Coached—Not Just Monitored: How the Best Shops Turn Data into Action, Ep #26

Lights Out · 17 Oct 2025 · 42m · Episode 26

What this episode covers

Hosts Nick Goellner and David Buick of MakingChips discuss the transition from monitored to coached manufacturing shops, emphasizing that data must drive action. They define OEE (Overall Equipment Effectiveness) as availability, performance, and quality, noting that world-class shops achieve 70-75% OEE while many struggle around 20%. Goellner introduces 'Other OEE' (Overall Employee Engagement) to measure human performance, arguing that coaching culture and daily stand-ups are essential to turning metrics into continuous improvement.

Other shows on the same ground, closest first.

  • The Manufacturing Executive · 28m

    Adapting to Change: Manufacturing Leadership Excellence w/ Dan Burgos

    Dan Burgos, President and CEO of Alphanova Consulting, explains how manufacturing leaders can combat labor shortages and supply chain disruptions by focusing on quantifiable metrics like on-time delivery and scrap rates, alongside less tangible cultural shifts. He argues that sustainable improvement requires treating continuous improvement as a permanent business system rather than a temporary program, emphasizing leadership behaviors and employee engagement. Burgos shares a case study of a client who improved on-time delivery from 39% to 97% and cut scrap in half by implementing these systemic changes and coaching leaders to adopt new behaviors.

  • Over the Air · 33m

    The Connected Factory Floor: L2L and Data Management

    Eric Whitley, Director of Industrial Transformation at L2L, explains how their connected workforce platform bridges the gap between enterprise ERP systems and shop-floor PLC data to provide real-time visibility into manufacturing operations. He details how L2L captures five key metrics—demand, build, scrap, labor, and downtime—to calculate Overall Equipment Effectiveness (OEE) and other critical KPIs for discrete manufacturers in automotive, food and beverage, and packaging. Whitley highlights the severe labor shortage in manufacturing, noting that 80% of surveyed firms report it impacts throughput, and describes how L2L’s AI tools and digital workflows help upskill workers by providing immediate, context-aware guidance on the shop floor. He also discusses the company's evolution from an in-house Excel tool at Autoleave to a global software provider, emphasizing the importance of practical AI applications that reduce wasted time and motion for mechanics and operators.

  • Manufacturing Happy Hour · 34m

    Rethinking Health & Wellness for Manufacturers with Laura Timbrook

    Laura Timbrook, a health and wellness coach specializing in the manufacturing industry, explains why traditional advice fails shift workers and how to reframe health metrics like 'first meal' versus 'breakfast'. She discusses how wellness initiatives impact retention and productivity, citing General Mills and Corning as examples of companies with strong cultures, while warning against superficial 'check-the-box' programs. Timbrook highlights the role of smartwatches in providing empowering data and predicts a future where virtual coaching and VR become standard for employee health management.

  • The Manufacturing Executive · 31m

    Human Input in a Data-Driven World w/ Martin Cloake

    Martin Cloake, CEO and co-founder of Raven.AI, explains how his company helps manufacturers balance data technology with human insight to drive continuous improvement. He recounts his early career at Blinds to Go, where he learned that shop floor engagement and problem-solving are more critical than raw data analysis. Cloake details how Raven.AI’s platform addresses data quality issues by combining machine telemetry with operator input, citing a Danaher plant case study where identifying maintenance wait times led to significant efficiency gains. He argues that successful Industry 4.0 adoption requires starting small, involving operators, and focusing on actionable guidance rather than complex dashboards.

  • The Manufacturing Executive · 35m

    What the Last Four Industrial Revolutions Teach Us About Today w/ Paul Lachance

    Paul Lachance, Chief Industry Strategist at Software Equity Group, draws parallels between the current AI revolution and the steam, electricity, and automation eras to advise manufacturing leaders on navigating disruption. He argues that maintenance teams are strategic levers for increasing organizational capacity through uptime, rather than just fixing broken equipment. Lachance illustrates how agentic AI can automate cross-system data analysis to solve operational issues like OEE slips, while emphasizing that technology must serve defined business outcomes rather than driving adoption through hype.

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