s reach and his own leadership confidence (50:54) “Load the workpiece, push the button, and go home to your family.” (51:20) Why you should listen to Machine Shop Mastery Resources Mentioned Investing in is an investment in your shop Grow your top and bottom line with Why you should listen to Connect with Yuto Matsuura Connect on Connect With Lights Out Subscribe to Lights Out On and /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37922405

The Automation Trap: Turning Struggle into a Lean Legacy, Ep #22 08/15/2025

The Automation Trap: Turning Struggle into a Lean Legacy, Ep #22 After three episodes of grit, missteps, and breakthroughs, the story of Iron Clunk Machining comes to its conclusion—and its rebirth as Iron Wheel Manufacturing. This isn’t just the end of a narrative—it’s proof that the right combination of lean principles, selective automation, and engaged leadership can completely transform a struggling shop into a thriving, joyful workplace. Twelve months after hitting rock bottom, Gary’s shop is unrecognizable. A fresh coat of paint and spotless windows signal more than cosmetic changes—they reflect a culture rebuilt from the inside out. Palletized automation, in-process probing, and zero-point clamping now hum alongside a new metric: Overall Employee Engagement (OEEg), tracking continuous improvement efforts and idea adoption. Machines are running at world-class efficiency, but more importantly, people are empowered to innovate every day. With new aerospace and defense certifications in hand, Iron Wheel is no longer chasing low-margin scraps. Selective customer partnerships, a marquee rocket component contract, and lights-out production have created both profitability and peace of mind. Gary can finally take a vacation—confident the team has everything under control. The transformation comes full circle when Iron Wheel is featured as a Top Shop Turnaround, hosting tours to show others the path from chaos to control. As Klaus tells Gary, “Automation isn’t a trap—it’s freedom.” And in this shop, that freedom now fuels not just productivity, but careers, creativity, and culture. You will want to hear this episode if you are interested in... (0:16) The real-life ROI of ProShop ERP (2:46) Intro to the final episode of The Automation Trap series (3:37) Recap—value stream mapping, bottlenecks, and early 5S changes (6:06) Iron Clunk reborn as Iron Wheel Manufacturing (6:40) Introduction of Overall Equipment Effectiveness (OEE) metric (9:25) How OEE measures availability, performance, and quality of improvement ideas (10:47) Why tracking engagement and continuous improvement matters (12:34) Pairing lean systems with people-driven problem solving (14:00) Lean-first automation that supports flow, not chaos (18:21) From low-margin work to a joyful, profitable workplace (18:49) Grow your top and bottom-line with CLA (19:27) Leadership without micromanagement—ERP, QMS, and machine monitoring (21:27) Building quality into every function of the business (22:58) Eric explains the “Vision, founder, fit” model (24:14) Balancing shop success with personal life and vision (26:34) The role of people in shop transformations—staffing and recruitment (27:31) Full-circle moment—Iron Wheel hosts a Top Shop Turnaround tour (29:15) How long does it take to turn a shop around? (33:07) Lean Principles + Smart Automation + Engaged People = Your Legacy (35:05) Future Lights Out episodes—practical implementation and tech focus (36:19) Teaser: Yuto Matsuura on automation and lights-out machining (38:50) Why you need to listen to Machine Shop Mastery Resources & People Mentioned The real-life ROI of Grow your top and bottom-line with Check out the podcast Connect With Lights Out Subscribe to Lights Out On and Audio Production by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37800620

