Manufacturing Transformed: Real Shops, Real Stories

Paul Van Metre
  • 5.0 (3)
  • TECH NEWS
  • UPDATED SEMIWEEKLY

In the bustling world of manufacturing and machining, efficiency and precision are key. The Manufacturing Transformed podcast is your peek into how companies benefit from being #PoweredByProShop.

  1. 3D AGO

    Turning Legacy Processes into Lean Systems: The Lafarge & Egge Transformation Story

    In this episode of Manufacturing Transformed, I sit down with Bryan from Lafarge & Egge to talk about what real operational transformation looks like inside a highly specialized aerospace manufacturer. When Bryan joined the company, he stepped into a shop full of deep experience and craftsmanship—but also a lot of legacy processes. Critical information lived across spreadsheets, Access databases, and paper-based work instructions. Drawings, inspection records, and job tracking were spread across multiple systems, making it difficult to see what was really happening across the business. Instead of jumping straight into new machines or automation, Bryan and his team made a strategic decision: fix the systems first. We talk through how Lafarge & Egge digitized their workflows, consolidated multiple tools into a single platform, and built a stronger operational foundation across two facilities. The impact has been significant—from faster quoting and contract review to better visibility on the shop floor and a much smoother audit process in a highly regulated aerospace environment. Bryan also shares lessons learned along the way, including how they capture tribal knowledge, manage complex quality requirements, and think about lean systems in a high-mix manufacturing environment. If you're interested in how manufacturers can modernize legacy processes while preserving the expertise that built the business, this conversation offers a practical and honest look at what that transformation actually takes. Topics Discussed Bryan's path from aerospace supply chain into manufacturing leadership What Lafarge & Egge manufactures and their specialization in high-pressure tube assemblies The operational challenges Bryan saw when he first joined the company The limitations of paper-based workflows and disconnected systems Why the team prioritized digitizing processes before investing in new equipment Replacing spreadsheets, databases, and manual workflows with a unified system Cutting contract review timelines from weeks to days Improving traceability, inspections, and audit readiness in aerospace manufacturing Coordinating operations across two facilities on a shared system How better visibility into data helps support growth and smarter decision-making Bryan on LinkedIn: linkedin.com/in/bryanluttrell Lafarge & Egge: https://lafargeandegge.com/ Email: Info@lafargeandegge.com

    58 min

  2. MAR 3

    Cultivating a Continuous Improvement Culture

    For most manufacturing founders, the early years mean fighting fires, working late nights, and inheriting old ways of working. But what if you could skip the legacy headaches and design your shop for the future—right from day one? That's exactly what David Bamforth did at Renscott Manufacturing. David didn't inherit a tired, paper-heavy organization—he started Renscott as a college student, purchasing his first CNC mill at 21 and building workflows around digital tools, not file cabinets. With a relentless focus on innovation, he and his team rolled out everything from paperless work orders and custom job management APIs to a powerhouse co-op program that develops talent in-house. Renscott has grown from a bootstrapped startup to a cutting-edge manufacturer with 40,000 square feet, 32 full-time employees, ISO/AS/ITAR certifications, and a customer roster spanning spaceflight and defense. Their digital-first mindset allowed them to break into metal 3D printing, implement traceability systems for complex powder inventories, and even inspire legacy shops to update their own game. In this episode, David shares his blueprint for shop design, workforce development, custom automation, and how a new generation is redefining what a job shop can be—with ProShop ERP as the operational foundation.   David Bamforth on LinkedIn: https://www.linkedin.com/in/david-bamforth/  Renscott Manufacturing: https://www.renscottmfg.com/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    1h 5m

  3. FEB 17

    Modernizing a High-Mix Machine Shop Lessons From DieCraft's Transformation

    For many job shops, the "perfect storm" looks like this: Your legacy ERP software is becoming obsolete due to Windows updates, and your two most senior employees, holding 72 years of combined tribal knowledge, are retiring at the same time. That was the reality facing Justin Westerfeld at Die-Craft Engineering. Die-Craft, a high-mix, low-volume shop averaging just 2-3 parts per order, was at a crossroads. They could continue operating as a traditional repair shop with heavy administrative overhead, or they could modernize. Justin chose the latter. By implementing ProShop ERP, Die-Craft didn't just replace software; they fundamentally changed their business economics. The results of this digital transformation are staggering. Die-Craft reduced their front-office staff from 11 people down to 6, saving nearly four full-time salaries strictly through efficiency gains, while simultaneously increasing milling capacity by 20%. In this episode, Justin reveals how accurate job costing allowed them to win back lost contracts, how they slashed office processing time from 10 days to 1, and why even their most "crotchety" manual machinists now panic if their computers go down. Justin Westerfeld on LinkedIn: https://www.linkedin.com/in/justin-westerfeld/ Die-Craft Engineering: https://www.diecraftmachine.com/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    1h 3m

