Lights Out Lenses: Inside an Automation Journey from the Operations & Production Frontlines, Ep #40

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What does automation actually look like when you’re in the middle of it—not from a vendor demo or a conference stage, but inside a real shop, with real constraints, real people, and real stakes? This episode of Lights Out kicks off a new series format—Lights Out Lenses—where the story of automation is told through multiple perspectives inside the same company. And not just any company, but ADVANCED MACHINING & FABRICATING Dba ADVANCED PMC, a shop that’s deep in the trenches of high-mix, low-volume manufacturing.

Instead of a single narrative, you’ll hear how automation is experienced differently depending on where you sit. From the Director of Operations thinking about material flow and process alignment, to the Director of Production obsessing over utilization and throughput, this episode pulls back the curtain on what it really takes to make automation work—not just in theory, but in practice.

Randel Hamilton shares how automation didn’t simplify the business—it expanded it. More output meant more coordination, more downstream pressure, and more need for structure. The machine might run lights out, but everything around it has to keep up. Meanwhile, PK brings a numbers-driven lens, breaking down the hidden opportunity in unused machine hours and why automation is less about technology and more about stability, repeatability, and smart part selection.

Together, their perspectives reveal a powerful truth: automation doesn’t eliminate complexity—it redistributes it. And for shops willing to embrace that shift, the payoff isn’t just more parts—it’s a fundamentally different way of thinking about the business.

You will want to hear this episode if you are interested in…

(0:00) Lights Out Lenses: exploring automation through multiple perspectives
(2:21) Randel Hamilton’s background and early exposure to automation
(4:29) The reality of automation implementation: years of iteration, not plug-and-play
(6:46) Common misconceptions about automation and the importance of building the system while running it
(8:22) How automation impacts jobs: shifting roles rather than eliminating them
(10:33) Deciding what should and shouldn’t be automated in a real-world shop
(12:19) Why we love SMW Autoblok workholding and its effectiveness
(15:00) Business impact: automation driving new responsibilities in sales, purchasing, and capacity planning
(17:59) Personal impact: improved scheduling, reduced overtime pressure, and process-driven operations
(22:06) Randel reflects on stress levels before and after automation
(23:40) Get a free report of sales opportunities in your area from Facturmfg.com/chips
(25:37) PK’s role and focus on execution, output, and maximizing existing equipment
(27:57) Overview of the FASTEMS automation cell and current utilization gap
(29:14) The opportunity: capturing unused machine hours and increasing throughput
(32:23) Key challenges including part selection, high-mix/low-volume work, and tight tolerances
(33:56) Why we created Hire MFG Leaders (and why you should use it)
(34:30) How production teams evaluate which parts are good candidates for automation
(35:49) The complexity of scheduling, tooling, workholding, and keeping the cell running
(38:47) Continuous improvement mindset: expanding automation across more machines and processes
(42:08) Using data and metrics to drive better performance and decision-making
(43:43) PK reflects on stress levels and ongoing challenges in production
(45:22) Key takeaway: automation shifts work, requires stability, and unlocks new levels of performance