You Don't Have a Capacity Problem — You Have a Visibility Problem, Ep #44

Lights Out · 3 Jul 2026 · 59m · Episode 44

What this episode covers

Brian Anderson, Solutions Architect at ProShop ERP, explains that machine shops often mistake visibility problems for capacity issues, leading to misguided investments in staff or equipment. He details how ProShop ERP provides end-to-end visibility through features like contract review and digital work instructions, allowing shops to identify root causes like shipping errors or poor tool life management. Anderson advocates for using data to optimize utilization—such as splitting jobs for unattended roughing—rather than simply adding headcount, emphasizing that small, continuous improvements compound to solve systemic bottlenecks.

Other shows on the same ground, closest first.

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    Focusing on the Constraint to Drive Meaningful Results

    Pavel Kuviarzin, a Business Growth Expert at Future State Engineering, explains how manufacturers often fail to improve productivity by focusing on efficiency in non-constraint areas rather than identifying and optimizing the system's bottleneck. He illustrates this with examples of a commercial refrigeration manufacturer that wasted money on laser automation while the forklift operator became the constraint, and a hand tool manufacturer that increased throughput despite a 15% labor shortage by applying the Theory of Constraints. Kuviarzin outlines a five-step 'systematic capacity expansion' process that prioritizes exploiting existing constraints before investing in new resources.

  • Manufacturing Happy Hour · 51m

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    Luke Manier, Adam Ruebsam, and Ryan Williams of Tri Tech Automation discuss how manufacturers can uncover their 'hidden factory'—untapped potential and invisible inefficiencies within existing resources. They explain that unlocking this value requires focusing on business outcomes first, empowering the workforce with data and guided instructions, and integrating OT data with ERP systems. The panel shares Tri Tech's own digital transformation journey, detailing how they used EPLAN and automated fabrication tools to shift from serial to parallel panel manufacturing, thereby increasing velocity and consistency across their St. Louis and Tulsa locations.

  • Manufacturing Happy Hour · 34m

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  • Manufacturing Happy Hour · 33m

    BONUS: From Spreadsheets to MRP: How SMB Manufacturers Are Improving Visibility to Inventory and Costs with MRPeasy

    Shane Dubbelman of MRPeasy and Sara Duff of Smart Manufacture discuss the transition from spreadsheets to MRP for small to midsize manufacturers. They explain why MRP is often a better fit than ERP for companies with 10-200 employees, focusing on manufacturing-specific needs like inventory and cost visibility. The episode highlights case studies, including a CNC machining shop that avoided burnout and an intumescent fire door seal manufacturer that achieved 25% growth without significant headcount increases after implementation.

  • The Manufacturing Executive · 23m

    How to Fix a Factory: Influencing the Direction of Your Company w/ Rob Tracy

    Rob Tracy, president of Rob Tracy Consulting and author of 'How to Fix a Factory', discusses how manufacturing leaders should navigate long-term capacity constraints and labor shortages. He outlines four key strategic decisions: managing customer tiering and lead times, trimming low-margin product lines, adjusting pricing to reflect supply scarcity, and re-evaluating capital investments as throughput generators rather than just cost reducers. Tracy also advocates for using structured operating systems like his Manufacturing Leadership System (MLS) or EOS to execute these new strategies effectively.

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