The Automation Trap: Saving a Shop with Systems, Not Spindles, Ep #21 08/01/2025

The Automation Trap: Saving a Shop with Systems, Not Spindles, Ep #21 Welcome back to Lights Out, where we’re continuing our deep dive into Iron Clunk’s lean transformation—and this one is a turning point. After hitting rock bottom, Gary’s found a lifeline in Klaus and the Lean Stream team. But this isn’t a charity case—it’s an investment. With tools like value stream mapping, theory of constraints, and 5S, Gary and his crew begin diagnosing their real problems: lost travelers, inefficient setups, no in-process inspection, and automation that added more chaos than value. In this episode, you’ll hear how Gary starts to regain control—not just of his machines, but of his culture. Tim, Sarah, and the rest of the Lean Stream crew don’t just swoop in with answers; they bring structure, empowerment, and a systematic approach to finding flow. Gary’s team starts to see themselves not just as operators, but as problem solvers. We also talk about how the right automation, used in the right way, can unlock real ROI. This isn’t about throwing tech at the problem—it’s about building the systems that help technology thrive. And it all comes back to visibility, strategy, and aligning your team around what truly drives profit. If you’ve ever felt like your shop was one big mess of potential—this one’s for you. You will want to hear this episode if you are interested in... (0:31) Investing in ProShop is investing in your business (2:55) Post-Europe recap, dad life, and terrible accents (4:23) Recap: Gary’s glimmer of hope and commitment to lean (5:55) Scene #1: Meet the Lean Stream team (7:37) Tim Woods = the 8 wastes explained (9:20) Acquiring messy shops with potential: the Gary investment thesis (10:35) Scene #2: Value Stream Mapping: identifying and solving bottlenecks (15:02) Shift the focus: it’s not just about cycle time (17:00) Deburring in or outside the machine? Depends on your readiness (18:45) Scene #3: Daily standups and 5S in action (20:41) Grow your top and bottom-line with CLA (21:50) Real-world benefits of a clean, organized shop (22:32) Why 5S fails without standardization and sustainability (23:45) Scene #4: Lean automation vision, from inspection to pallets (25:00) In-process inspection integrated into the system (27:25) Flexibility and smarter job switching with pallets (28:07) The tradeoff: spindle utilization vs. quality (29:00) What’s the right OEE target for high-mix shops? (29:43) Dinner scene: Linda’s back, and so is hope (31:40) Klaus’s story reminds Gary he’s not alone (32:36) Final scene: A new future for Iron Clunk takes shape (34:07) Vision → Strategy → Tactics: the right order for shop success (35:30) Personalizing lean: what works for your goals (38:19) What kind of pie? (The real debate of the episode) (39:20) Teaser: next time, Gary takes the lead (39:41) Why you should listen to Machine Shop Mastery Resources & People Mentioned Investing in is investing in your business Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37595205

The Connected Advantage: Solving Real Problems with Hexagon’s Digital Workforce, Ep #20 07/18/2025

The Connected Advantage: Solving Real Problems with Hexagon’s Digital Workforce, Ep #20 In this special episode of Lights Out, we step away from the Automation Trap series for a special episode recorded at Hexagon Live, where the buzz wasn’t just about race car simulators—but about revolutionizing shop floor productivity. We sit down with Darren Metherell, Head of Sales for Hexagon’s Connected Worker team, to explore how modern manufacturing operations can digitize smarter, faster, and with less friction than ever before. Hexagon may be known for metrology and measurement tech, but as you’ll hear in this conversation, they’re playing a much bigger role in the factory of the future. Darren shares how Hexagon is helping mid-sized shops unlock value from the equipment and software they already have—without the six-figure consulting bill. From paperless travelers to real-time dashboards, from tribal knowledge capture to KPI-driven gamification, the Connected Worker platform is all about helping you run a smarter shop, not just a busier one. The conversation hits on the deep-rooted challenges many shops face: communication gaps, generational shifts, underutilized data, and the overwhelming pressure to automate without disrupting flow. But as Darren explains, real solutions start with empathy, integration, and a roadmap—not a rip-and-replace mentality. Whether you're a job shop looking to go paperless or a multi-plant manufacturer chasing lights-out efficiency, this episode sheds light on how digital transformation can be practical, scalable, and ROI-positive from day one. You will want to hear this episode if you are interested in... (0:18) An investment in ProShop is an investment in your business (2:00) Introducing Darren Metherell and recapping Hexagon Live (5:38) Darren’s journey from VCR data collection to connected manufacturing (7:58) Hexagon’s dual strategy: direct sales and enabling their channel (9:05) The paperless traveler solution: eliminating 6 inches of paperwork per job (11:30) Mike explains Hill Manufacturing’s structure and core challenges (13:16) Tribal knowledge: Collecting data to actually using it for improvement (15:54) Dashboards and real-time visibility and gamifying performance (18:15) Breaking down OEE vs. spindle utilization (21:38) Grow your top and bottom-line with CLA (22:16) More Connected Worker workflows: quality, inventory, audits, training (26:51) How Hexagon tailors solutions to actual pain points (28:52) Capturing tribal knowledge as interactive digital checklists (30:14) Automating more lights-out hours: sensors, cameras, RFID (32:40) Bringing life to legacy equipment through smart retrofitting (34:10 Why time-to-value beats big custom builds every time (35:15) Making this tech accessible to 10-person shops—not just OEMs (36:32) What Darren’s most excited about: unlocking value from existing systems (38:44) Mike reflects on buying shops with aging tech—and scaling anyway (39:43) Connected workers = empowered workers = future leaders (40:33) Check out the Machine Shop Mastery Podcast Resources & People Mentioned Connect with Darren Metherell Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37452330

The Automation Trap: One Shop’s Hard Lesson in Lean Thinking, Ep #19 07/04/2025

The Automation Trap: One Shop’s Hard Lesson in Lean Thinking, Ep #19 In this explosive second installment of our manufacturing audio drama, The Automation Trap, we return to the saga of Gary and his struggling shop, Iron Clunk Machining. Desperate to prove himself and catch up to his more successful rival Klaus, Gary dives headfirst into automation—but without the foundational principles that make automation work. The result? A perfect storm of waste, burnout, and broken trust. Through vivid storytelling, the Lights Out team unpacks the brutal consequences of automating without strategy. We see veteran machinists demoted to deburring, quality control falling apart, and a lonely cobot churning out parts no one can use. The shop floor becomes a textbook case of lean gone wrong: overproduction, motion waste, inventory overflow, and worst of all—unused employee creativity. But the story isn’t just about failure. It's a hard look at leadership missteps and the redemptive power of collaboration. When Gary finally hits rock bottom, the very competitor he resented—Klaus—offers him a lifeline and a fresh start. Along the way, we explore why lean thinking matters, what value stream mapping really looks like, and how to turn chaos into clarity. If you’re leading a shop through automation or scaling up with tight margins, don’t miss this episode. It's raw, real, and packed with lessons you can’t afford to learn the hard way. You will want to hear this episode if you are interested in... (0:20) Invest in your shop by investing in ProShop ERP (4:07) How the audience is relating to Gary’s story (5:23) A breakdown of lean’s eight wastes—and how they show up (12:13) The team recaps Gary’s struggles (13:54) Scene 1: The cobot goes live, but chaos erupts—flawed parts, angry employees, and mounting delays (19:53) Grow your top and bottom line with CLA (20:33) Scene 2: Deburring, quality, and morale collapse as Gary isolates his team (26:13) Scene 3: Gary's marriage and shop fall apart as his machine monitoring data lies (27:25) Scene 4: Gary misses out on hiring Sarah, who joins Lean Stream instead (30:11) Scene 5: Klaus offers Gary a second chance—if he’s willing to commit (34:12) What Gary (and the audience) can learn from pausing to evaluate the real bottlenecks (37:31) Scene 6: Gary begins the process of transformation—with Klaus as a mentor (39:13) Reflections on community, leadership, and what’s next for Gary (41:08) Reasons you should listen to Machine Shop Mastery Resources & People Mentioned Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37277535

The Automation Trap: Why Automating Chaos Won’t Save You, Ep #18 06/20/2025

The Automation Trap: Why Automating Chaos Won’t Save You, Ep #18 What happens when a desperate shop owner tries to copy someone else’s success—without understanding the system behind it? In this episode of Lights Out, Nick and Kaleb are joined by their friend and workholding expert Eric Nekich to break down the first chapter of a fictional story that might hit a little too close to home. “The Automation Trap” follows Gary, the stressed-out owner of IronClunk Machining, who’s drowning in inefficiency and envy—especially after touring Klaus’s pristine, automated, award-winning shop. Gary’s heart is in the right place. But what happens when he throws his last dollars at a cobot, lowballs a high-stakes job, and hopes for a miracle? We explore why copying someone else’s automation playbook can backfire, how the wrong KPIs (like spindle utilization) can lead you astray, and why automation should never be the first step in a struggling shop. We also dig into red flags around collaborative robots, the danger of skipping process readiness, and the importance of shop culture and team buy-in. Whether you see yourself in Gary or Klaus—or somewhere in between—this episode will challenge your thinking and spark some laughs along the way. This is part one of a story-driven series you won’t want to miss. You will want to hear this episode if you are interested in... (0:18) Invest in your business by investing in ProShop ERP (2:45) Welcoming Eric Nekich back to the show (3:47) Recapping the previous episode (5:24) Dinosaur vises, angry quality guys, and bad vibes (9:01) The real trap: automating before your process is ready (11:19) The Maestro moment: solving quality bottlenecks with automation (16:43) Enter Klaus: the lean legend with smiling operators and Modern Machine Shop awards (18:50) Is your envy even valid? Why copying Klaus might not make sense (20:57) Grow your top and bottom line with CliftonLarsonAllen (21:36) Gary’s backstory: loans, burnout, and a desperate dream (25:13) High mix vs. high volume: why the context matters (26:27) Team buy-in, financial transparency, and culture shifts (29:32) Spindle utilization vs. OEE: don’t get distracted (33:22) The cobot mistake: throwing money at a process you haven’t measured (35:59) Pallet vs. part loading: how to match automation to application (36:54) Cobot myths: it’s not collaborative unless the whole setup is (39:10) Cliffhanger: Gary wins the job—but he’s not ready to deliver (41:18) What Gary should’ve done instead: value stream mapping and expert help (45:51) Why you should listen to Machine Shop Mastery Resources & People Mentioned Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/37081195

Dimming the Lights: How to Build a Shop Ready for Automation, Ep #17 06/06/2025

Dimming the Lights: How to Build a Shop Ready for Automation, Ep #17 What if going “lights out” wasn’t about giant robots or million-dollar cells—but about one simple mindset shift? In this kickoff to our new Automation Academy series, we break down the truth behind successful automation. Spoiler: it's not just about buying a robot. It's about building a stable process, defining standards, and rethinking what’s possible in your shop. Whether you’re already dabbling in automation or still think it’s “not the right fit,” this episode is your wake-up call. We get real about the labor gap, international competition, and why automation is no longer optional—it’s a matter of survival for shops in North America. Then we get practical. We talk through what automation readiness actually looks like, how to run no-risk simulations, and what most shops get wrong when they rush into technology. If you’ve ever said, “We’re not the kind of shop that can automate,” this one’s for you. Because the first step to lights-out isn’t a machine—it’s a decision. You will want to hear this episode if you are interested in... (0:23) Why investing in ProShop ERP is investing in your business (2:51) Launching the Automation Academy and why it matters (5:58) Breaking the myth: “We’re not the right shop for automation” (9:30) Labor cost comparisons and reshoring pressure (12:00) Automation as a path to upskilling, not layoffs (15:17) Mapping your process before automating anything (17:59) Why standardization is the real foundation for automation (19:58) How to simulate lights-out before buying equipment (21:51) How to grow your top and bottom line with CLA (23:01) Monitoring, readiness, and proving ROI from the start (28:59) Managing cultural resistance and getting team buy-in (31:43) Infrastructure checklist: air, power, network, layout (37:34) Why cobots aren’t a magic bullet (and what to ask first) (41:00) Wrapping up with key takeaways and what’s next in the series (43:10) Why you need to listen to Machine Shop Mastery Connect With Lights Out Subscribe to Lights Out On and Audio Production by /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/36882040

