Lights Out: Technology and Automation Podcast by MakingChips

Nick Goellner
  • 5.0 (4)
  • Management

Inspiring and teaching Manufacturing Leaders in the areas of automation.

  1. May 22

    Lights Out Lenses: Engineering, Quality & the Leadership Behind Automation (Part 2), Ep #41

    Part 2 of Lights Out Lenses moves deeper into the automation journey at Advanced Machine & Fabricating—this time through the eyes of engineering, programming, quality, and ownership. If Part 1 was about feeding the beast, Part 2 is about building the systems, standards, and culture that keep it alive. Director of Engineering & Programming Forrest Vaught shares how automation forced his team to rethink everything from tooling strategies to fixture design and program standardization. In a high-mix, low-volume environment, success doesn't come from simply buying automation. It comes from building repeatable systems that can survive unattended machining, changing priorities, and constant production pressure. Standardization becomes the language that ties everything together. The episode then shifts into a powerful conversation with owner Scott Shortess, who opens up about the emotional and financial realities behind automation. From struggling with low utilization and chaos to benchmarking shops overseas and realizing how much further the industry could go, Scott explains how automation exposed weaknesses in leadership, processes, and culture—and ultimately forced growth in all three. But beneath the technology discussion is something even more important: people. This episode becomes a conversation about trust, humility, patience, and creating a company where automation doesn't just improve throughput—it improves lives. Four-day workweeks, empowered teams, stronger culture, and leaders who genuinely care about the people around them all become part of the equation. At its core, this isn't just an automation story. It's a story about what happens when a manufacturing company aligns technology, systems, and culture around a shared vision. You will want to hear this episode if you are interested in... (0:00) Dave recaps Part 1 and introduces the engineering and quality side of the automation journey (1:17) Forrest shares his background and path into CNC machining and engineering leadership (3:30) Combining CNC programming, quality planning, estimating, and CMM programming into one collaborative team (5:19) How strong teams and trust reduce micromanagement and improve execution (6:42) Designing automation around tooling, fixturing, material, and program stability (8:43) Why standardization is critical for successful automation in high-mix manufacturing (9:46) How automation changed the company's approach to tooling, fixtures, and part families (11:17) Check out the Hennig WorkFlow Automated Pallet Delivery solution (12:08) Inside the FASTEMS system and how "Pistol Pete" optimizes pallets, tooling, and scheduling decisions (15:02) The reality of automation bottlenecks and the challenge of feeding the system (16:06) Forrest discusses fixture design, programming demands, and balancing technical complexity (17:29) How continuous learning and evolving technology have shaped Forrest professionally (19:07) Forrest reflects on stress, growth, and how automation changes over time (20:22) Investing in ProShop ERP is an investment in your business (22:01) Scott Short joins the conversation to discuss leadership, culture, and the owner's perspective (25:38) The origins of Advanced Machine & Fabricating and building a culture-driven company (26:25) How automation exposes weak leadership, broken systems, and cultural issues (29:35) The challenges of implementing automation while managing chaos and organizational change (32:21) Lessons learned from benchmarking highly automated European manufacturers (35:08) Why automation is about amplifying people—not replacing them (37:03) Real-world examples of instability, troubleshooting, and continuous improvement on the shop floor (38:13) Get a free report of sales opportunities in your area at FacturMFG.com/chips (39:21) The financial risks, ROI considerations, and personal guarantees behind automation investments (41:13) Measuring machine utilization and the early steps that started the company's automation journey (43:47) How automation forced Scott to develop patience, trust his team, and think differently as a leader (47:25) The power of culture, unity, and aligning teams around shared goals (50:13) Scott reflects on creating a company where automation improves both business performance and quality of life Resources & People Mentioned Check out the Hennig WorkFlow Automated Pallet Delivery solution Investing in ProShop ERP is an investment in your business Get a free report of sales opportunities in your area at FacturMFG.com/chips Connect with ADVANCED MACHINING & FABRICATING DBA ADVANCED PMC ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC Scott Shortess on LinkedIn Forrest Vaught on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    52 min

  2. May 8

    Lights Out Lenses: Inside an Automation Journey from the Operations & Production Frontlines

