Épisodes

  • From ROI to Reality — Measuring Success After You Automate, Ep #32
    Jan 16 2026

    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 table after implementation.

    Rather than chasing dozens of KPIs, the discussion focuses on practical measurement frameworks that connect directly back to the original business problem automation was meant to solve. From labor efficiency and throughput to OEE and cost per unit, the hosts explain how to create visibility without overwhelming leadership or alienating the shop floor.

    This episode also explores the human side of post-automation success. Metrics aren't meant to be surveillance tools. When used correctly, they become shared scorecards that drive engagement, continuous improvement, and ownership across the organization. For shops serious about lights-out manufacturing, this final chapter reinforces a simple truth: automation only delivers value when outcomes are measured, understood, and continuously improved.

    You will want to hear this episode if you are interested in...
    • (0:00) Recap of the three-part automation ROI series
    • (2:03) The risk of flying blind without a measurement framework
    • (3:20) Why tracking everything dilutes ROI visibility
    • (3:58) Tying KPIs back to the original business problem
    • (4:46) Core automation KPIs tied to ROI calculations
    • (6:08) What realistic ROI looks like 90 days after implementation
    • (6:45) Join us at the 2026 IMTS Exhibitor Workshop
    • (8:52) Why labor savings alone don't tell the full story
    • (10:55) Manufacturing cost as a percentage of revenue
    • (11:44) Translating KPIs into shop-floor language
    • (12:50) Capacity gains, lead times, and customer impact
    • (13:39) Breaking down OEE into availability, performance, and quality
    • (16:36) How fixturing and workholding affect automation ROI
    • (18:46) Process reliability, chip management, and coolant considerations
    • (20:06) Why ROI ownership must extend beyond leadership
    • (21:22) Why we love SMW Autoblok for workholding
    • (22:33) Benchmarking without falling into the comparison trap
    • (25:36) Industry averages for OEE, OTD, and cycle time reduction
    • (27:40) Crawl, walk, run expectations for lights-out automation
    • (29:52) Change management and shop-floor buy-in
    • (34:24) Three post-implementation actions to lock in ROI
    • (38:56) Use Hire MFG Leaders for your next hire
    Resources & People Mentioned
    • Join us at the 2026 IMTS Exhibitor Workshop
    • Check out SMW Autoblok's catalog
    • ProShop ERP
    Connect With Lights Out
    • LinkedIn
    • MakingChips.com

    Subscribe to Lights Out

    On Apple and Spotify


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    38 min
  • How to Calculate Automation ROI — The Right Way, Ep #31
    Dec 26 2025
    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 ROI model that actually reflects how automation performs on the shop floor. Instead of guesswork, gut instinct, or "we tried that once," we show you how to quantify annual savings, increased capacity, reduced scrap, payback period, and more. We simplify the math in a way that works for high-mix job shops, multi-shift production cells, and every workflow in between. Whether you're evaluating a robotic tending system, a pallet pool, high-density workholding, or a Cobot, understanding the financial impact of your decision is the foundation for long-term, scalable automation success. With real scenarios, honest discussion, and a few holiday-season laughs (including Nick's mysterious disappearance), this episode gives you the practical tools you need to approach automation with clarity—not confusion. If you want to make 2026 your most efficient year yet, start by calculating ROI the right way You will want to hear this episode if you are interested in... (0:23) How ProShop ERP delivered rapid ROI in Mike Payne's shop(2:49) Today's focus on ROI and key metrics(4:15) Review of required baseline data including utilization, setup time, labor load, and cost per part(6:32) Breakdown of the simple ROI formula and the more detailed expanded formula(8:53) ROI Example: Labor savings, increased spindle hours, and scrap reduction(12:39) Method for calculating labor savings using remaining labor percentage(13:45) Why you should use Hire MFG Leaders for your next hire(14:16) Converting increased machine utilization into measurable financial value(15:02) Impact of pallet pools and high-density workholding on cutting setup and changeover time(16:49) Importance of including maintenance, programming, and depreciation in ROI models(19:38) Role of adaptive feed-rate controls in improving uptime and process reliability(21:57) ROI scenarios for robotic tending cells and five-axis pallet pool systems(24:18) Value of redeploying skilled operators to higher-impact work as part of automation ROI(25:16) When Cobots are an appropriate automation choice and when integrators are necessary(27:18) Key homework steps: running a basic ROI estimate and identifying utilization gaps(29:32) Why you need to check out the SMW Autoblok catalog Resources & People Mentioned How ProShop ERP delivered rapid ROI in Mike Payne's shopWhy you should use Hire MFG Leaders for your next hireWhy you need to check out the SMW Autoblok catalog The Core ROI Formula for Automation Simple version: ROI (%) = (Annual Savings – Annual Costs) ÷ Investment × 100 Expanded version for manufacturing: ROI = [(Labor Savings + Increased Machine Utilization + Scrap Reduction + Overtime Avoided) – Maintenance & Depreciation] ÷ Capital Cost Connect With Lights Out LinkedInMakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK
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    31 min
  • The Automation Adoption Boom: Why ROI is the 2026 Metric That Matters, Ep #30
    Dec 12 2025

