Lights Out: Technology and Automation Podcast by MakingChips – Details, episodes & analysis

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.

• (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

• The 8 Wastes of Lean
• The Goal

• LinkedIn
• MakingChips.com

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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. 

• (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

• Keys to Maintaining a Manufacturing Leadership Mindset
• Workholding Evolves with Great Partnerships 
• The Toyota Way
• The Goal

• LinkedIn
• MakingChips.com

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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

• 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] 

• Shop Matters Podcast on YouTube
• At The Boring Bar #1
• Connect with Steve DeGrasse

• Connect on LinkedIn
• Okuma America

• LinkedIn
• MakingChips.com

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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!

• [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 

• Blaser Swisslube
• Hennig
• Connect with Tiffany Bryson
• Connect with Christopher Porsch
• Connect with Scott Cooley
• Connect with Camoren Schley

• LinkedIn
• MakingChips.com

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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!

• [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?

• The Oscar Mike Foundation
• Noah Currier
• The Checklist Manifesto
• NetSuite by Oracle
• Moseys Production Shop Tour

• www.MakingChips.com
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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!

• [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

• IMTS Sectors
• IMTS Community
• Go listen to the Manufacturing Transformed podcast

• www.MakingChips.com
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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

• [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 

• IMTS Elevate
• ChillHop Radio
• Pop Goes Classical on Spotify
• Erica Violet on Spotify
• Manufacturing Technology Orders Grow Despite Sustained High Interest Rates

• www.MakingChips.com
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Can small shops begin to automate their processes? Where do they start with automation? In this episode of MakingChips, the CNC Samurai, Steve Courchane, returns to share his passion for automation. He lays out his 3M process and how it changes the way you view automation. Because if you’re not modeling, making, or measuring—you’re not MakingChips. And if you’re not MakingChips, you’re not making money. BAM!

– Jason Zenger

• [0:20] Join the AMT community! 
• [4:06] Update on my progress! 
• [5:40] Welcoming Steve Courchane back
• [7:35] Machine Shop Masterclass
• [14:53] Manufacturing Leadership Spotlight
• [19:52] Who is the CNC Samurai? 
• [23:30] Why branding was important to Steve
• [26:13] It’s time to graduate to NetSuite by Oracle
• [27:33] How Steve’s mindset has changed about automation
• [34:27] When Steve learned to love automation 
• [36:37] Steve’s 3M process: model, make, and measure

• Join the AMT community! 
• What the Heck is a Samurai CNC Machinist?
• Winning the War for Talent by Chris Czarnik
• Steve Courchane on Instagram
• Chris Luecke on LinkedIn
• The Cultish Show
• NetSuite by Oracle

• www.MakingChips.com
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POV: You’ve decided to start the process of implementing automation in your machine shop—but it isn’t as easy as flipping a switch. It’s a process that consists of failing forward and learning from every mistake. Tom Schroeder—the Executive Vice President at PBC Linear—joins us in this episode of Lights Out to share how to prioritize flexibility when you invest in and begin to implement automation in your shop. Because if you’re not making the right chips, you’re not making money.

– Nick

• [1:28] Learn more about Kaleb Mertz
• [4:04] Today’s guest: Tom Schroeder 
• [5:16] What's the Chip on Your Shoulder? 
• [11:44] PBC Linear’s investment in an MCM 
• [16:52] Get NetSuite’s KPI Checklist 
• [19:31] Managing high mix low volume 
• [23:40] Steps to take before automating 
• [27:11] Why automation is necessary 
• [30:00] Innovation = learning to think differently 
• [32:30] Automation doesn’t take away jobs 

• Get your free KPI checklist from NetSuite by Oracle! 
• Kaleb Mertz on LinkedIn
• Tom Schroeder on LinkedIn
• Episode #399: Do We Need More Manufacturing Entrepreneurs?

• www.MakingChips.com
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Are you embracing automation in your shop? Or are you hesitating because you’re unsure how to implement it so that you’re making the best use of your time and money? Brian Kippen—the owner and CEO of KAD Models & Prototypes—reframes how you can use automation. 

In this episode of MakingChips, Brian Kippen, Steve DeGrasse, and I share how you can approach automation from a different perspective. Because if you’re not automating efficiently, you’re not MakingChips, and if you’re not MakingChips, you’re not making money. BAM!

– Nick

• [0:15] The Lean Setup Guide from ProShop
• [1:48] Introducing Brian Kippen and Steve DeGrasse
• [3:12] What's the Chip on Your Shoulder?
• [5:30] Brian Kippen’s origin story
• [20:36] How Brian approaches automation differently 
• [24:28] Running his company like a barbershop
• [30:21] What Brian looks for in new talent
• [36:44] How Brian is using automated pallet delivery
• [41:10] Why Brian took a job as a high school teacher

• The Lean Setup Guide from ProShop
• Connect with Steve DeGrasse on LinkedIn
• Connect with Brian Kippen on LinkedIn

• www.MakingChips.com
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• On YouTube