    What does automation actually look like when you're in the middle of it—not from a vendor demo or a conference stage, but inside a real shop, with real constraints, real people, and real stakes? This episode of Lights Out kicks off a new series format—Lights Out Lenses—where the story of automation is told through multiple perspectives inside the same company. And not just any company, but ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC, a shop that's deep in the trenches of high-mix, low-volume manufacturing. Instead of a single narrative, you'll hear how automation is experienced differently depending on where you sit. From the Director of Operations thinking about material flow and process alignment, to the Director of Production obsessing over utilization and throughput, this episode pulls back the curtain on what it really takes to make automation work—not just in theory, but in practice. Randel Hamilton shares how automation didn't simplify the business—it expanded it. More output meant more coordination, more downstream pressure, and more need for structure. The machine might run lights out, but everything around it has to keep up. Meanwhile, PK brings a numbers-driven lens, breaking down the hidden opportunity in unused machine hours and why automation is less about technology and more about stability, repeatability, and smart part selection. Together, their perspectives reveal a powerful truth: automation doesn't eliminate complexity—it redistributes it. And for shops willing to embrace that shift, the payoff isn't just more parts—it's a fundamentally different way of thinking about the business.  You will want to hear this episode if you are interested in... (0:00) Lights Out Lenses: exploring automation through multiple perspectives (2:21) Randel Hamilton's background and early exposure to automation (4:29) The reality of automation implementation: years of iteration, not plug-and-play (6:46) Common misconceptions about automation and the importance of building the system while running it (8:22) How automation impacts jobs: shifting roles rather than eliminating them (10:33) Deciding what should and shouldn't be automated in a real-world shop (12:19) Why we love SMW Autoblok workholding and its effectiveness (15:00) Business impact: automation driving new responsibilities in sales, purchasing, and capacity planning (17:59) Personal impact: improved scheduling, reduced overtime pressure, and process-driven operations (22:06) Randel reflects on stress levels before and after automation (23:40) Get a free report of sales opportunities in your area from Facturmfg.com/chips (25:37) PK's role and focus on execution, output, and maximizing existing equipment (27:57) Overview of the FASTEMS automation cell and current utilization gap (29:14) The opportunity: capturing unused machine hours and increasing throughput (32:23) Key challenges including part selection, high-mix/low-volume work, and tight tolerances (33:56) Why we created Hire MFG Leaders (and why you should use it)  (34:30) How production teams evaluate which parts are good candidates for automation (35:49) The complexity of scheduling, tooling, workholding, and keeping the cell running (38:47) Continuous improvement mindset: expanding automation across more machines and processes (42:08) Using data and metrics to drive better performance and decision-making (43:43) PK reflects on stress levels and ongoing challenges in production (45:22) Key takeaway: automation shifts work, requires stability, and unlocks new levels of performance Resources & People Mentioned Why we love SMW Autoblok workholding and its effectiveness Get a free report of sales opportunities in your area from Facturmfg.com/chips Why we created Hire MFG Leaders (and why you should use it)  Connect with ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC DVANCED MACHINING & FABRICATING Dba ADVANCED PMC Randel Hamilton on LinkedIn Connect with PK (Pankaj Khanal) on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    47 min

  3. Apr 24

    DIY Automation That Actually Works: How One 80-Person Shop Cracked High-Mix Lights-Out Manufacturing, Ep #39

    Automation has a reputation problem. It's often painted as something reserved for massive factories, predictable part runs, and deep pockets. But what happens when a small, high-mix shop decides to challenge every one of those assumptions—and wins? In this episode of Lights Out, we sit down with Katie Murphy from Arcamed, an 80-person medical manufacturing company that did what most shops think is impossible: they built a fully functional, high-mix automation system… themselves. No massive integrator contracts. No perfect production environment. Just curiosity, grit, and a willingness to figure it out as they went. Katie walks us through how their team tackled one of the toughest use cases for automation—low volume, constantly changing parts—and still managed to unlock serious gains in machine utilization, throughput, and employee growth. From a "hokey bookshelf" prototype to a system capable of running 50+ hours unattended, this is a masterclass in progress over perfection. But this isn't just a story about robots. It's about mindset. It's about rethinking what your people should be doing, where your real bottlenecks are, and how much hidden capacity is sitting idle in your shop right now. The result? More output, higher wages, and a team that's more engaged than ever. If you've ever said, "automation won't work here," this episode might just change your mind. You will want to hear this episode if you are interested in... (0:00) Busting automation myths: small shops, high-mix work, and non-standard materials (1:57) Introducing Katie Murphy and the Arcamed automation journey (5:41) Inside Arcamed: medical manufacturing, machining plastics, and fabrication (9:07) The real problem: high-mix, low-volume production bottlenecks (11:21) Katie's role in continuous improvement and hands-on automation development (13:24) The goal: increasing machine utilization without adding labor (14:48) Why you need to look into grants for your businesses (16:28) Head to the DN Solutions Manufacturing Without Limits event (17:31) Measuring success through unattended runtime and capacity gains (21:52) Avoiding "local optimization" and freeing operators to do higher-value work (24:56) Upskilling employees and increasing wages through automation (26:42) Why Arcamed chose DIY automation over turnkey systems (29:06) From prototype "bookshelf" to scalable automation cell design (31:22) Using common features (like vises) to automate diverse part geometries (34:00) Get a free report of opportunities in your industry from FacturMFG.com/chips (35:08) The iterative process: trial, error, and continuous improvement (37:21) Learning automation skills on the job through problem-solving (42:15) The impact: major gains in spindle utilization and overall capacity (44:16) Investing in ProShop ERP is an investment in your shop (45:55) What's next: scaling systems and expanding press brake automation (47:37) The future: AI, vision systems, and bin picking capabilities (49:40) Advice for shops: the 80/20 rule and avoiding perfection paralysis (52:21) Arcamed's plans for learning at IMTS 2026 Resources & People Mentioned Conexus Indiana Head to the DN Solutions Manufacturing Without Limits event Get a free report of opportunities in your industry from FacturMFG.com/chips Investing in ProShop ERP is an investment in your shop IMTS 2026 Connect with Katie Murphy Arcamed Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    55 min