    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 shops are buying robots before they fix the fundamentals. From workholding to setup reduction to operator loading, the guys lay out the baseline measurements every shop must capture before investing in automation.

    They also explore why automation adoption surged 30% this year and how reshoring, labor shortages, and rising demand are pushing shops to think differently about their processes. But enthusiasm alone isn't enough—what separates successful adopters from fence-sitters is the ability to quantify ROI quickly and accurately, not in a vacuum, but across the entire upstream-downstream workflow.

    This episode serves as the foundation for the ROI model the hosts will build in Part 2. You'll walk away knowing which numbers matter, how to capture them (even with pen and paper), and how to prepare your shop for real automation readiness. And yes…you'll also get your homework.

    You will want to hear this episode if you are interested in...
    • (0:00) Why automation fails when processes and fixturing are unreliable
    • (0:12) Why we love SMW Autoblok for workholding
    • (2:18) Launching the Automation ROI series and framing the conversation
    • (3:42) Industry trends driving a 30% rise in automation adoption
    • (6:31) Fence-sitters, misconceptions, and why ROI must lead decisions
    • (7:29) Step one of ROI: defining the process and the goal behind automation
    • (11:03) Why ROI must include upstream and downstream impacts
    • (13:46) Common automation failures, cobot misuse, and "coat hanger" systems
    • (16:44) Core ROI foundations and costs affected by automation
    • (17:43) Partner with Verdant Commercial Capital for financing
    • (22:35) Metric #1: Measuring spindle utilization accurately
    • (25:22) Metric #2: Understanding setup time and the role of modular workholding
    • (28:50) Metric #3: Operators per machine and multi-machine tending
    • (31:18) Metric #4: Labor cost per part and machine burden calculations
    • (32:18) Metric #5: Remaining Labor Percentage and what "good" looks like
    • (35:34) Homework: identify bottlenecks and capture current-state metrics
    • (38:14) Make your next hire with Hire MFG Leaders
    Resources & People Mentioned
    • Why we love SMW Autoblok for workholding
    • Partner with Verdant Commercial Capital for financing
    • Make your next hire with Hire MFG Leaders
    Connect With Lights Out
    • LinkedIn
    • MakingChips.com