  4. FEB 3

    Huge Parts, Huge Success: Craig Lange of Lange Machine & Tool

    Some shops measure parts in millimeters. Lange Machine and Tool measures them in tons, up to 80,000 pounds, to be exact. But running a shop that handles massive mining and foundry components with a small batch, high-mix workflow presents a unique data challenge. For decades, Craig Lange's family business relied on paper cost cards and a custom-built Access database to keep track of it all. It worked, but at a cost. It required nearly a full-time employee just to handle data entry, and tribal knowledge was constantly slipping through the cracks. When a job came back three years later, the team often had to "relearn" the setup from scratch. In this episode, Craig shares how moving to ProShop ERP was the administrative equivalent of upgrading from a manual lathe to a CNC machine. By digitizing their entire workflow, Lange Machine cut office processing time from days to just five minutes. They captured critical setup data, reducing setup times by 10%. Most impressively, when a key administrative employee retired, the new efficiencies allowed them to handle a 15% increase in growth without backfilling the position. This is a story about how a 52-year-old family business modernized their operations to handle monster parts with precision and profitability. Craig Lange on LinkedIn: https://www.linkedin.com/in/craig-lange-83974b1a/ Lange Machine and Tool: https://www.langemachine.com/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    50 min

  5. JAN 20

    Small Headcount - High Discipline: Building Success with Garrett from Elemental Design + Machinery

    Most machine shop startups are defined by hustle, long hours, and organized chaos. But when Garrett Wolfford founded Elemental Design + Machinery in January 2024, he had a different blueprint: "Small headcount, high discipline". While many owners wait years to professionalize their operations, Garrett built the foundation of a major aerospace facility for a team of just three people. He didn't wait to "grow into" systems; he implemented AS9100 certification, ITAR registration, and ProShop ERP almost immediately. The goal was audacious: to transition from general manufacturing to critical "hard parts" for the aerospace and defense sectors. After a site visit to a major rocket manufacturing facility ignited a fire in the team, they worked backward from the customer's vendor checklist, acquiring the necessary CMM technology, Model-Based Definition (MBD) capabilities, and digital infrastructure to qualify. The strategy paid off. In less than two years, Elemental went from an empty floor to an approved supplier for a major rocket company, securing their first six-figure purchase order shortly after certification. This episode is a case study on why "too small" is a myth. It explores how digital manufacturing systems, rigid quality planning, and a refusal to compromise on discipline allow a small shop to compete directly with industry giants. Garrett Wolfford on LinkedIn: https://www.linkedin.com/in/garrett-wolfford-567714311/ Elemental Design + Machinery: https://elementaldesignandmachinery.com/about/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    1h 3m

  6. JAN 6

    Scaling a Machine Shop Without Losing Control with Wesley of B&W Machine Works

    In this episode, I chat with Wesley Traumbauer of B&W Machine works. We examine what happens when a manufacturing business grows faster than the systems supporting it. As complexity increases, reliance on memory, informal communication, and disconnected tools creates friction that compounds daily. What once felt manageable begins to erode trust in schedules, delivery dates, and capacity, making even simple decisions heavier than they need to be. When estimating, scheduling, purchasing, and quality exist in separate places, visibility disappears. Work-in-process grows, interruptions increase, and leadership is forced into reactive mode. The episode highlights how uncertainty, not workload, is often the real driver of stress inside a growing shop. A central theme is the shift toward integrated systems and what that transition actually changes. Centralization doesn't eliminate problems, but it exposes them early and forces clarity. Data replaces assumptions. Accountability becomes visible. Decisions are made with confidence instead of instinct. The discussion reinforces that this shift is less about software and more about operational discipline. Leadership and culture remain constant threads throughout. Systems only work when they are used consistently. Side spreadsheets, workarounds, and exceptions undermine trust and keep businesses stuck in chaos. Real transformation requires commitment, standardization, and a willingness to let the system surface uncomfortable truths. The result is not slower work, but calmer work. Planning extends further into the future. Communication improves. Problems live in the system instead of in people's heads. The episode illustrates how structure creates resilience and why sustainable growth depends on visibility, process, and trust in the data. Make sure you give it a listen. LinkedIn: Wesley Traumbauer - https://www.linkedin.com/in/wesley-trumbauer-a30953324/ B&W Machine Works Inc. - https://bandwmachine.com/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    52 min