  4. Apr 10

    Lights Out, Level Up: Inside Imago's Next Phase of Automation and Time Freedom

    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... (0:00) Cigar, bourbon jokes, and setting the stage for a return visit to Imago (2:47) Introduction to Imago Manufacturing and recap of the first Lights Out episode (5:05) What's changed in a year and continuing the lights-out vision (6:59) Same team, more automation, and a thriving shop culture (8:41) Why you need to check out the Hennig WorkFlow system (9:34) New robot loader and instant buy-in from the team (12:03) Respecting machinists' time and eliminating repetitive work (14:45) Parenting advice, focus, and the philosophy behind time freedom (18:07) Automation as a path to better quality of life (20:32) SMW Autoblok offers world-class workholding (21:51) New mill automation and flexible vise-based workflow (26:57) Using automation as a competitive quoting advantage (30:12) The 50 percent growth goal and finding hidden capacity (37:28) Automating inspection and the ROI of measurement time (42:56) Head to the DN Solutions Manufacturing Without Limits Event (43:57) Introducing "lights in" manufacturing Resources & People Mentioned The Key to Time Freedom in Machining The Juice to Squeeze Ratio Imago Manufacturing Daily Lights Out Checklist Why you need to check out the Hennig WorkFlow system SMW Autoblok offers world-class workholding AI5X Smart Assistant by Intelligent Automation Head to the DN Solutions Manufacturing Without Limits Event The Goal Connect with Ryan Bankel Imago Manufacturing  Imago Manufacturing on Instagram Connect with Ryan on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    48 min

  5. Mar 27

    Additive Manufacturing on the Shop Floor: Hype, Reality, and Where It Actually Works

    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... (0:00) Real-world additive use cases including jigs, fixtures, and lightweight tooling (2:19) Introducing Mark Barfoot and the current state of metal additive manufacturing (6:54) Understanding additive hype cycles and why adoption takes time (11:23) Why we created Hire MFG Leaders (and why you should use it) (11:53) Why additive sticks: design freedom and enabling impossible geometries (14:31) Designing for additive vs trying to replace traditional machining (16:13) Where additive technology stands today across plastics and metals (19:51) Production applications and additive adoption in job shops (22:53) Justifying additive versus subtractive manufacturing  (24:35) An investment in ProShop ERP is an investment in your business (26:10) Facility requirements for bringing metal additive into a machine shop (32:45) Come see us at IMTS 2026! (33:39) Resources that shop owners should dig into to learn more (35:19) Common misconceptions about additive cost and capabilities (38:09) How AI and topology optimization are shaping additive design (41:57) Practical ways shops can start using additive internally (46:04) Training, education, and building additive expertise in-house (49:23) When additive makes sense and how shops should evaluate adoption Resources & People Mentioned Why we created Hire MFG Leaders (and why you should use it) An investment in ProShop ERP is an investment in your business Come see us at IMTS 2026! Connect with Mark Barfoot  Xactmetal.com Mark@Xactmetal.com Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    52 min

