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

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

• (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

• How ProShop ERP delivered rapid ROI in Mike Payne's shop
• Why you should use Hire MFG Leaders for your next hire
• Why you need to check out the SMW Autoblok catalog

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

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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. 

• (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

• Why we love SMW Autoblok for workholding
• Partner with Verdant Commercial Capital for financing
• Make your next hire with Hire MFG Leaders

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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.

• (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

• Investing in ProShop ERP is investing in your business
• Episode 12 of Lights Out
• Lean Process Improvement with Noah Goellner
• Traction

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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.

• (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

• Hexagon Connected Worker

• Hexagon
• Connect on LinkedIn

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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

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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

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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. 

• (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

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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. 

• (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!

• Grow your top and bottom-line with CLA
• Take the Top Shops Survey
• HIREMfgLeaders.com
• Storybrand

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• CloudNC

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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.

• (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!

• Complete the Modern Machine Shop Top Shops Survey
• How Ryan named Imago 

• The Imago Manufacturing Daily Lights Out Checklist
• Imago Manufacturing 
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