Is Coaching the Key to Lights-Out Success? Ep #16 04/25/2025

Is Coaching the Key to Lights-Out Success? Ep #16 What happens when cutting-edge CAM automation meets boots-on-the-ground manufacturing know-how? You get an eye-opening conversation that will challenge the way you think about the future of your shop—and your role in it. In this episode of Lights Out, we sit down with David Vuyk, a guy who’s walked every inch of the shop floor and now finds himself at the forefront of digital manufacturing transformation with CloudNC. But don’t expect a tech sales pitch—this is a candid, no-holds-barred look at the human side of automation and why real success hinges on more than just software. If you’ve ever felt the tension between adopting new technology and keeping your team engaged, this episode is for you. David shares his journey from mechanical designer, to job shop operator, to now driving customer success for bleeding-edge CAM automation. Along the way, he tackles the tough questions: What happens when programmers fear being replaced? How do you overcome resistance from the shop floor? And why is customer success just as important—if not more—than sales when it comes to scaling disruptive tech? But this isn’t just about change management—it’s about reimagining what your people can achieve when they're empowered, not threatened, by automation. We dive deep into the mindset shifts that shop owners and frontline leaders need to make to truly go Lights Out. Plus, they reveal why failing to engage your team can lead to churn, wasted tech investments, and missed opportunities for growth. Whether you’re a shop owner, an operations leader, or just someone who wants to future-proof your manufacturing business, you’ll leave this episode with a fresh perspective on how to turn resistance into results. The message is clear: if you can run lights out, you must run lights out—and it all starts with making your people the heroes of your automation journey. You will want to hear this episode if you are interested in... (0:47) Why you need to complete the Top Shops benchmarking survey (2:30) David Vuyk’s journey from mechanical design to CNC machining to tech solutions (10:31) Navigating resistance on the shop floor and managing change (13:03) Engaging frontline workers and leadership for tech adoption (14:53) Dave’s role at CloudNC and how he works with decision-makers (18:45) Elevating employees through automation, not replacing them (22:27) The CloudNC phased approach to customer success (25:04) Grow your top and bottom line with CLA (26:57) The StoryBrand framework: Communicating your company’s true value (34:17) Thinking beyond your product: Coaching customers for long-term lights-out success (38:42) Solving constraints beyond your offering (tools, processes, mindsets) (41:23) The responsibility of software teams to simplify adoption (42:16) Our final takeaways from the conversation (51:37) Check out the Machine Shop Mastery podcast! Resources & People Mentioned Grow your top and bottom-line with Take the Connect with David Vuyk Connect on Connect With Lights Out Subscribe to Lights Out On and /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/36310635

The Quiet Cut That's Loudly Threatening Small Manufacturing 04/19/2025

The Juice-to-Squeeze Ratio: Why Time Freedom Isn’t Optional for Shop Owners, Ep #15 04/11/2025

The Juice-to-Squeeze Ratio: Why Time Freedom Isn’t Optional for Shop Owners, Ep #15 What if the real sign of a thriving machine shop isn’t how hard the lights are on—but how confidently you can turn them off? In this episode of Lights Out, we sit back down with Ryan Bankel of Imago Manufacturing to get into the guts of how a high-performing shop can run with minimal human presence and still crank out quality parts. This isn't about overnight success—it’s about obsessing, intelligently and intentionally, over what "lights out" actually takes, from tooling considerations to culture, chip control to checklists. Ryan pulls back the curtain on how he reengineered not just his machines but his mindset. He breaks down the daily “Lights Out Checklist” laminated on every machine, the unsexy decisions that fuel unattended machining, and the radical belief that automation isn’t just about more parts—it’s about more life. With bourbon in hand and clarity on tap, we get real about boundaries, freedom, and the juice-to-squeeze ratio that drives modern manufacturing forward. Whether you’re still tied to the spindle or just starting to imagine what your shop could look like without you in it, this episode offers a blueprint for rethinking everything—from how you spend your hours to how you scale your value. Automation isn’t just for the big guys. It’s for anyone ready to lead with intention, accountability, and maybe a little help from Bon Jovi. You will want to hear this episode if you are interested in... (00:00) Bourbon, broken phones, and kicking off part two (00:38) Why you should complete the Modern Machine Shop Top Shops Survey (03:10) Why “lights out” isn’t just for large shops (04:40) The role of positive constraints in Ryan’s business philosophy (08:09) Designing schedules for freedom—not burnout (11:55) Trust and autonomy: the cultural foundation of unattended machining (13:42) The case for decoupling the owner from the day-to-day (15:51) Live tooling, bar feeders, and why Okuma gets the job done (20:05) The Imago Manufacturing Daily Lights Out Checklist (21:38) The must-run-unattended mindset and its ripple effect (25:44) Ryan’s “three-day rule” for qualifying lights-out jobs (30:33) Real-world risks: scrap, tool failure, and power loss (33:48) Chip control, part ejection, and machine limitations (36:57) Checklist development from real pain points (41:27) Defining the juice-to-squeeze ratio and scoring process viability (44:09) How to access the Daily Lights Out Checklist + wrap-up (46:15) Check out the Buy the Numbers podcast! Resources & People Mentioned Connect with Ryan Bankel Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/36077530

