Explore every episode of the podcast Lights Out: Technology and Automation Podcast by MakingChips
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| The Automation Trap: One Shop’s Hard Lesson in Lean Thinking, Ep #19 | 04 Jul 2025 | 00:42:35 | |
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...
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| The Automation Trap: Why Automating Chaos Won’t Save You, Ep #18 | 20 Jun 2025 | 00:47:20 | |
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...
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| Business Moves at the Speed of Trust with Wade Anderson, Ep #10 | 11 Dec 2024 | 00:39:32 | |
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...
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| Chip and Coolant Management for Machining Automation with Blaser Swisslube and Hennig, Ep #9 | 20 Nov 2024 | 00:40:23 | |
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...
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| Are You Even Prepared to Run a Lights Out Shop? Ep #8 | 20 Nov 2024 | 00:41:53 | |
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
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| Connecting Advanced Machining Strategies to Business Results Part 2 | 20 Nov 2024 | 00:26:10 | |
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
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| Connecting Advanced Machining Strategies to Business Results Part 1 | 20 Nov 2024 | 00:28:48 | |
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
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| A Samurai's Journey to Automation, Ep #5 | 20 Nov 2024 | 00:46:25 | |
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 Segments
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| How to Prioritize Flexibility when You Invest in Automation, Ep #4 | 20 Nov 2024 | 00:36:09 | |
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 Segments
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| How a Prototyping Shop is Shattering the Status Quo with Automation, Ep #3 | 20 Nov 2024 | 00:45:00 | |
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 Segments
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| Automation 101 with Chris Luecke Manufacturing Happy Hour, Ep #2 | 20 Nov 2024 | 00:48:38 | |
Automation continues to be a popular and divisive topic in the manufacturing world. Automation is important for attracting and retaining young talent and growing your business. So we’ve been working hard to highlight the importance of automation—and where you can dive in—with our Lights Out series. Chris Luecke—the host of Manufacturing Happy Hour—has a similar goal. We’re using our platforms to squash the rumors, lessen fears, and highlight how automation can and will benefit your business. Because if you’re not automating, you’re not making enough chips, and you’re missing out on money. BAM! Segments
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| Training Machinists with an Automation Mindset with Titan Gilroy, Ep #1 | 20 Nov 2024 | 00:39:39 | |
Lights out manufacturing isn’t only a large topic of conversation but it’s also the way of the future. Shops around the world are embracing automation. Are you? If you haven’t become part of the automation conversation, don’t miss our first lights-out-focused episode with Special guest Titan Gilroy. He shares how automation has progressed, the mindset you need to embrace to be successful, and how to mitigate the risks. Because if you’re not automating, you’re not MakingChips. And if you’re not MakingChips, you’re not making money. BAM! – Jason Segments
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| Dimming the Lights: How to Build a Shop Ready for Automation, Ep #17 | 06 Jun 2025 | 00:44:40 | |
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...
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| Lights Out Intro | 17 Sep 2024 | 00:00:57 | |
| Is Coaching the Key to Lights-Out Success? Ep #16 | 25 Apr 2025 | 00:53:01 | |
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...
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| The Quiet Cut That's Loudly Threatening Small Manufacturing | 19 Apr 2025 | 00:35:09 | |
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 | |||
| The Juice-to-Squeeze Ratio: Why Time Freedom Isn’t Optional for Shop Owners, Ep #15 | 11 Apr 2025 | 00:47:30 | |
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...
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| Automation: The Key to Time Freedom in Machining, Ep #14 | 28 Mar 2025 | 00:41:46 | |
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...
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| The AI Revolution: Rethinking Automation with Al Whatmough, Ep #13 | 26 Feb 2025 | 00:38:32 | |
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...
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| Make the Right Chips, Do the Right Work, Ep #12 | 05 Feb 2025 | 00:39:51 | |
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...
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| The Throughput Mindset: How Automation and Culture Drive Success, Ep #11 | 22 Jan 2025 | 00:48:35 | |
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...
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