Hardware Podcasts
Lights Out podcast cover art

Lights Out

MakingChips' show on automating machine shops, from robots and pallet systems to machine monitoring and the data needed to run CNC production unattended.

53 episodes · 41 hours · since 2024

Visit Lights Out

Lights Out is filed under manufacturing, supply chain & operations, mechanical and interviews. Its most recent episode published on , so it is still actively publishing. Listeners have left 4 ratings on Apple Podcasts, averaging 5 out of 5.

Latest episodes

The 10 newest episodes of Lights Out, each with a summary and chapters.

  • · 52m

    Automation, Machining, and a Coal Mine: What Vertical Integration Buys You | Ep. 51

    Michael McHale, founder of PSA Systems, explains how his vertically integrated automation integrator and machine shop in Pennsylvania grew from $900,000 in revenue to over $30 million by owning fabrication, machining, and engineering capabilities in-house. He discusses the capital-intensive nature of modern manufacturing, citing an $800,000 five-axis mill that cost nearly a million to install, and advocates for a five-year strategic plan over short-term EBITDA chasing. McHale also details PSA's rollout of IBM Watson for enterprise AI workflow automation, emphasizing the need for data guardrails when handling Department of Defense contracts, and shares his philosophy that employee prosperity is the true measure of business success.

    Scaling productionAI & machine learning
    9 chapters

  • · 52m

    The $5 Automation Project Hiding in Your Shop | Ep. 50

    Uriel Eisen, founder of Arda and Austere Manufacturing, explains how he doubled throughput in his 325-square-foot shop by implementing Kanban and lean principles rather than buying robots. He details the transition from index cards to his software platform, Arda, to solve inventory stockouts that were derailing production. Eisen discusses the hidden costs of micro-interruptions, the importance of reliability over cycle time, and how reducing friction in processes like tooling and ordering yields faster ROI than expensive automation.

    Scaling productionSourcing & supply chain
    8 chapters

  • · 52m

    Zero Setup Time: Inside Norbert Kempf CNC-Technik GmbH's 23-Machine Automated Shop | Ep. 49

    Stefan Kempf, owner of Norbert Kempf CNC-Technik, explains how he transformed his father's 1970 turning shop into a 23-machine automated facility with zero setup time and over 90% utilization. Risto Niemi of Fastems and Yanick Müller of swissMODULAR discuss the critical roles of standardized tooling, flexible work holding, and long-term strategic planning in achieving this level of automation. The episode highlights the 'monoculture' of machines, the central tool system (CTS) with Fanuc robots, and a unique company-wide bonus system tied to daily machine utilization.

    Scaling productionManufacturing partners & offshoring
    6 chapters

  • · 52m

    Your Machines Have a Heartbeat: Here's What It's Telling You | Ep #48

    Lauren Dunford, co-founder and CEO of Guidewheel, explains how their platform uses current transformers on power cords to monitor machine electrical heartbeats, providing non-invasive visibility into run, idle, and down states without PLC integration. She details how this data enables cycle counting, anomaly detection, and predictive maintenance, while emphasizing a philosophy of using data to empower teams rather than surveil them. Dunford shares origin stories from her food manufacturing background and describes how customer feedback shaped Guidewheel’s API-first approach, allowing partners like Slytek to layer industry-specific depth onto their broad platform.

    Connected products & IoTQuality & yield
    8 chapters

  • · 49m

    You Can't Automate What You Can't Find: RTLS and the Data Foundation for Lights-Out | Ep. 47

    Mitch Tucker of HID explains how Real-Time Location Systems (RTLS) provide the data foundation necessary for lights-out manufacturing and Industry 5.0. He argues that shops must first standardize processes through Gemba walks and 5S before implementing RTLS to solve the costly problem of 'tribal knowledge' and search time. The discussion covers scaling from simple RFID to ultra-wideband, using location data for safety and digital twins, and the ethical considerations of worker tracking.

    Connected products & IoTScaling production
    6 chapters

  • · 52m

    Inside Conexus Indiana: The Industry Network Driving Manufacturing Tech and Talent | Ep. 46

    Bryce Carpenter, Executive Vice President and Chief Operating and Strategy Officer at Conexus Indiana, explains how this industry-led nonprofit facilitates collaboration among 126 manufacturing, logistics, academic, and public sector partners to drive workforce development and technology adoption. He details the evolution of the industry from viewing automation as an enemy to embracing it as a necessity, highlighting a specific case where automating hated palletizing jobs improved retention. The episode also covers the Manufacturing Readiness Grants program, which has supported over 700 small and midsize shops, and success stories like FiberX and Arcamed, illustrating how strategic peer learning and targeted investments accelerate growth.

    Manufacturing partners & offshoringScaling production
    10 chapters

  • · 59m

    Don't Automate Chaos: Running Lights Out with Sarah Wierman of Fastems, Ep #45

    Sarah Wierman of Fastems explains why automation is driven by labor shortages and retirements rather than just replacing people, and why shops must standardize processes before automating. She describes Fastems as a production orchestration company whose core product is the MMS software, which plans, runs, and monitors production, including predictive tool life alerts up to 96 hours in advance. Wierman emphasizes that repeatable workholding is the foundation of any automation strategy and advises shop owners to document practices and track downtime to avoid automating chaos.

    Scaling productionDesign for manufacturing & NPI
    8 chapters

  • · 59m

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

    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.

    Quality & yieldScaling production
    15 chapters

  • · 1h 00m

    Before You Buy Another Spindle, Use the Ones You Have, #43

    Walt Swenton, Senior Manager of Advanced Manufacturing at Eaton, explains why shops must solve problems with data before buying new CNC equipment. He outlines a three-level OEE strategy, starting with basic machine monitoring to identify idle time, then adding operator context, and finally leveraging advanced data for AI-driven insights. Swenton emphasizes that standardized, digitized tool management via ZOLLER systems is the critical foundation for any smart factory or automation initiative.

    Quality & yieldSourcing & supply chain
    5 chapters

  • · 53m

    The 20-Hour Machine: Automation, Throughput & Smarter Capacity Planning, Ep #42

    Mike Padilla, founder of Hill Manufacturing, and Nick Golner of Making Chips discuss how Hill is using automation and strategic capital expenditure planning to scale capacity without simply adding headcount. They detail the concept of the '20-hour machine,' explaining that realistic unattended runtime targets must account for tooling and setups, and how integrating machine monitoring with tool life optimization prevents costly crashes during lights-out operations. The conversation highlights how automation frees skilled machinists from 'doorman' tasks to focus on higher-value work, while also emphasizing the critical importance of vendor service support and calculating the true cost of downtime when making equipment investments.

    Scaling productionConnected products & IoT
    9 chapters

If you like Lights Out

Manufacturing Happy Hour

Chris Luecke interviews makers, founders, and manufacturing leaders about the trends and technologies reshaping modern manufacturing, going past the buzzwords into real tactics.

manufacturingsupply chain
Visit Website

EMS@C-LEVEL

Interviews with executives of electronics manufacturing services companies on their businesses, their customers and the state of the contract electronics manufacturing industry.

manufacturingsupply chain
Visit Website

Catalyst

Latitude Media's weekly interview show on the energy transition, covering the technologies, costs and investment behind clean power, the grid, fuels and decarbonization.

climate energysupply chain
Visit Website

The Manufacturing Executive

Joe Sullivan talks with the leaders driving midsized manufacturers forward, alongside B2B sales and marketing experts, about growth strategy, industrial marketing, and modernising the shop floor.

manufacturingsales marketing
Visit Website