Lights Out, Level Up: Inside Imago's Next Phase of Automation and Time Freedom, Ep #38

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What happens when a shop that’s already running lights-out decides to push even further? The Lights Out team returns to Imago Manufacturing nearly a year after their first visit to see how Ryan’s lights-out vision has evolved. What they find is a shop that looks similar on the surface, same team, same footprint, but dramatically more capable thanks to thoughtful automation, improved workflows, and a relentless focus on unlocking unused capacity. It’s a real-world look at what continuous improvement actually looks like in a small, highly automated shop.

Ryan shares how Imago is pushing toward an ambitious goal: grow revenue by 50 percent over three years without adding people, spindles, or floor space. That challenge forces a different mindset, one centered on maximizing throughput, eliminating wasted motion, and using automation not just at night, but throughout the workday. The conversation explores how new robot loading, automated inspection, and smarter quoting strategies are helping the team move closer to that target.

Beyond the technical strategies, the episode dives into the philosophy behind lights-out machining. Ryan explains how automation improves quality of life, removes repetitive work, and allows machinists to focus on higher-value problem solving. The group also introduces the concept of “lights in” manufacturing, automating processes during the day to create more freedom, focus, and productivity while the team is in the building.

This return visit to Imago blends practical automation insights with a bigger message: lights-out isn’t just about running machines unattended. It’s about building a shop that respects people’s time, increases capability without increasing headcount, and creates the kind of flexibility that makes both the business and the people inside it stronger.

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

(0:00) Cigar, bourbon jokes, and setting the stage for a return visit to Imago
(2:47) Introduction to Imago Manufacturing and recap of the first Lights Out episode
(5:05) What’s changed in a year and continuing the lights-out vision
(6:59) Same team, more automation, and a thriving shop culture
(8:41) Why you need to check out the Hennig WorkFlow system
(9:34) New robot loader and instant buy-in from the team
(12:03) Respecting machinists’ time and eliminating repetitive work
(14:45) Parenting advice, focus, and the philosophy behind time freedom
(18:07) Automation as a path to better quality of life
(20:32) SMW Autoblok offers world-class workholding
(21:51) New mill automation and flexible vise-based workflow
(26:57) Using automation as a competitive quoting advantage
(30:12) The 50 percent growth goal and finding hidden capacity
(37:28) Automating inspection and the ROI of measurement time
(42:56) Head to the DN Solutions Manufacturing Without Limits Event
(43:57) Introducing “lights in” manufacturing