    Subscribe to Lights Out

    On Apple and Spotify


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    39 min
  • Facing the Future: Automation Truths from 40 Years on the Shop Floor with Mike Gamache, Ep #29
    Nov 28 2025
    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 really makes this conversation valuable is the unfiltered truth Mike brings about automation. We explore what makes it succeed, why it fails, and how shops can avoid the painful mistakes that come from chasing trends instead of defining real problems. Throughout our conversation, we pull back the curtain on how companies like Metalcraft of Mayville use automation to transform throughput, stabilize processes, and eliminate the dirty, dull, dangerous, and demanding work no one wants. Mike walks us through identifying bottlenecks, understanding ROI, choosing between prefab and custom solutions, and overcoming the cultural resistance that keeps shops stuck in the past. We also talk about the mindset behind automation—how lean thinking, stable processes, and leadership alignment create the foundation for truly running lights out. And in a powerful shift, we explore Mike's "Create Holy Moments" philosophy, a reminder that continuous improvement isn't just for machines—it's for people, teams, and communities as well. This episode blends humor, hard-earned wisdom, and practical guidance you can use right away. If you're serious about improving your shop and moving toward lights-out operations, this is one conversation you don't want to miss. You will want to hear this episode if you are interested in... (0:22) Partner with Verdant Commercial Capital for a smooth process(1:53) Introducing Mike Gamache (and how Eric met him)(7:24) Mike's manufacturing and engineering origins(11:07) Growing value-added steel work and machine shops(13:38) Cornerstone Design: sales, marketing, and leadership(16:44) Starting Gamache Systems and eventual acquisition by Metalcraft(18:08) Overview of Metalcraft's automation investment and Skag product line(20:10) How ROI is measured and how projects are selected(21:27) Case studies: rearranging facilities and implementing robotic processes(23:12) What shops should automate first (and why processes must be stable beforehand)(26:24) Check out the SMW Autoblok catalog(27:40) How to prioritize automation (start at shipping, work upstream)(29:36) Common blockers: legacy thinking, unclear processes, poor flow(31:14) Value of fresh eyes and cross-industry solutions(33:13) Lean foundations as a prerequisite for automation success(34:05) Strategic conviction vs short-term ROI thinking(37:30) Fear of automation and overcoming failed attempts(39:18) Leadership alignment as the key to adoption(40:42) Global competition and why automation is mandatory(44:06) Custom vs prefabricated automation: when to choose each(48:50) Sticker shock, engineering hours, and ROI evaluation(49:58) Mike's "Create Holy Moments" movement(57:58) Mike's five-step process for improvement(1:01:36) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Partner with Verdant Commercial Capital for a smooth processCheck out the SMW Autoblok catalogThe Biggest Lie in the History of ChristianityThe Toyota Way Connect with Mike Gamache Metalcraft Automation GroupConnect on LinkedIn Connect With Lights Out LinkedInMakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK
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    1 h et 3 min
  • From SWAT to Spindles: How Johnny Goode Led MSP Manufacturing's Lights-Out Transformation, Ep #28
    Nov 14 2025
    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 kind—the MSP logo—he brought with him the tactical mindset and resilience that now define his company's culture and growth. Today, MSP is running 24/5, leveraging modular workholding, five-axis machining, and ProShop ERP to deliver quality aerospace parts on time, every time. In this conversation, Johnny opens up about the leadership lessons he carried from the field to the factory floor, how he earned the trust of veteran machinists, and why he believes that culture, values, and integrity are the real foundation for successful automation. From implementing five-axis technology to reducing stress on his shop floor, Johnny proves that the human element still drives even the most automated operations. If you've ever wondered what it takes to modernize a legacy manufacturer without losing its soul—or how to build trust and innovation into every shift—this episode is one you won't forget. You will want to hear this episode if you are interested in… (0:22) Achieve on-time delivery with ProShop ERP(2:13) Johnny Goode of MSP Manufacturing's origin story(6:00) Life on the SWAT team: Lessons in pressure, discipline, and adaptability(11:15) How law enforcement and military experiences shaped Johnny's leadership style(14:24) Early challenges as a next-generation leader and implementing a new ERP system(18:27) Lessons from crisis: How COVID forced diversification and sparked innovation(20:13) Enter automation: Partnering with consultants and leveraging state grants(23:14) Get a true partner in your corner with Verdant Commercial Capital (25:00) Overcoming obstacles in automation and standardizing for success(27:38) Shop floor efficiency: 5S, tool management, and the value of observation(31:51) MSP's core values: Integrity, efficiency, resilience, precision, respect, and innovation(36:30) Managing change and getting buy-in from the team(38:03) Tracking progress: Using ProShop ERP for traceability, scheduling, and visibility(42:36) The next frontier: Expanding capacity and eliminating new bottlenecks(45:30) Balancing growth with sustainability and employee well-being(49:02) Lessons learned and what Johnny would (and wouldn't) do differently(53:33) Closing reflections and takeaway for manufacturers ready to evolve(55:40) Why you need to check out Hire MFG Leaders for your next hire Resources & People Mentioned Achieve on-time delivery with ProShop ERPGet a true partner in your corner with Verdant Commercial Capital Why you need to check out Hire MFG Leaders for your next hire Connect with Johnny Goode Connect on LinkedInMSP Manufacturing Connect With Lights Out LinkedInMakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK
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    56 min
  • The Real Takeaways from EMO: Monitoring, AI, and the Changing Face of Automation, Ep #27
    Oct 31 2025

