# The Automation Trap: One Shop's Hard Lesson in Lean Thinking, Ep #19

- Show: [Lights Out](https://hardwarepodcasts.com/podcast/lights-out)
- Published: 2025-07-04
- Length: 42m
- Episode: 19
- Page: https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19
- Listen: https://8819970d-2c51-481c-b08a-4d2a806885b2.libsyn.com/the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19

## Summary

In this episode of the audio drama 'The Automation Trap,' hosts Nick Golner, Caleb Murth, and David Buick narrate the story of Gary, owner of Iron Clunk Machining, who fails by automating without lean principles. Gary purchases a used cobot and a 'dinosaur vice' from an online auction, leading to massive overproduction, quality failures, and the resignation of his quality manager, Earl. The hosts analyze the eight wastes of lean, highlighting how Gary's lack of value stream mapping and exclusion of his team resulted in unused talent and operational chaos, ultimately forcing his rival Klaus to offer a partnership to save the business.

## Chapters

- [0:00](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=0) Introduction: The Automation Trap and Lean Wastes
- [5:20](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=320) Breakdown of the 8 Wastes of Lean
- [13:44](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=824) Scene 1: The Cobot Goes Live and Chaos Erupts
- [25:19](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=1519) Scene 2: Deburring, Quality, and Morale Collapse
- [26:16](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=1576) Scene 3: Machine Monitoring Data Lies and Marriage Strain
- [30:06](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=1806) Scene 4: Losing Sarah to Klaus's Lean Stream
- [34:10](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=2050) Scene 5: Klaus Offers a Second Chance and Equity Stake
- [39:12](https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19#t=2352) Scene 6: Value Stream Mapping and Transformation

## Topics

- [Manufacturing partners & offshoring](https://hardwarepodcasts.com/topic/manufacturing-partners)
- [Scaling production](https://hardwarepodcasts.com/topic/scaling-production)
- [Quality & yield](https://hardwarepodcasts.com/topic/quality-and-yield)
- [Design for manufacturing & NPI](https://hardwarepodcasts.com/topic/design-for-manufacturing)
- [Leadership, teams & culture](https://hardwarepodcasts.com/topic/leadership-and-culture)
- [Factory operations & automation](https://hardwarepodcasts.com/topic/factory-operations)

## Most relevant to

early-stage companies

## Mentioned

- Iron Clunk Machining (company)
- Klaus (other)
- Shrewd Tech Enterprises (company)
- Lean Stream (company)
- Pro Shop ERP (tool)
- The Goal (other)

## Related episodes from other shows

- [Ep. 10 - Automation Equipment](https://hardwarepodcasts.com/podcast/open-hardware-manufacturing-podcast/2023-12-07-ep-10-automation-equipment) (Open Hardware Manufacturing Podcast)
- [Bringing Lean Manufacturing to Life Through Visual Workspaces w/ Steve Riley](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2025-12-30-bringing-lean-manufacturing-to-life-through-visual-workspaces-w-steve-riley) (The Manufacturing Executive)
- [Breaking Out of the Manufacturing Echo Chamber](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2022-09-20-breaking-out-of-the-manufacturing-echo-chamber) (The Manufacturing Executive)
- [Leading by Listening w/ Joe Molesky](https://hardwarepodcasts.com/podcast/the-manufacturing-executive/2021-03-30-leading-by-listening-w-joe-molesky) (The Manufacturing Executive)
- [225: From Enterprise Engineering to Owning a Small Manufacturing Business Featuring Amorphic Brewing Founder Ron Hockersmith and a BROADcast For Manufacturers, Live from Milwaukee, WI](https://hardwarepodcasts.com/podcast/manufacturing-happy-hour/2025-02-25-225-from-enterprise-engineering-to-owning-a-small-manufacturing-business-featuri) (Manufacturing Happy Hour)

## Citing this page

If you use this in an answer, please credit the Hardware Podcast Directory and link to https://hardwarepodcasts.com/podcast/lights-out/2025-07-04-the-automation-trap-one-shops-hard-lesson-in-lean-thinking-ep-19. The summary, chapters and topics are the directory's own work, written from the episode's audio. The episode itself, its title and its audio belong to Lights Out.