Automation: The Key to Time Freedom in Machining, Ep #14 03/28/2025

Automation: The Key to Time Freedom in Machining, Ep #14 Have you ever felt like the traditional path of working harder to get ahead isn't the answer? In this episode, Ryan Bankel, founder of Imago Precision Machining, shares the story of how he built his business from the ground up. What started in a garage has grown into a company with a strong focus on sustainability and automation. Ryan talks about how he carefully crafted his shop’s operations to run smoothly, even without him being physically present. His goal? Time freedom—not just for himself, but for his employees, too. As a self-taught machinist, Ryan didn’t follow the traditional path of learning in a formal setting. Instead, he honed his skills on the job, navigating the challenges of running a business while staying true to his vision. He reflects on the tough early years, working long hours to make ends meet and building a company that would eventually allow him the flexibility he always dreamed of. Through trial and error, he developed a model that works for him—a model that combines quality, innovation, and a commitment to time freedom. What stands out about Ryan’s journey is his approach to business growth. Unlike many entrepreneurs who focus on scaling for the sake of growth, Ryan has embraced a model that values sustainability and keeping the business at a manageable size. Ryan’s model prioritizes not just technology and automation, but also a strong shop culture and a sustainable pace of growth, challenging the common belief that bigger is always better. His approach ensures that his shop maintains a strong, close-knit culture, while still embracing modern technologies and automation. Ryan’s story is a powerful example of how success doesn’t have to mean sacrificing your values or your time. You will want to hear this episode if you are interested in... (0:00) Introduction to Ryan Bankel (0:31) Why you need to take the Modern Machine Shop Top Shop Survey (3:38) Our tour of the Imago shop (including the suave bathroom) (6:53) How we connected with Ryan on LinkedIn (12:13) Ryan’s journey into metalworking (21:59) From running a shop to launching Imago (24:42) The significance of Ryan’s decision to keep his shop small (29:30) Bringing in new technology & keeping employees engaged (33:03) What “time freedom” means for Ryan (37:24) Ryan’s evolving vision for his business: What’s next? (39:11) Stay tuned for part 2 to learn how Ryan runs his business lights out (40:57) Why you need to check out the MakingSparks podcast Resources & People Mentioned Connect with Ryan Bankel Connect on Connect With Lights Out Subscribe to Lights Out On and Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/35873365

The AI Revolution: Rethinking Automation with Al Whatmough, Ep #13 02/26/2025

The AI Revolution: Rethinking Automation with Al Whatmough, Ep #13 In this episode of Lights Out, we’re joined by a true innovator in the manufacturing space, Al Whatmough, CEO of Toolpath. Al brings a wealth of experience from his time at Autodesk and his leadership at Toolpath, where he’s driving the next wave of automation in CNC machining. Together, we dive into the revolutionary role that AI is playing in reshaping manufacturing operations, offering fresh perspectives on how automation can enhance productivity and streamline processes on the shop floor. Throughout the conversation, Al unpacks the exciting developments at Toolpath, including their acquisition of Chatter, a key technology that helps shops automate their operations more effectively. He shares his vision for the future of manufacturing, where AI doesn’t just automate processes but actively assists in decision-making, freeing up cognitive load for operators and improving workflow efficiency. We also explore the challenges traditional shops face when integrating new technology and how bridging generational gaps in the workforce is crucial for embracing the full potential of automation. This episode is a must-listen for manufacturing leaders looking to understand how AI and automation can create smarter, more agile operations. Al’s insights into the real-world applications of AI, along with his thoughtful reflections on industry trends, will inspire you to think differently about the tools you use and the systems you have in place. You'll want to hear this episode if you are interested in... (0:00) Chatting about our time at the MFG Meeting 2025 (3:06) Introducing Al Whatmough, CEO of Toolpath (3:40) Bridging the generational divide in manufacturing (6:20) Al's journey from Autodesk to Toolpath and what they aim to achieve (8:37) Building trust in AI and overcoming skepticism from more traditional shops (11:11) The acquisition of Chatter and how it enhances Toolpath’s capabilities (12:39) Why automation should focus on the mundane tasks to free up cognitive load (13:38) The dangers of chasing complex problems rather than solving simple ones (15:52) The importance of understanding customer needs and creating tailored solutions (18:13) The intersection of AI and existing technologies in modern manufacturing (21:24) Rethinking workflows with AI and improving the connection between tools (26:57) Know what you’re good at and learn to do it well (33:22) Reflections on the future of AI and automation in manufacturing Connect with Al Whatmough Connect on Connect With Lights Out Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/35431585

Make the Right Chips, Do the Right Work, Ep #12 02/05/2025

Make the Right Chips, Do the Right Work, Ep #12 Are robots really taking over human jobs, or is it the other way around? In this eye-opening episode of Lights Out, hosts Nick and Kaleb sit down with automation expert Max Falcone to challenge one of the biggest misconceptions in manufacturing: that automation replaces workers. Instead, they argue that too many people are still stuck performing tedious, repetitive tasks that should already be automated—tasks that drain productivity, increase injuries, and contribute to worker burnout. With over 23 years of experience in automation, robotics, and material finishing, Max brings a fresh perspective on how manufacturers can rethink their processes. As Vice President of Sales Engineering at PushCorp, he has helped countless shops integrate automation in ways that make businesses more efficient while creating better jobs for skilled workers. In this episode, you’ll hear why the right technology can help manufacturers maximize their workforce, eliminate bottlenecks, and improve safety—without sacrificing jobs. Plus, we dig into how manufacturers should be approaching automation today, from understanding the difference between passive and active compliance in robotics to identifying the right tasks to automate. If you’re a shop owner, machinist, or anyone in the manufacturing industry looking for ways to optimize operations and stay ahead of the curve, this is an episode you won’t want to miss. You will want to hear this episode if you are interested in... (02:00) Flipping the script: Are humans taking robot jobs? (3:00) Max’s journey into automation and robotics (12:00) The power of PushCorp (and why it matters) (16:33) Passive vs. active compliance in robotic automation (21:40) How automation can improve safety and efficiency in manufacturing (23:41) Why machine shops should rethink deburring and finishing processes (27:37) The importance of hands-on experience in engineering and manufacturing (31:56) Why the industry needs more problem solvers and skilled workers Connect with Max Falcone Connect on Connect With Lights Out Subscribe to Lights Out Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/35161535

The Throughput Mindset: How Automation and Culture Drive Success, Ep #11 01/22/2025

The Throughput Mindset: How Automation and Culture Drive Success, Ep #11 What separates the best shops from the crowd? It’s not just the technology they use—it’s the way they think. The top manufacturing leaders aren’t content with operators who say, ‘I run a mill,’ or ‘She programs machines.’ Instead, they cultivate a culture where everyone is focused on one goal: increasing throughput. By aligning your people, resources, and technology to make your business successful, you build a team where nobody is a cog in the wheel—everyone is part of a powerful engine. For years, many in the industry have seen robotics and automation as unnecessary expenses, asking, ‘Why invest in a $200,000 robot loading cell when I could just add another spindle?’ But what if that mindset is holding your shop back from unlocking its true potential? By automating tasks like workpiece delivery and machine loading, you free your team to focus on high-value work, maximizing throughput and creating a culture of innovation and growth. We’ll also explore what the machine tool dealer of the future looks like, share real-world stories of shops that made the leap into automation, and address common concerns—like how much programming experience your team really needs. Whether you’re looking to inspire your team, adopt cutting-edge technology, or simply break free from outdated mindsets, this episode is packed with actionable advice and fresh perspectives. Tune in now to learn why throughput is more than just a metric—it’s a mindset that can transform your business. You will want to hear this episode if you are interested in... (1:54) Get to know Lights Out Co-host Kaleb Mertz (4:16) Max Rothenhausler’s origin story (10:43) The project that Max and Kaleb are spearheading (14:52)The importance of automation to career longevity? (17:04) Why is it easier to work with the end-user instead of the dealer? (20:22) Overcoming the old-school mentality and adopting automation (25:56) How much robotic programming experience do you need? (28:38) What would the machine shop of the future look like? (31:47) How to structure the machine shop of the future (33:41) The industry is lacking machinists (37:30) Take on a new product line—or find partners? (44:58) Your customer will always be your best salesman Resources & People Mentioned Connect with Max Rothenhausler Connect on Connect With Lights Out Subscribe to Lights Out Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/34930465