    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 conversation covers more than just new gadgets on the trade-show floor—it's about how cultural adoption, change management, and continuous improvement determine whether those technologies actually deliver ROI.

    We explore the parallels between software as a service and machine tool ownership models, the challenge of aligning shop-floor teams around innovation, and why data-driven manufacturing will define the next generation of top shops.

    Whether you're a shop owner wondering which investments will truly pay off, or a manufacturing leader preparing your business for the next wave of automation, this episode offers practical insights drawn straight from the global stage.

    You will want to hear this episode if you are interested in...
    • (0:22) Achieve RASRAM with SMW Autoblok
    • (1:58) IMTS vs. EMO: Comparing global manufacturing events
    • (6:52) Eric's three major takeaways from EMO
    • (8:23) What's driving the shift from Horizontal to 5-axis?
    • (10:10) The acquisition of Heller (and what it signals about market dynamics)
    • (11:52) Why one-and-done machining is critical in today's talent-scarce environment
    • (14:30) OEM strategy shift: Removing underused tech to lower sticker prices
    • (16:00) Adoption gaps: Why built-in monitoring often goes unused
    • (18:16) Investing in your business is an investment in ProShop ERP
    • (19:52) Lessons from CRM and SaaS adoption
    • (22:05) How technology should be offered and priced to match real shop behavior
    • (25:18) The argument for offering advanced tech as optional—not standard—to increase real adoption
    • (26:18) Lights-Out intermission: Eric's unexpected award-winning hobby
    • (28:56) Monitoring explosion: Using data to drive continuous improvement
    • (32:40) The case for hiring a dedicated integrator or continuous improvement lead in every modern shop
    • (36:27) Why offering monitoring and condition-control tools lowers risk and improves adoption
    • (39:30) Debating whether machine builders are truly adapting their business models
    • (42:52) Three practical tips to takeaway from this episode of Lights Out
    • (44:48) Join us at Top Shops 2025 (Get 20% off with code MAK20)
    Resources & People Mentioned
    • Achieve RASRAM with SMW Autoblok
    • Join us at Top Shops 2025 (Get 20% off with code MAK20)
    • Investing in your business is an investment in ProShop ERP
    Connect With Lights Out
    • LinkedIn
    • MakingChips.com

    Subscribe to Lights Out

    On Apple and Spotify


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    46 min
  • Coached—Not Just Monitored: How the Best Shops Turn Data into Action, Ep #26
    Oct 17 2025

    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 coaching tool, and how to align both machines and people toward a shared goal of improvement.

    Nick also introduces the idea of the "other OEE"—Overall Employee Engagement—and explores how the best shops connect coaching, culture, and continuous improvement into measurable performance. From building the right tech stack (ERP, MES, and machine monitoring) to running better daily standups, this conversation breaks down what it really takes to lead a high-performance, data-driven manufacturing team.

    Whether you're running one shift or lights out, this episode will challenge how you think about data, leadership, and what it means to truly coach your people toward operational excellence.