  7. 12/23/2025

    45: Eliminating Chaos: How Ferrera Tooling Streamlined Scheduling, Quality, and Traceability

    When Cody Joy joined Ferrera Tooling Company in 2020, the shop was growing rapidly but struggling with chaotic systems. Scheduling relied on a single Google Sheet, paper travelers cluttered the floor, and quality records were scattered across uncontrolled spreadsheets. Twice-weekly meetings attempted to manage priorities, but inefficiencies threatened to stall the company's expansion into aerospace and space exploration. Ferrera's leadership recognized the need for a paperless ERP solution. After considering building their own system, they adopted ProShop, which consolidated scheduling, inventory, serial number tracking, and estimating into one integrated platform. The transition eliminated redundant spreadsheets, improved traceability, and gave machinists confidence in their instructions and materials. This confidence translated directly into speed and throughput, reducing delays and boosting productivity. Quality assurance, once a bottleneck, was transformed. Ferrera expanded from two to eight CMM machines, while ProShop scheduled inspections and integrated static checks to reduce cycle times. Parts no longer piled up waiting for inspection, and audits became smoother, with AS9100 reviews shortened from five days to two. Auditors praised ProShop's robustness, reinforcing customer trust in Ferrera's processes. Culturally, ProShop became the backbone of Ferrera's operations. Cody, now Director of Systems and Process Engineering, emphasized how the system fostered accountability and teamwork, replacing endless meetings and email chains with a single source of truth. Employees embraced ownership, documenting setups with photos and detailed instructions, further strengthening the company's culture of continuous improvement. On a personal level, Cody noted that while his hours remain long due to Ferrera's growth, his stress is far more manageable. ProShop allows problems to "live in the system" rather than in his head, reducing the burden he once carried home. He believes that without ProShop, Ferrera would have reverted to chaos, unable to sustain its current scale. Instead, the company now thrives with streamlined scheduling, robust quality control, and reliable traceability. LinkedIn: Cody - https://www.linkedin.com/in/codyjoy/ Ferrera Tooling - https://www.ferreratooling.com/ Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    48 min

  8. 12/09/2025

    44: Massive Transformation with David Pannell of Faircloth Machine

    Faircloth Machine Shop's journey is one of remarkable transformation. Founded in the late 1960s as a manual machining operation, it was modernized under David Pannell, who joined in 1994 and helped transition the shop into CNC machining. By 2017, Faircloth adopted ProShop ERP, moving away from paper records and embracing digital systems that enabled growth into aerospace manufacturing. ProShop proved pivotal, offering built-in AS9100 compliance and integrated tools for audits, documentation, and quality management. Though the shift was a cultural shock, it allowed Faircloth to expand from 10 employees to nearly 40, with advanced CNC, Swiss, and five-axis machines producing complex aerospace assemblies. Lessons in standardization and systematization became critical as the stakes grew higher with expensive equipment, and ProShop's tooling and inspection modules helped prevent costly mistakes while streamlining operations. The company's success has also been defined by its people. David takes pride in hiring individuals with little experience and training them into skilled machinists and leaders. Employees like Brandon grew into pivotal roles, while mentors like Brian introduced systems that improved efficiency and quality. Even during crises, such as David's near-fatal accident in 2023, the staff kept the business running seamlessly, proving the strength of both the systems and the team. Today, Faircloth Machine Shop stands as a testament to persistence and tenacity. From humble beginnings with manual equipment and paper records, it has evolved into a certified aerospace manufacturer with advanced technology and a strong workforce. David's philosophy is simple: never give up, adapt to change, and keep building systems that support growth. With ProShop as a trusted partner and a dedicated team, Faircloth has become a thriving business that sustains livelihoods and strengthens American manufacturing. Email: Brandon B. McKinney - bmckinney@fairclothmachine.com.  LinkedIn: David Pannell - https://www.linkedin.com/in/david-pannell-62431a68/ Faircloth Machine Shop - https://fairclothmachine.com Audio and Video Production and Show Notes by - PODCAST FAST TRACK

    50 min
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In the bustling world of manufacturing and machining, efficiency and precision are key. The Manufacturing Transformed podcast is your peek into how companies benefit from being #PoweredByProShop.

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