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. 21H AGO

    Carrying the Legacy Forward: Yuto Matsuura on Family, Precision, and the Future of Automation

    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... (0:27) Investing in ProShop is an investment in your shop (2:56) Learn about Yuto Matsuura and his family’s four-generation legacy (6:26) Making the decision at 15 to commit to Matsuura during Japan’s recession (8:43) Feeling obligation versus genuine passion in carrying on the legacy (11:30) Outside expectations—from classmates to relatives—about his future role (13:13) Why his father limited family involvement to one successor (14:44) Yuto’s education abroad (earning a master’s degree in Canada in one year) (18:38) The influence of his grandfather’s legacy and the promise to honor it through work (21:33) Grow your top and bottom line with CLA (23:16) Why Matsuura has become synonymous with automation and precision (27:38) Real-world examples of reliability: Matsuura machines running 15 years straight (30:49) Why five-axis with pallet changers is the foundation of flexible automation (34:28) Standardization as the milestone for successful automation adoption (37:47) Yuto’s vision for the next 10–20 years: ERP, processes, and overcoming labor shortages (40:35) Why people and recruiting are as important as technology in manufacturing (41:54) What Yuto is most proud of: dealership networks, global partnerships, and digital transformation (44:26) How online marketing transformed both Matsuura’s reach and his own leadership confidence (50:54) “Load the workpiece, push the button, and go home to your family.” (51:20) Why you should listen to Machine Shop Mastery  Resources Mentioned Investing in ProShop is an investment in your shop Grow your top and bottom line with CLA Why you should listen to Machine Shop Mastery  Connect with Yuto Matsuura Matsuura Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    53 min

  2. AUG 15

    The Automation Trap: Turning Struggle into a Lean Legacy

    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... (0:16) The real-life ROI of ProShop ERP (2:46) Intro to the final episode of The Automation Trap series (3:37) Recap—value stream mapping, bottlenecks, and early 5S changes (6:06) Iron Clunk reborn as Iron Wheel Manufacturing (6:40) Introduction of Overall Equipment Effectiveness (OEE) metric (9:25) How OEE measures availability, performance, and quality of improvement ideas (10:47) Why tracking engagement and continuous improvement matters (12:34) Pairing lean systems with people-driven problem solving (14:00) Lean-first automation that supports flow, not chaos (18:21) From low-margin work to a joyful, profitable workplace (18:49) Grow your top and bottom-line with CLA (19:27) Leadership without micromanagement—ERP, QMS, and machine monitoring (21:27) Building quality into every function of the business (22:58) Eric explains the “Vision, founder, fit” model (24:14) Balancing shop success with personal life and vision (26:34) The role of people in shop transformations—staffing and recruitment (27:31) Full-circle moment—Iron Wheel hosts a Top Shop Turnaround tour (29:15) How long does it take to turn a shop around?  (33:07) Lean Principles + Smart Automation + Engaged People = Your Legacy (35:05) Future Lights Out episodes—practical implementation and tech focus (36:19) Teaser: Yuto Matsuura on automation and lights-out machining (38:50) Why you need to listen to Machine Shop Mastery Resources & People Mentioned The real-life ROI of ProShop ERP Grow your top and bottom-line with CLA The Machine Shop MBA on MakingChips Check out the Machine Shop Mastery podcast Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by - PODCAST FAST TRACK