Business Moves at the Speed of Trust with Wade Anderson, Ep #10 12/11/2024

Business Moves at the Speed of Trust with Wade Anderson, Ep #10 In this episode of Lights Out, Wade Anderson, VP of Engineering and Automation at Okuma delivers a compelling look at how automation is transforming the manufacturing landscape. Along with Steve DeGrasse, the East Coast Regional Sales Director at Hennig, we uncover why tomorrow’s machine tools will require rethinking—like side-door access for robots and integrated pallet delivery systems—and how additive manufacturing and AI will reshape priorities even for small shops aiming to go lights-out. With a trust-first approach, Wade explains how maximizing a customer’s current capabilities builds the foundation for introducing transformative automation solutions. This conversation isn’t just about technology—it’s about people. We explore how sales strategies, compensation plans, and service roles must evolve to meet the demands of an automation-driven world. Fostering collaboration between sales professionals and engineers is critical for success and how the next generation of talent, raised with robotics, will lead the way. Packed with real-world insights and forward-thinking strategies, this episode is a must-listen for anyone navigating the future of manufacturing. Don’t miss their candid take on what it takes to build trust and drive innovation in a rapidly changing industry. – Nick You will want to hear this episode if you are interested in... Introducing Wade Anderson from Okuma [2:40] Steve’s hilarious IMTS Oyster story [8:11] How do we make machine tools automation friendly? [12:00] Should we adjust compensation plans for salespeople? [25:00] How does service need to evolve with automation? [30:50] Resources & People Mentioned Shop Matters Podcast on Connect with Connect with Wade Anderson Connect on Connect With LightsOut Subscribe to SHOW NAME Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/34364510

Chip and Coolant Management for Machining Automation with Blaser Swisslube and Hennig, Ep #9 11/20/2024

Chip and Coolant Management for Machining Automation with Blaser Swisslube and Hennig, Ep #9 In this episode of Lights Out, we explore how cutting-edge coolant technology is transforming manufacturing by enabling efficiency, stability, and sustainability. Tiffany Bryson and Christopher Porsch of Blaser emphasize the need for a repeatable, reliable process, noting that automation hinges on stable coolant systems. Scott Cooley, with Hennig, explains how tailored solutions address each customer’s specific materials and machining needs, with advanced filtration systems supporting lights-out operations by maintaining a clean, stable environment. Blaser’s approach to coolant as a “liquid tool” highlights its importance beyond mere maintenance—coolant is an essential investment in long-term productivity and profitability. Camoren Schley adds that high-pressure systems enhance heat dissipation and extend tool life, further stabilizing production. This episode dives into how the right coolant technology can solve key challenges, helping manufacturers optimize processes, reduce downtime, and prepare for continuous, efficient production. Don’t miss it! You will want to hear this episode if you are interested in... [1:09] Introducing today’s special guests [3:16] Everyone’s Day #1 IMTS experience [4:11] Manufacturing leader spotlight [9:10] Does technology change how you serve customers? [11:54] Understanding the chemistry of coolant [15:52] How high pressure can solve chip accumulation challenges [18:32] What does the term “liquid tool” mean to Blaser? [21:12] The importance of material compatibility [24:24] Reducing the amount of "sludge" created [28:16] How coolant helps with heat dissipation [31:42] What’s on the horizon for Blaser, Hennig, and Slytek? [37:09] Why foam control is incredibly important Resources & People Mentioned Connect with Connect with Connect with Connect with Connect With LightsOut Subscribe to SHOW NAME Audio Production and Show Notes by - /episode/index/show/8819970d-2c51-481c-b08a-4d2a806885b2/id/34010582

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A Samurai's Journey to Automation, Ep #5 11/20/2024

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How a Prototyping Shop is Shattering the Status Quo with Automation, Ep #3 11/20/2024

Lights Out: Technology and Automation Podcast by MakingChips

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