Lights Out: Technology and Automation Podcast by MakingChips

AI can write your emails, summarize your shop's performance, and help you make your next big decision. But how do you know when it deserves your confidence—and when it just sounds convincing?

On this episode of Lights Out, Nick and Eric sit down with AI ethicist Rebecca Boltsma to explore the questions that rarely make it into the sales pitch. When does automating communication put a customer relationship at risk? What happens when a shop leader starts making decisions based on AI-generated insights? And where's the line between getting help with your thinking and handing it ov...

Most automation conversations stop at the cell. This one keeps going, through a fab shop, a machine shop, a Department of Defense contract, and eventually a coal mine.

Michael McHale runs PSA Systems, an automation integrator in Pennsylvania that also fabricates, machines, and delivers turnkey projects in house. He bought the business in 2016 with four employees and about $900,000 in revenue. Today it's 100 people, 65 engineers, and over $30 million, split across five verticals that all feed each other. That structure is the whole point of this episode. When PSA chases something that looks like a distraction, like reclaiming and...

When Uriel Eisen needed more capacity in his 325-square-foot shop, his first instinct was to buy a robot. But the machine wasn't the real bottleneck. Production kept getting derailed by missing material, forgotten orders, and inexpensive supplies that nobody noticed until they were gone.

Uriel's path from designing spacesuits to manufacturing CNC-machined hardware eventually led him deep into Kanban, lean manufacturing, and continuous improvement. What began with index cards and a Sharpie ultimately became Arda—a system built to connect what happens on the shop floor with the people responsible for keeping it supplied.

In th...

Eric opens this episode describing a dream he had. A shop with no standalone machines. Three hundred and nine pallets moving 1,600 times a day. A central tool system holding 5,500 tools, five Fanuc robots shuttling up to 800 of them daily, and not a single crash. The punchline is that it wasn't a dream. He'd just walked through it.

That shop is Norbert Kempf CNC-Technik in St. Ingbert, Germany, a 100-person contract machine shop that runs simple to highly complex parts in batches of one to 500. We caught up with owner and managing director Stefan Kempf on his own...

What if the most powerful sensor on your shop floor isn't a camera or a probe or a vibration puck—but a power cord? That's the premise Lauren Dunford, co-founder and CEO of Guidewheel, brought to the show, and she explained it using a hundred toasters.

Guidewheel clips a current transformer around the cord and reads the electrical heartbeat of a machine. No PLC integration, no open heart surgery, no waiting on a controller vendor. From those tiny fluctuations the platform gets run, idle, and down, then cycle counts, cycle times, early maintenance warnings, and in a lo...

Every shop runs on a little tribal knowledge, the person who just knows where that tray of parts is headed and where it tends to get stuck. It works right up until they take a day off and the whole floor is hunting for a job that vanished somewhere between the mill and the heat treat rack. That gap is exactly what this episode is about: what happens when you stop guessing and start actually seeing where everything is.

Dave and Eric brought in Mitch Tucker of HID to break down RTLS, real-time location systems. In plain...

Conexus Indiana is an industry-led nonprofit that pulls the state's manufacturers, logistics companies, colleges, and public sector into the same room to tackle the problems they all share: building a workforce pipeline, speeding up tech adoption, and getting shops to actually help each other. Every state is scrambling for exactly that, and Indiana seems to have cracked it. This week we sat down with Bryce Carpenter, EVP and Chief Operating and Strategy Officer at Conexus Indiana, to ask a blunt question. Is this a model the rest of us should be stealing?

At its core, Conexus runs...

Most shops picture automation the same way. A robot arm bolted to a machine, a green button, and a quiet promise that you can finally walk out the door at night. This episode takes that picture apart, and what replaces it is a lot more useful.

The trio is back together, and to kick off a new run of episodes we brought in Sarah Wierman of Fastems, someone Nick worked alongside for five years in workholding before both of them drifted into automation. Her big reframe is the one worth sitting with. Fastems isn't really a pallet...

Every shop owner has stared at a floor full of expensive machines and thought the same thing: I need more capacity. More people. A second shift. Maybe another spindle. But the honest answer, most of the time, is that you already own the capacity you need. You just can't see how it's being used.

This week we sat down with Brian Anderson, Solutions Architect at ProShop ERP, for a conversation that hit uncomfortably close to home for all three of us. Brian has spent his whole career on both sides of this, first on the shop floor...

Every shop wants the shiny new machine. Walk a showroom floor like the one at ZOLLER's Technology Days in Ann Arbor and it's hard not to feel like a kid in a candy store. But the most useful question on this episode isn't which spindle to buy next. It's whether you're actually using the ones you already own.

We sat down at the ZOLLER Smart Manufacturing Summit with Walt Swenton, Senior Manager of Advanced Manufacturing at Eaton, for a conversation about problem-first thinking. Before you spend a dollar on technology, Walt argues, you have to name the...

Recorded live from the DN Solutions open house near Chicago, this special crossover episode between Lights Out and Buy the Numbers dives deep into what modern automation actually looks like inside growing machine shops. This isn't theory from a conference stage. It's a real-time conversation about throughput, utilization, machine strategy, and how shops can scale smarter without simply throwing more labor at the problem.

Nick and Mike explore one of the most important concepts in automation today: the "20-hour machine." Not the fantasy of perfect 24/7 uptime, but the practical reality of building reliable workflows that consistently create...

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 pr...

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 differ...

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.

Kati...

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...

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...

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 sh...

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? Te...

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...

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 3...

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...

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...

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 sh...

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 re...

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 ki...

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...

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 co...

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 so...

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, fr...

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...

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 hu...

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...

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. Da...

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 pa...

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...

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 matt...

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.

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...

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...

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 did...