    40 min

  3. AUG 1

    The Automation Trap: Saving a Shop with Systems, Not Spindles

    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... (0:31) Investing in ProShop is investing in your business (2:55) Post-Europe recap, dad life, and terrible accents (4:23) Recap: Gary’s glimmer of hope and commitment to lean (5:55) Scene #1: Meet the Lean Stream team (7:37) Tim Woods = the 8 wastes explained (9:20) Acquiring messy shops with potential: the Gary investment thesis (10:35) Scene #2: Value Stream Mapping: identifying and solving bottlenecks (15:02) Shift the focus: it’s not just about cycle time (17:00) Deburring in or outside the machine? Depends on your readiness (18:45) Scene #3: Daily standups and 5S in action (20:41) Grow your top and bottom-line with CLA (21:50) Real-world benefits of a clean, organized shop (22:32) Why 5S fails without standardization and sustainability (23:45) Scene #4: Lean automation vision, from inspection to pallets (25:00) In-process inspection integrated into the system (27:25) Flexibility and smarter job switching with pallets (28:07) The tradeoff: spindle utilization vs. quality (29:00) What’s the right OEE target for high-mix shops? (29:43) Dinner scene: Linda’s back, and so is hope (31:40) Klaus’s story reminds Gary he’s not alone (32:36) Final scene: A new future for Iron Clunk takes shape (34:07) Vision → Strategy → Tactics: the right order for shop success (35:30) Personalizing lean: what works for your goals (38:19) What kind of pie? (The real debate of the episode) (39:20) Teaser: next time, Gary takes the lead (39:41) Why you should listen to Machine Shop Mastery Resources & People Mentioned Investing in ProShop ERP is investing in your business Episode 12 of Lights Out Lean Process Improvement with Noah Goellner Traction Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

    41 min

  4. JUL 18

    The Connected Advantage: Solving Real Problems with Hexagon’s Digital Workforce

    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... (0:18) An investment in ProShop is an investment in your business  (2:00) Introducing Darren Metherell and recapping Hexagon Live (5:38) Darren’s journey from VCR data collection to connected manufacturing (7:58) Hexagon’s dual strategy: direct sales and enabling their channel (9:05) The paperless traveler solution: eliminating 6 inches of paperwork per job (11:30) Mike explains Hill Manufacturing’s structure and core challenges (13:16) Tribal knowledge: Collecting data to actually using it for improvement (15:54) Dashboards and real-time visibility and gamifying performance (18:15) Breaking down OEE vs. spindle utilization (21:38) Grow your top and bottom-line with CLA (22:16) More Connected Worker workflows: quality, inventory, audits, training (26:51) How Hexagon tailors solutions to actual pain points (28:52) Capturing tribal knowledge as interactive digital checklists (30:14) Automating more lights-out hours: sensors, cameras, RFID (32:40) Bringing life to legacy equipment through smart retrofitting (34:10 Why time-to-value beats big custom builds every time (35:15) Making this tech accessible to 10-person shops—not just OEMs (36:32) What Darren’s most excited about: unlocking value from existing systems (38:44) Mike reflects on buying shops with aging tech—and scaling anyway (39:43) Connected workers = empowered workers = future leaders (40:33) Check out the Machine Shop Mastery Podcast Resources & People Mentioned Hexagon Connected Worker Connect with Darren Metherell Hexagon Connect on LinkedIn Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

    42 min

  5. JUL 4

    The Automation Trap: One Shop’s Hard Lesson in Lean Thinking

    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... (0:20) Invest in your shop by investing in ProShop ERP (4:07) How the audience is relating to Gary’s story (5:23) A breakdown of lean’s eight wastes—and how they show up (12:13) The team recaps Gary’s struggles (13:54) Scene 1: The cobot goes live, but chaos erupts—flawed parts, angry employees, and mounting delays (19:53) Grow your top and bottom line with CLA (20:33) Scene 2: Deburring, quality, and morale collapse as Gary isolates his team (26:13) Scene 3: Gary's marriage and shop fall apart as his machine monitoring data lies (27:25) Scene 4: Gary misses out on hiring Sarah, who joins Lean Stream instead (30:11) Scene 5: Klaus offers Gary a second chance—if he’s willing to commit (34:12) What Gary (and the audience) can learn from pausing to evaluate the real bottlenecks (37:31) Scene 6: Gary begins the process of transformation—with Klaus as a mentor (39:13) Reflections on community, leadership, and what’s next for Gary (41:08) Reasons you should listen to Machine Shop Mastery Resources & People Mentioned The 8 Wastes of Lean The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

    43 min

  6. JUN 20

    The Automation Trap: Why Automating Chaos Won’t Save You, Ep #18

    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... (0:18) Invest in your business by investing in ProShop ERP (2:45) Welcoming Eric Nekich back to the show (3:47) Recapping the previous episode (5:24) Dinosaur vises, angry quality guys, and bad vibes (9:01) The real trap: automating before your process is ready (11:19) The Maestro moment: solving quality bottlenecks with automation (16:43) Enter Klaus: the lean legend with smiling operators and Modern Machine Shop awards (18:50) Is your envy even valid? Why copying Klaus might not make sense (20:57) Grow your top and bottom line with CliftonLarsonAllen (21:36) Gary’s backstory: loans, burnout, and a desperate dream (25:13) High mix vs. high volume: why the context matters (26:27) Team buy-in, financial transparency, and culture shifts (29:32) Spindle utilization vs. OEE: don’t get distracted (33:22) The cobot mistake: throwing money at a process you haven’t measured (35:59) Pallet vs. part loading: how to match automation to application (36:54) Cobot myths: it’s not collaborative unless the whole setup is (39:10) Cliffhanger: Gary wins the job—but he’s not ready to deliver (41:18) What Gary should’ve done instead: value stream mapping and expert help (45:51) Why you should listen to Machine Shop Mastery Resources & People Mentioned Keys to Maintaining a Manufacturing Leadership Mindset Workholding Evolves with Great Partnerships  The Toyota Way The Goal Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK

    47 min

  7. JUN 6

    Dimming the Lights: How to Build a Shop Ready for Automation, Ep #17

    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... (0:23) Why investing in ProShop ERP is investing in your business (2:51) Launching the Automation Academy and why it matters (5:58) Breaking the myth: “We’re not the right shop for automation” (9:30) Labor cost comparisons and reshoring pressure (12:00) Automation as a path to upskilling, not layoffs (15:17) Mapping your process before automating anything (17:59) Why standardization is the real foundation for automation (19:58) How to simulate lights-out before buying equipment (21:51) How to grow your top and bottom line with CLA (23:01) Monitoring, readiness, and proving ROI from the start (28:59) Managing cultural resistance and getting team buy-in (31:43) Infrastructure checklist: air, power, network, layout (37:34) Why cobots aren’t a magic bullet (and what to ask first) (41:00) Wrapping up with key takeaways and what’s next in the series (43:10) Why you need to listen to Machine Shop Mastery Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production by PODCAST FAST TRACK

    45 min

  8. APR 25

    Is Coaching the Key to Lights-Out Success?

    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... (0:47) Why you need to complete the Top Shops benchmarking survey (2:30) David Vuyk’s journey from mechanical design to CNC machining to tech solutions (10:31) Navigating resistance on the shop floor and managing change (13:03) Engaging frontline workers and leadership for tech adoption (14:53) Dave’s role at CloudNC and how he works with decision-makers (18:45) Elevating employees through automation, not replacing them (22:27) The CloudNC phased approach to customer success (25:04) Grow your top and bottom line with CLA (26:57) The StoryBrand framework: Communicating your company’s true value (34:17) Thinking beyond your product: Coaching customers for long-term lights-out success (38:42) Solving constraints beyond your offering (tools, processes, mindsets) (41:23) The responsibility of software teams to simplify adoption (42:16) Our final takeaways from the conversation  (51:37) Check out the Machine Shop Mastery podcast! Resources & People Mentioned Grow your top and bottom-line with CLA Take the Top Shops Survey HIREMfgLeaders.com Storybrand Connect with David Vuyk Connect on LinkedIn CloudNC Connect With Lights Out LinkedIn MakingChips.com Subscribe to Lights Out On Apple and Spotify

    53 min
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Inspiring and teaching Manufacturing Leaders in the areas of automation.

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