Lights Out

🚨 The Automation Trap continues—and this time, Gary’s finally doing it right. After nearly automating his shop into chaos, he’s getting a second chance. But not with more tech—with systems, structure, and a team that actually knows how to build flow. In this episode of Lights Out, Klaus and the Lean Stream crew hit the floor at Iron Clunk with a vengeance: ✔️ Value Stream Mapping ✔️ Theory of Constraints ✔️ 5S (for real this time—not just a shiny floor) ✔️ Palletized automation that actually works in a high-mix shop More importantly? Gary’s team stops resisting change and starts owning it. The clutter clears. The cobots get replaced. And a clear vision starts to emerge—one that’s finally aligned with flow, not just utilization. If you’ve ever wondered how to turn a messy shop around—or how to make automation actually pay off—this one’s for you. 🎧 https://xmrrwallet.com/cmx.plnkd.in/ec27FQ5g 📽️ https://xmrrwallet.com/cmx.plnkd.in/ecrMMthk Nick Goellner Kaleb Mertz David Vuyk Eric Nekich Mike Payne Paul Van Metre Jennifer Dubose #LightsOutPodcast #TheAutomationTrap #LeanManufacturing #JobShopLife #SmartAutomation #ManufacturingLeadership #ContinuousImprovement #MachineShop #5S #TheoryOfConstraints #OEE #ValueStreamMapping

With this weeks Boring Bar Newletter, you have to wonder, is being smart boring? From CAM to Culture…We’re spotlighting what smart shops are actually doing to stay ahead. 🎯 Smarter programming with software that learns from every part 💸 A crash course in building real exit value (not just revenue) 🧠 A rising star in QC calling out what young talent really wants 📋 Immigration, audits, and how to protect your people and process 💬 Live chat that doesn’t feel like a chatbot 🤖 And the AI-fueled reality of paid search in manufacturing 👉 The tools are sharper. 👉 The talent is evolving. 👉 And the conversations are getting real. If you’re leading a shop, growing a team, or just trying to make sense of this fast-moving industry… You’ll find something in this lineup that hits home. Special thank you to all our guests this week! Ryan Pembroke Michael Pohl, CPA, CFP® Michael Britten Nush A. Matt Meltzer Nelson Bruton Kevin McClary Erin Mickels (Henseler), CPA Brandan Davis 🚀 👇 Check out all the episodes and give us a listen today. Don't forget to subscribe 🔔 to the newsletter for weekly updates and check out hiremfgleaders.com to find your next #MFGLeader! MakingChips Machine Shop Mastery Buy the Numbers The Manufacturing Executive Podcast Nick Goellner Paul Van Metre Matthew Nix Casey Voelker Jennifer Dubose Kaleb Mertz Mike Fritz CEO Kirk Phelps David Vuyk Jon Franko Joe Sullivan Big thanks to our sponsors: 👉 Hexagon Manufacturing Intelligence 👉 ProShop ERP 👉 SMW Autoblok Group 👉 Verdant Commercial Capital 👉 Phoenix Heat Treating 👉 Modern Machine Shop 👉 IMTS - International Manufacturing Technology Show 👉 CLA (CliftonLarsonAllen) 👉 Tree Top Staffing LLC (3DPhil) Phillip Lewis Larry Robbins Ty Willis Charlie Hushek Brent M. Donaldson Mary Cecile Neville Leslie Boyd Myles Rickerd

What is Hexagon’s Connected Worker—and why should you care? Most shops have some digital tools. An ERP here. A monitoring system there. Maybe a few spreadsheets that still get printed for the floor. But what if all of that data actually worked together—in real time—and in a way your team could use? That’s what Hexagon’s Connected Worker is all about. 💡 It’s not another massive system to implement. It’s a lightweight, scalable layer that: ✅ Replaces paper travelers with tablets and mobile workflows ✅ Connects to your ERP, MES, QMS—even Excel ✅ Displays real-time dashboards on the floor (OEE, quality, shift performance) ✅ Captures tribal knowledge and turns it into digital checklists ✅ Helps younger, screen-native workers get up to speed fast ✅ Costs about as much as a Netflix subscription to get started Instead of “ripping and replacing,” Connected Worker helps you maximize the value of what you already have—while empowering your team to work smarter, safer, and more efficiently. In our latest Lights Out episode, we sat down with Darren Metherell from Hexagon to break it all down. If you’ve got legacy systems, tribal knowledge issues, or a shop full of paper—you need to hear this. 🎧 https://xmrrwallet.com/cmx.plnkd.in/eKPQtwSg Nick Goellner Kaleb Mertz Eric Nekich David Vuyk Mike Payne Paul Van Metre #Manufacturing #SmartFactory #ConnectedWorker #DigitalTransformation #LightsOut #Hexagon #Automation #OEE #ERP #MES #JobShop

From parts that fit on the tip of your finger to weldments the size of a school bus—and even homes built on assembly lines—this week’s episodes on the MakingChips network cover the full spectrum of modern manufacturing. We dive into: 👉  How a watchmaker is solving challenges for quantum computing 👉  Why your banker might matter more than your next 5-axis 👉  What it takes to turn healthcare into a hiring advantage 👉  How prefab housing is being transformed by microfactories and mass customization If you want to grow your shop, think bigger, or just stay ahead of the curve, don’t miss this week’s lineup. 📩 Read the newsletter and catch the latest episodes 👇 Mike Payne Nick Goellner Paul Van Metre Jennifer Dubose #MakingChips #Manufacturing #Machining #Leadership #ShopOwnership #WorkforceDevelopment

