Lights Out: Technology and Automation Podcast by MakingChips

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 ProShop ERP Partner with CLA to improve profitability and efficiency 7 Habits of Highly Effective People Imago Precision Machining’s episode of Lights Out Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 ProShop is an investment in your shop Grow your top and bottom line with CLA Why you should listen to Machine Shop Mastery  Connect with Yuto Matsuura Matsuura Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

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 ProShop ERP Grow your top and bottom-line with CLA The Machine Shop MBA on MakingChips Check out the Machine Shop Mastery podcast Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by - PODCAST FAST TRACK

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 ProShop ERP is investing in your business Episode 12 of Lights Out Lean Process Improvement with Noah Goellner Traction Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 Hexagon Connected Worker Connect with Darren Metherell Hexagon Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 The 8 Wastes of Lean The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 Keys to Maintaining a Manufacturing Leadership Mindset Workholding Evolves with Great Partnerships  The Toyota Way The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by PODCAST FAST TRACK

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 CLA Take the Top Shops Survey HIREMfgLeaders.com Storybrand Connect with David Vuyk Connect on LinkedIn CloudNC Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

Most small manufacturers don’t realize they’re being quietly supported by one of the most impactful public-private partnerships in the country. The Manufacturing Extension Partnership (MEP) has long been the hidden backbone behind training programs, grant facilitation, process improvements, and critical tech upgrades for shops across the U.S. But recent Federal decisions to defund these programs—without clear communication or reasoning—have sparked confusion and alarm among industry insiders. In this episode, a passionate roundtable of manufacturers and advocates reveals just how deeply the MEPs have shaped their businesses, supported workforce development, and opened doors to opportunity they couldn’t have accessed alone. From AR-integrated quoting tools to automation investment guidance, these stories show a clear economic impact that extends far beyond individual shops—right into the health of local communities and the national manufacturing strategy. If you're just hearing about MEPs now, you're not alone—but you are at risk. This conversation lays out what’s at stake, why it matters, and what you can do right now to help save a resource that quietly powers tens of thousands of manufacturers nationwide. YouTube: https://youtu.be/WNjevmTNUu4 VideoAsk: https://www.videoask.com/fiyvfkcdd

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 Complete the Modern Machine Shop Top Shops Survey How Ryan named Imago  Connect with Ryan Bankel The Imago Manufacturing Daily Lights Out Checklist Imago Manufacturing  Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 Machine Shop MBA: How to Become a Top Shop Complete the Modern Machine Shop Top Shops Survey Connect with Ryan Bankel Imago Manufacturing  Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

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 Toolpath Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Audio Production and Show Notes by - PODCAST FAST TRACK

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 PushCorp Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out Audio Production and Show Notes by - PODCAST FAST TRACK

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 Business Moves at the Speed of Trust Connect with Max Rothenhausler Connect on LinkedIn 21st Century Machine Tools Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out Audio Production and Show Notes by - PODCAST FAST TRACK

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 YouTube At The Boring Bar #1 Connect with Steve DeGrasse Connect with Wade Anderson Connect on LinkedIn Okuma America Connect With LightsOut LinkedIn MakingChips.com Subscribe to SHOW NAME Audio Production and Show Notes by - PODCAST FAST TRACK

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 Blaser Swisslube Hennig Connect with Tiffany Bryson Connect with Christopher Porsch Connect with Scott Cooley Connect with Camoren Schley Connect With LightsOut LinkedIn MakingChips.com Subscribe to SHOW NAME Audio Production and Show Notes by - PODCAST FAST TRACK

What do you need to know before you launch automation in your shop? What would be signs that you’re not ready to automate? If you’re launching the process, how can you use your ERP/MRP to the fullest?  Even the smallest mistakes—like not having a process in place to deal with the chips your machines are creating while running lights out—can be costly. We want to help you avoid those costly errors.  That’s why Paul Van Metre and Mike Payne join me to tackle the important things you need to consider before you run lights out. Because if you’re not MakingChips, you’re not making money. BAM! Segments [0:35] Why you need ProShop ERP [5:08] What’s new with the crew [6:43] Manufacturing Leadership Spotlight [13:52] Do you have a repeatable process?  [19:03] NetSuite by Oracle [20:31] Do you have a chip management process? [23:48] Cutting tool management features [26:24] Are you making adjustments for accurate costs? [34:06] Do you have training in place for your team?  [37:16] Do you have a preventative maintenance program? Resources mentioned on this episode The Oscar Mike Foundation Noah Currier The Checklist Manifesto NetSuite by Oracle Moseys Production Shop Tour Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Here’s our controversial take: We believe that “automated” is more important than “operated”. It’s a stance that scares a lot of operators—but it shouldn’t. In this episode of MakingChips, Mike Payne and Kaleb Mertz return to dive into part loading and pallet loading, a mixed vs fixed mindset, and why predictive is better than reactive. We’ll connect all of it back to every shop's end goal: business results. Don’t miss it! Segments [0:18] Learn about IMTS 2024 Sectors [4:03] Part loading vs pallet loading [9:53] Embrace a mixed vs fixed mindset [16:00] Manufacturing Transformed [17:32] Predictive is better than reactive  [22:29] If you can sense it, you can do it Resources mentioned on this episode IMTS Sectors IMTS Community Go listen to the Manufacturing Transformed podcast Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Machine monitoring can give us insights into our machines that can and should change how we’re operating. The end goal is to drive better business results. But how should monitoring be paired with advanced business strategies to help you achieve those results? Mike Payne, Kaleb Mertz and I connect the dots in this episode of MakingChips. Because if you’re not efficiently MakingChips, you’re not making money. BAM!  – Nick Goellner Segments [0:20] Learn more about IMTS 2024 Elevate [2:28] What we listen to at work [7:00] Manufacturing News: Technology Orders Grow [13:08] Latin America Conference at IMTS [15:02] Using ProShop for cutting tool management [16:11] Coaching is more important than monitoring [21:21] Adaptive controls and tooling optimizations  Resources mentioned on this episode IMTS Elevate ChillHop Radio Pop Goes Classical on Spotify Erica Violet on Spotify Manufacturing Technology Orders Grow Despite Sustained High Interest Rates Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube