Explore every episode of the podcast Lights Out: Technology and Automation Podcast by MakingChips
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| How to Calculate Automation ROI — The Right Way, Ep #31 | 26 Dec 2025 | 00:31:05 | |
Automation is exploding across the manufacturing world, but the real differentiator isn't the robot, pallet pool, or software you buy—it's whether you know how to calculate ROI the right way. In this episode of Lights Out, we break down the financial side of automation in plain language so every shop owner, operator, and leader can make smarter investment decisions with confidence. This is the follow-up to our baseline episode, where we had listeners identify their current spindle utilization, setup times, labor load, and cost per part. Now we take the next step: turning those numbers into an ROI model that actually reflects how automation performs on the shop floor. Instead of guesswork, gut instinct, or "we tried that once," we show you how to quantify annual savings, increased capacity, reduced scrap, payback period, and more. We simplify the math in a way that works for high-mix job shops, multi-shift production cells, and every workflow in between. Whether you're evaluating a robotic tending system, a pallet pool, high-density workholding, or a Cobot, understanding the financial impact of your decision is the foundation for long-term, scalable automation success. With real scenarios, honest discussion, and a few holiday-season laughs (including Nick's mysterious disappearance), this episode gives you the practical tools you need to approach automation with clarity—not confusion. If you want to make 2026 your most efficient year yet, start by calculating ROI the right way You will want to hear this episode if you are interested in...
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| The Automation Adoption Boom: Why ROI is the 2026 Metric That Matters, Ep #30 | 12 Dec 2025 | 00:39:01 | |
Before a shop can automate confidently, it has to understand one thing clearly: ROI drives every great automation decision. In this episode of Lights Out, David Vuyk and Eric Nekich kick off a multi-part series on Automation ROI—focusing not on hype or shiny tech, but on the real metrics and methods that determine whether automation will pay off or become an expensive paperweight. With "Jolly St. Nick Goellner" out preparing for the holiday season, David and Eric take the mic to break down a critical truth: you cannot automate an unreliable process, and far too many shops are buying robots before they fix the fundamentals. From workholding to setup reduction to operator loading, the guys lay out the baseline measurements every shop must capture before investing in automation. They also explore why automation adoption surged 30% this year and how reshoring, labor shortages, and rising demand are pushing shops to think differently about their processes. But enthusiasm alone isn't enough—what separates successful adopters from fence-sitters is the ability to quantify ROI quickly and accurately, not in a vacuum, but across the entire upstream-downstream workflow. This episode serves as the foundation for the ROI model the hosts will build in Part 2. You'll walk away knowing which numbers matter, how to capture them (even with pen and paper), and how to prepare your shop for real automation readiness. And yes…you'll also get your homework. You will want to hear this episode if you are interested in...
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| The Automation Trap: Saving a Shop with Systems, Not Spindles, Ep #21 | 01 Aug 2025 | 00:41:11 | |
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...
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| The Connected Advantage: Solving Real Problems with Hexagon's Digital Workforce, Ep #20 | 18 Jul 2025 | 00:42:01 | |
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...
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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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| 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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| 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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| Facing the Future: Automation Truths from 40 Years on the Shop Floor with Mike Gamache, Ep #29 | 28 Nov 2025 | 01:02:41 | |
As we dive into this episode of Lights Out, we sit down with someone who's seen automation evolve from pencil drawings and flame-cut templates to fully integrated robotic systems: our friend and longtime industry leader, Mike Gamache. For decades, Mike has lived at the intersection of machining, fabrication, automation, and continuous improvement, and we couldn't be more excited to bring his experience to our listeners. We reflect on how we first met Mike—a mix of Germany trips, delayed flights, Delta drink tickets, and a little tough love that eventually turned into friendship and collaboration. But what really makes this conversation valuable is the unfiltered truth Mike brings about automation. We explore what makes it succeed, why it fails, and how shops can avoid the painful mistakes that come from chasing trends instead of defining real problems. Throughout our conversation, we pull back the curtain on how companies like Metalcraft of Mayville use automation to transform throughput, stabilize processes, and eliminate the dirty, dull, dangerous, and demanding work no one wants. Mike walks us through identifying bottlenecks, understanding ROI, choosing between prefab and custom solutions, and overcoming the cultural resistance that keeps shops stuck in the past. We also talk about the mindset behind automation—how lean thinking, stable processes, and leadership alignment create the foundation for truly running lights out. And in a powerful shift, we explore Mike's "Create Holy Moments" philosophy, a reminder that continuous improvement isn't just for machines—it's for people, teams, and communities as well. This episode blends humor, hard-earned wisdom, and practical guidance you can use right away. If you're serious about improving your shop and moving toward lights-out operations, this is one conversation you don't want to miss. You will want to hear this episode if you are interested in...
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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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| 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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| From SWAT to Spindles: How Johnny Goode Led MSP Manufacturing's Lights-Out Transformation, Ep #28 | 14 Nov 2025 | 00:56:29 | |
What do law enforcement, SWAT operations, and CNC machining have in common? More than you'd think. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and Dave Vuyk welcome Johnny Goode, President and Co-owner of MSP Manufacturing in Bloomington, Indiana—a precision aerospace manufacturer that's rapidly transforming its operations with automation and digital processes. Johnny's journey is anything but typical. From police officer and SWAT team member to Army National Guard sergeant, his story is packed with grit, discipline, and leadership under pressure. When he traded in his badge for a badge of a different kind—the MSP logo—he brought with him the tactical mindset and resilience that now define his company's culture and growth. Today, MSP is running 24/5, leveraging modular workholding, five-axis machining, and ProShop ERP to deliver quality aerospace parts on time, every time. In this conversation, Johnny opens up about the leadership lessons he carried from the field to the factory floor, how he earned the trust of veteran machinists, and why he believes that culture, values, and integrity are the real foundation for successful automation. From implementing five-axis technology to reducing stress on his shop floor, Johnny proves that the human element still drives even the most automated operations. If you've ever wondered what it takes to modernize a legacy manufacturer without losing its soul—or how to build trust and innovation into every shift—this episode is one you won't forget. You will want to hear this episode if you are interested in…
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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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| Lights Out Intro | 17 Sep 2024 | 00:00:57 | |
| The Real Takeaways from EMO: Monitoring, AI, and the Changing Face of Automation, Ep #27 | 31 Oct 2025 | 00:45:32 | |
In this episode of Lights Out, we debrief from one of the largest manufacturing technology shows in the world—EMO Hannover. From automation and adaptive controls to AI-driven machining and the evolving economics of shop ownership, the team unpacks what's really changing in manufacturing and what's just noise. As the hosts reflect on trends like the shift from horizontal to 5-axis machining centers, the rise of machine monitoring and IoT integrations, and the reality of underused OEM technology, they dig into what these patterns mean for modern shops aiming to run smarter—not just harder. The conversation covers more than just new gadgets on the trade-show floor—it's about how cultural adoption, change management, and continuous improvement determine whether those technologies actually deliver ROI. We explore the parallels between software as a service and machine tool ownership models, the challenge of aligning shop-floor teams around innovation, and why data-driven manufacturing will define the next generation of top shops. Whether you're a shop owner wondering which investments will truly pay off, or a manufacturing leader preparing your business for the next wave of automation, this episode offers practical insights drawn straight from the global stage. You will want to hear this episode if you are interested in...
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| Coached—Not Just Monitored: How the Best Shops Turn Data into Action, Ep #26 | 17 Oct 2025 | 00:42:49 | |
You can collect data all day—but if you're not using it to coach your team, you're missing the point. In this episode of Lights Out, hosts Nick Goellner and Dave Vuyk wrap up their "Mindset Shifts for Lights Out Legends" series with one final transformation: moving from a monitored shop to a coached one. Drawing on lessons from Nick's recent talk at the Automated Shop Conference, the hosts unpack how to turn dashboards into decisions and metrics into motivation. They explain why dashboards don't make chips, how to turn OEE from a vanity metric into a coaching tool, and how to align both machines and people toward a shared goal of improvement. Nick also introduces the idea of the "other OEE"—Overall Employee Engagement—and explores how the best shops connect coaching, culture, and continuous improvement into measurable performance. From building the right tech stack (ERP, MES, and machine monitoring) to running better daily standups, this conversation breaks down what it really takes to lead a high-performance, data-driven manufacturing team. Whether you're running one shift or lights out, this episode will challenge how you think about data, leadership, and what it means to truly coach your people toward operational excellence. You will want to hear this episode if you are interested in...
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| Adaptive Over Aggressive: Redefining Lights-Out Manufacturing with Camoren Schley, Ep #25 | 26 Sep 2025 | 00:54:32 | |
Lights-out manufacturing isn't just about adding robots or running machines overnight — it's about creating a culture and a system where your shop can perform at its peak without constant human intervention. In this episode of Lights Out, hosts Nick Goellner, Eric Nekich, and David Vuyk sit down with innovator and entrepreneur Camoren Schley of Slytek to explore the technologies and mindsets making true lights-out operations possible. Camoren's story begins in his grandfather's Denver manufacturing shop and evolves into a journey of building and selling high-pressure coolant systems, developing machine monitoring technology, and launching Slytek's advanced adaptive control solutions. He's not just creating products—he's redefining how small and mid-sized shops can compete with enterprise-level operations. This episode dives into the mindset shift from being aggressive to adaptive and reactive to predictive—a crucial transformation for any shop looking to scale its production, reduce tool wear, and embrace automation. Camoren explains how adaptive controls, process monitoring, and integrated machine intelligence can help shops run longer, safer, and smarter while dramatically cutting costs. Listeners will also hear real-world examples of shops that implemented Slytek technology to move from constant babysitting and tool breakage to fully unattended overnight production. Whether you're running five machines or 150, this conversation shows how measuring, monitoring, and coaching can unlock the next level of performance. Finally, the hosts discuss how Slytek's holistic approach—from machine monitoring to process control to coaching—bridges the gap between data and decision-making. It's a blueprint for any manufacturer looking to shift from firefighting to future-proofing. You will want to hear this episode if you are interested in...
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| From Fixed to Mixed: Mindset Shifts That Power Lights-Out Manufacturing, Ep #24 | 12 Sep 2025 | 00:42:38 | |
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...
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| Carrying the Legacy Forward: Yuto Matsuura on Family, Precision, and the Future of Automation, Ep #23 | 29 Aug 2025 | 00:52:49 | |
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...
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| The Automation Trap: Turning Struggle into a Lean Legacy, Ep #22 | 15 Aug 2025 | 00:40:19 | |
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...
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| Lights Out, Level Up: Inside Imago's Next Phase of Automation and Time Freedom, Ep #38 | 10 Apr 2026 | 00:47:42 | |
What happens when a shop that's already running lights-out decides to push even further? The Lights Out team returns to Imago Manufacturing nearly a year after their first visit to see how Ryan's lights-out vision has evolved. What they find is a shop that looks similar on the surface, same team, same footprint, but dramatically more capable thanks to thoughtful automation, improved workflows, and a relentless focus on unlocking unused capacity. It's a real-world look at what continuous improvement actually looks like in a small, highly automated shop. Ryan shares how Imago is pushing toward an ambitious goal: grow revenue by 50 percent over three years without adding people, spindles, or floor space. That challenge forces a different mindset, one centered on maximizing throughput, eliminating wasted motion, and using automation not just at night, but throughout the workday. The conversation explores how new robot loading, automated inspection, and smarter quoting strategies are helping the team move closer to that target. Beyond the technical strategies, the episode dives into the philosophy behind lights-out machining. Ryan explains how automation improves quality of life, removes repetitive work, and allows machinists to focus on higher-value problem solving. The group also introduces the concept of "lights in" manufacturing, automating processes during the day to create more freedom, focus, and productivity while the team is in the building. This return visit to Imago blends practical automation insights with a bigger message: lights-out isn't just about running machines unattended. It's about building a shop that respects people's time, increases capability without increasing headcount, and creates the kind of flexibility that makes both the business and the people inside it stronger. You will want to hear this episode if you are interested in...
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| Additive Manufacturing on the Shop Floor: Hype, Reality, and Where It Actually Works, Ep #37 | 27 Mar 2026 | 00:52:27 | |
Additive manufacturing has been "the future" of manufacturing for decades. And yet, for many shops, it still feels just out of reach—either too expensive, too complex, or too uncertain to justify. So where does it actually stand today? In this episode of Lights Out, we sit down with Mark Barfoot, VP of Global Sales at Xact Metal, to cut through the noise. With more than two decades of experience in additive, Mark has seen the technology evolve from experimental curiosity to a legitimate production tool—and he brings a grounded, shop-floor perspective on what's real versus what's hype. We explore where additive is delivering real value right now, starting with jigs, fixtures, and tooling, and how shops are using those applications as a gateway into more advanced production parts. Along the way, we unpack the biggest misconceptions—especially the idea that additive is simply a cheaper way to make the same parts—and why success starts with designing for the technology, not forcing it into existing workflows. The conversation also dives into what it actually takes to bring metal additive into a machine shop—from facility requirements and safety considerations to the learning curve your team should expect. If you've ever wondered whether additive belongs in your shop (or how to even begin evaluating it), this episode gives you a clear, practical starting point. Because the real question isn't whether additive will replace traditional machining—it's where the two work better together. You will want to hear this episode if you are interested in...
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| Lights Out Jeopardy: Additive, Automation, and Absolute Chaos, Ep #36 | 13 Mar 2026 | 00:53:15 | |
What happens when you take months of serious conversations about automation ROI, additive manufacturing, machine monitoring, adaptive controls, and digital factory strategy… and turn them into Jeopardy? Chaos. Competitive chaos. In this special episode of Lights Out, Eric Nekich steps into full game-show-host mode and challenges Dave Vuyk, Nick Goellner, and special guest Mike Payne to prove they've actually been paying attention to everything the show has covered recently. The result is part recap, part rivalry, and part unhinged manufacturing trivia night. The categories pull directly from some of the biggest themes the show has explored lately: machine tool monitoring, automation, adaptive control, additive manufacturing, CNC myths and stereotypes, and digital factory tech. Along the way, the group revisits ideas around hybrid manufacturing, predictive maintenance, collaborative automation, and why modern machinists are far more than button pushers. But this episode is more than a gag. It's a fun, fast-moving summary of the real lessons behind recent Lights Out conversations. Underneath the jokes, arguments, and questionable Jeopardy rulings is a sharp reminder that the future of manufacturing belongs to shops willing to learn, adapt, and apply technology with intention. And yes, in true Jeopardy fashion, wrong answers cost money. Which makes the final scoreboard even more entertaining. You will want to hear this episode if you are interested in...
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| Who Killed the Cobot Dream? The Truth About Collaborative Robots, Ep #35 | 27 Feb 2026 | 00:41:00 | |
There's been a murder on the shop floor. Or at least… that's how this episode begins. In this creative, detective-themed installment of Lights Out, Dave Vuyk, Eric Nekich, and Nick Goellner investigate what happened to the once red-hot promise of collaborative robots. A decade ago, cobots were projected to revolutionize machine shops. They were marketed as affordable, easy-to-deploy, cage-free automation that would solve the labor crisis and democratize robotics for small and mid-sized manufacturers. But the explosive growth forecasts never quite materialized. So what happened? Was it marketing overpromise? Technical limitations? Payload constraints? Misapplication? Integration complexity? Market saturation? Or was the industry simply expecting too much, too fast? The verdict might surprise you. This episode blends humor, hard-earned lessons, and practical automation strategy to unpack what actually works — and what doesn't — when bringing robotics onto the shop floor. You will want to hear this episode if you are interested in...
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| Hybrid Manufacturing: Why Additive vs. Subtractive Is the Wrong Debate, Ep #34 | 13 Feb 2026 | 01:03:26 | |
Is hybrid manufacturing just a buzzword, or is it the next logical evolution of modern machining? In this episode of Lights Out, David Vuyk, Nick Goellner, and Eric Nekich sit down with Dr. Jason Jones, CEO and founder of Hybrid Manufacturing Technologies, to unpack what hybrid manufacturing actually means and why it's gaining real traction inside production environments. Rather than framing additive and subtractive manufacturing as competing technologies, Dr. Jones explains how the real opportunity lies in integrating them. By combining metal 3D printing, CNC machining, and in-process inspection into a single digitally controlled workflow, manufacturers can dramatically reduce wasted motion, eliminate handoffs, and unlock new efficiencies, especially in repair, feature addition, and late-stage configuration. The conversation goes beyond hype. The hosts dig into practical applications, certification challenges, inspection integration, ROI expectations, and what's truly holding shops back from adopting hybrid systems. For shops looking to modernize without blindly chasing the newest trend, this episode offers a grounded look at where hybrid fits into a broader automation strategy. You'll want to hear this episode if you are interested in...
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| Lights Out at 20: Inside a One-Man, Multi-Axis Machine Shop with Michael King, Ep #33 | 30 Jan 2026 | 00:52:47 | |
What does the future of manufacturing look like when it's built by someone who has never known a world without digital tools, automation, or on-demand learning? In this episode of Lights Out, the hosts sit down with Michael King, founder of Munkworks, whose story feels almost implausible until you hear it unfold. Michael bought his first CNC machine as a teenager, owns a five-axis machining center before he's old enough to legally drink, and runs a growing shop almost entirely on his own. But this conversation isn't about novelty. It's about mindset. From early hands-on building and 3D printing to running production parts lights-out overnight, Michael's approach challenges long-held assumptions about experience, labor, and scale in manufacturing. The discussion traces his unconventional path from RC airplanes and additive manufacturing into full-scale CNC machining, contract manufacturing, and automation. Along the way, the hosts explore how content, curiosity, and community replaced traditional apprenticeships, and why automation was never an afterthought for Michael, but the starting point. More than a technical discussion, this episode is a reflection on priorities. Michael is building a business designed around time freedom, family, and stewardship, not just output. It's a candid look at how the next generation may redefine what a successful machine shop looks like, and why lights-out manufacturing often starts with intention, not robots. You will want to hear this episode if you are interested in...
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| From ROI to Reality — Measuring Success After You Automate, Ep #32 | 16 Jan 2026 | 00:38:05 | |
Automation doesn't end when the system is powered on. In fact, that's often where the real work begins. In the third and final episode of this Lights Out series, the conversation shifts from planning and justification to execution, measurement, and long-term performance. After covering market forces driving automation adoption and breaking down ROI math in the first two episodes, this installment tackles the question many shop owners wrestle with once automation is live: Is this actually working? Dave Vuyk and Eric Nekich dig into how to validate performance, track meaningful metrics, and avoid leaving ROI on the table after implementation. Rather than chasing dozens of KPIs, the discussion focuses on practical measurement frameworks that connect directly back to the original business problem automation was meant to solve. From labor efficiency and throughput to OEE and cost per unit, the hosts explain how to create visibility without overwhelming leadership or alienating the shop floor. This episode also explores the human side of post-automation success. Metrics aren't meant to be surveillance tools. When used correctly, they become shared scorecards that drive engagement, continuous improvement, and ownership across the organization. For shops serious about lights-out manufacturing, this final chapter reinforces a simple truth: automation only delivers value when outcomes are measured, understood, and continuously improved. You will want to hear this episode if you are interested in...
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