    You will want to hear this episode if you are interested in...
    • (0:24) Why Verdant Commercial Capital is a partner in your business
    • (2:50) Highlights from Nick's trip to EMO (and global trends about machine monitoring)
    • (7:30) Recap of previous Lights Out mindset shifts
    • (8:25) "Dashboards don't make chips" — why data without action is waste
    • (9:14) The difference between a head coach and a head monitor in manufacturing
    • (13:11) How cadenced meetings and daily standups drive accountability
    • (14:30) Why starting manual helps validate processes before investing in tech
    • (15:45) Breaking down ERP, MES, and machine monitoring (and how they work together)
    • (20:33) Check out the SMW Autoblok catalog
    • (21:13) Defining OEE: availability × performance × quality as the shop's north star metric
    • (23:05) Adaptive vs. accelerated performance—why slowing down can speed you up
    • (27:09) What world-class OEE looks like and why most shops start around 20%
    • (29:13) Coaching strategies to improve machine availability and uptime
    • (32:00) How capturing downtime reasons reveals the real improvement opportunities
    • (33:46) Dissecting the other OEE: Overall Employee Engagement
    • (38:09) Turning OEE into a coaching tool rather than a vanity metric
    • (40:12) Football and manufacturing: how coaching and data awareness drive success
    • (42:21) Use Hire MFG Leaders for your next hire
    Resources & People Mentioned
    • Why Verdant Commercial Capital is a partner in your business
    • Check out the SMW Autoblok catalog
    • Use Hire MFG Leaders for your next hire
    Connect With Lights Out
    • LinkedIn
    • MakingChips.com

    Subscribe to Lights Out

    On Apple and Spotify


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    43 min
  • Adaptive Over Aggressive: Redefining Lights-Out Manufacturing with Camoren Schley, Ep #25
    Sep 26 2025
    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 solutions. He's not just creating products—he's redefining how small and mid-sized shops can compete with enterprise-level operations. This episode dives into the mindset shift from being aggressive to adaptive and reactive to predictive—a crucial transformation for any shop looking to scale its production, reduce tool wear, and embrace automation. Camoren explains how adaptive controls, process monitoring, and integrated machine intelligence can help shops run longer, safer, and smarter while dramatically cutting costs. Listeners will also hear real-world examples of shops that implemented Slytek technology to move from constant babysitting and tool breakage to fully unattended overnight production. Whether you're running five machines or 150, this conversation shows how measuring, monitoring, and coaching can unlock the next level of performance. Finally, the hosts discuss how Slytek's holistic approach—from machine monitoring to process control to coaching—bridges the gap between data and decision-making. It's a blueprint for any manufacturer looking to shift from firefighting to future-proofing. You will want to hear this episode if you are interested in... (0:20) Invest in your business by investing in ProShop ERP(2:48) Why we get to record this episode in person(6:12) Camoren's family manufacturing legacy and how it shaped his approach to problem-solving(8:44) From repairing high-pressure coolant systems to designing his own solutions(11:10) Early machine monitoring experiments and the surprising boost in operator productivity(13:03) Founding Slytek and expanding into tool optimization and adaptive control technology(16:08) Adaptive controls—what they are and why small and mid-size shops need them(17:54) How Slytek's adaptive controls mimic an expert machinist adjusting feed rates in real time(20:23) Shifting from aggressive to adaptive mindsets (A case study on tool breakage)(26:33) Beyond the spindle: Coolant concentration, chip management, and process monitoring(29:37) Grow your top and bottom-line with CliftonLarsonAllen (CLA)(30:35) Slytek's process monitoring in graphite electrode manufacturing(33:43) The "villains" of lights-out manufacturing and how to measure before you manage(38:53) Understanding ROI: tailoring technology to solve the right problem for your shop(43:30) Coaching, accountability, and helping shops turn data into action(46:38) Why Slytek technology is built for small and mid-sized shops as well as big players(48:35) Your Lights Out "Plan of Action" to implement immediately (53:05) Why you need to listen to Machine Shop Mastery Resources & People Mentioned Invest in your business by investing in ProShop ERPPhoenix Heat TreatingGrow your top and bottom-line with CliftonLarsonAllen (CLA)Why you need to listen to Machine Shop Mastery Connect with Camoren Schley Connect on LinkedInSlytek Connect With Lights Out LinkedInMakingChips.com Subscribe to Lights Out On Apple and Spotify Audio Production and Show Notes by - PODCAST FAST TRACK
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    55 min