  6. Mar 13

    Lights Out Jeopardy: Additive, Automation, and Absolute Chaos

    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... (0:00) Welcome to the first episode of Lights Out Jeopardy (2:51) The game board: six categories covering automation, additive, monitoring, and digital factory tech (3:26) The first round begins with CNC myths, machine monitoring, and predictive maintenance (6:51) Additive manufacturing trivia: hybrid manufacturing and common misconceptions (10:28) Unlock Real Sales Opportunities in Your Market: Get a free report at facturmfg.com/chips (11:36) Daily Double: the biggest barrier to automation (13:44) Adaptive control, tool breakage prevention, and the economics of smart machining (16:43) What actually makes a smart factory "smart?" Data, reporting, and decision-making (19:05) Why you need to come to IMTS 2026 (20:03) ERP systems, Industry 4.0, and machine-to-machine communication (24:46) Lights-out manufacturing: what robots really replace in the shop (29:30) Machine monitoring myths: helping machinists instead of replacing them (33:02) Manufacturing myths, modern shops, and the "tech lab" reality of today's factories (39:30) Why we love SMW Autoblok for workholding (40:20) Adaptive machining explained using cruise control (43:58) Machine monitoring alerts, efficiency, and reducing unplanned downtime (47:25) Final round chaos: aerospace, robots, and a bottom-row Jeopardy sweep (50:44) The winner is revealed… Resources Mentioned  Unlock Real Sales Opportunities in Your Market: Get a free report of at facturmfg.com/chips IMTS 2026 SMW Autoblok Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    53 min

  7. Feb 27

    Who Killed the Cobot Dream? The Truth About Collaborative Robots, Ep #35

    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... (1:00) The "murder mystery" setup: Who killed the cobot dream? (4:04) The golden age of cobot hype and early trade show buzz (5:03) Democratizing automation: what cobots promised (8:08) The speed problem: why machinists called them "too slow" (11:40) The payload limitation reality in CNC applications (9:42) Join us at the 2026 MFG Meeting (13:37) Reliability and durability concerns on real shop floors (15:31) Suspect #1: Marketing overpromise (15:55) Suspect #2: Technical limitations (speed, strength, communication) (17:16) Suspect #3: Misapplication (20:26) Suspect #4: Integration complexity in imperfect environments (22:51) Suspect #5: Market saturation and low-cost competitors (25:50) The plot twist: The dream didn't die (19:13) Why you should check out the SMW Autoblok catalog (27:13) Why ISO and ANSI eliminated the term "cobot" in 2025 (29:11) Application-specific risk assessments and safety standards (31:19) When collaborative applications make sense (budget, space, repetition) (39:36) Get a free report of opportunities in your industry from Factormfg.com/chips (34:16) Real-world success story: medical plastics and lightweight parts (36:23) Final verdict: The right automation is the one that actually works Resources & People Mentioned Join us at the 2026 MFG Meeting, March 10th-12th in Ft. Lauderdale, FL Why you should check out the SMW Autoblok catalog Get a free report of opportunities in your industry from Facturmfg.com/chips Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    41 min

  8. Feb 13

    Hybrid Manufacturing: Why Additive vs. Subtractive Is the Wrong Debate

    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... (0:15) Mark your calendars and join at IMTS 2026 (3:17) Introducing Dr. Jason Jones and Hybrid Manufacturing Technologies (5:36) What hybrid manufacturing is (and how it will impact the industry) (9:32) Dr. Jones' journey from machinist to hybrid pioneer (16:10) Why hybrid manufacturing is often misunderstood (18:52) The false "additive vs. subtractive" debate (21:02) Real-world hybrid applications happening today (26:37) Why quality validation is the biggest adoption barrier (29:42) Blade repair and aerospace up-revision case study (32:28) Large-scale additive and gantry-style systems (35:00) Investing in ProShop ERP is an investment in your shop? (36:35) The chicken-and-egg problem with design adoption (39:52) Hybrid manufacturing and Industry 4.0 (43:57) Integrating in-process inspection (ultrasound, eddy current, etc.) (46:39) Adoption trends: early adopters vs. practical majority (49:40) Typical cost ranges for hybrid implementation (54:47) Why partnership matters in implementation (58:37) Practical advice for shops evaluating hybrid manufacturing (1:02:39) Why we created Hire MFG Leaders (and why you should use it) Resources & People Mentioned Mark your calendars and join at IMTS 2026 Investing in ProShop ERP is an investment in your shop Hire MFG Leaders Connect with Dr. Jason Jones Hybrid Manufacturing Technologies Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    1h 3m
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Inspiring and teaching Manufacturing Leaders in the areas of automation.

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