It's easy to get excited about #automation. You've got great plans in place for the future—but do you have team buy-in? We can't forget the role of #empathy in lights-out #leadership. How are you involving your team in the #evolution of your shop? Tell us in the comments 👇 Nick Goellner Mike Payne Paul Van Metre Eric Nekich Kaleb Mertz David Vuyk Jennifer Dubose

In this episode of Lights Out, we follow what happens when a shop skips the lean fundamentals and tries to scale with chaos. The result? ➡️ Parts piling up ➡️ Quality falling apart ➡️ Good employees walking out It’s a cautionary tale—but also a roadmap to do it right. We break down the 8 wastes of lean as they happen in real time and show what it takes to turn things around. Learn the difference between automation and actual improvement. 📽️ https://xmrrwallet.com/cmx.plnkd.in/e_grdY6M Nick Goellner Eric Nekich David Vuyk Kaleb Mertz Jennifer Dubose #LightsOut #MakingChips #LeanManufacturing #AutomationStrategy #MachineShopLeadership #Independence

💡Automation isn't just about machines—it's about people, process, and vision. That’s why we’re heading to The Automated Shop Conference (TASC) this fall—and you should too. 🎙️ Three of us from the MakingChips crew are hitting the stage: • Mike Payne – Passing the Torch: Why Manufacturing’s Future Depends on the Next Generation • Paul Van Metre – Automating the Front Office Delivers Gains on the Shop Floor • Nick Goellner – Lights Out: How Advanced Manufacturing Leaders Stay Ahead of Their Machines If you're serious about improving throughput, reducing labor constraints, or preparing your shop for the next evolution of manufacturing, TASC is the place to be. 📍 It’s not a tradeshow. It’s a room full of forward-thinking shop owners and operators who are actually doing the work—and sharing exactly how. 🎟️ Want to join us? Message us for a 15% off registration code and we’ll see you there. 👉 https://xmrrwallet.com/cmx.pwww.tascevent.com/ Sponsored by: Modern Machine Shop, Gardner Business Media, Inc., Production Machining, and MoldMaking Technology #manufacturing #automation #jobshops #TASC #LightsOut #FrontOfficeAutomation #NextGenMFG #MakingChips

Thinking about automating? Measure first. In this episode of Lights Out, we tell the story of Gary—a well-meaning shop owner who sees robots, reads dashboards, and decides automation is his ticket to survival. The problem? He skips the part where you actually measure what’s happening on your floor. “If you don’t know your current state, how do you even know you were successful? Or if it got worse?” – Kaleb Mertz Spindle utilization might look like the magic metric—but it’s only one piece of the puzzle. Without quality, reliability, and performance in check, you’re just automating chaos. Want to know what Gary missed (and how to avoid the same trap)? Listen to The Automation Trap on Lights Out with this week's special guest, Eric Nekich! 🎧 https://xmrrwallet.com/cmx.plnkd.in/enQRD8z8 📽️ https://xmrrwallet.com/cmx.plnkd.in/dFthk6aB Nick Goellner David Vuyk Mike Payne Paul Van Metre Jennifer Dubose #automation #manufacturing #lightsout #machineautomation #kpi #leanmanufacturing #proshop #oee #cobot #cnc

Gary thought adding a robot and chasing spindle utilization would save his struggling shop. Instead, it pushed everything—his team, his marriage, his business—to the edge. Dun, Dun, Duuun... On Lights Out we are kicking off a new series that tells the story of Gary in an all too common situation for many machine shops. But will this be a redemption story?? Watch/Listen on all platforms and make sure you aren't Gary (unless your actual name is Gary, then sorry about that 😁) YouTube -> https://xmrrwallet.com/cmx.plnkd.in/gxT6Dw8s Website -> https://xmrrwallet.com/cmx.plnkd.in/gHv7qp82 Apple Music -> https://xmrrwallet.com/cmx.plnkd.in/gBxusNJG Spotify -> https://xmrrwallet.com/cmx.plnkd.in/gFWHc3G9 Nick Goellner Eric Nekich David Vuyk #MakingChips #LightsOut #AutomationTrap #ManufacturingLeadership #LeanManufacturing

That’s a wrap on Hexagon LIVE…what a blast! Huge thanks to Hexagon Manufacturing Intelligence for having Nick Goellner and me out to represent the MakingChips network. We saw real, practical manufacturing tech that I’m fired up to immediately explore for use at Hill Manufacturing & Fabrication. But like any great event in manufacturing…the best part? 👉 The people. From great conversations to late-night laughs, this crew made the entire trip worth it. Some are in the photos, many more aren’t, but every single one of you made the show perfect. Nick and I will be sharing what we learned, and who we met, right here and on the pods. So ring the bell, hit that like, follow, and subscribe button or whatever else you want so you can stay on top of all the news. 💥 Chris Luecke Nikki Gonzales Bonnie Gurney Mary Cecile Neville Jim Mayer (3DPhil) Phillip Lewis) Jennifer Dubose Dana Trismen Elaine Griffith Greg C. Buy the Numbers # Lights Out Manufacturing Happy Hour Automation Ladies AMT - The Association For Manufacturing TechnologyIMTS - International Manufacturing Technology Show The Manufacturing Connector CMMSradio Greg McHale Datanomix #MakingChips #HexagonLIVE #MetalworkingNation #MFGTech #Manufacturing #GrowingValue