Making Chips Podcast for Manufacturing Leaders

What do a luxury wristwatch and a 50-foot-long aerospace weldment have in common? They’re both precision-machined, but that’s where the similarities end.  In this episode of MakingChips, we’re exploring the extremes of manufacturing—from parts that fit on the tip of your finger to parts so massive they require cranes and riggers just to load onto a machine. Paul Van Metre and Mike Payne are joined by two guests who represent the far ends of the machining scale. Josh Hacko, a fourth-generation watchmaker from Sydney, Australia, crafts ultra-small and ultra-precise components for timepieces and high-tech applications like quantum computing and medical implants.  On the other end, Jerry from Baker Industries in Michigan oversees the fabrication and machining of massive weldments and structural components for aerospace, defense, and nuclear energy—some measuring over 50 feet and weighing tens of tons. This episode dives deep into the radically different strategies each shop uses for tooling, fixturing, inspection, quoting, and problem-solving. From tea strainers used to sort microscopic parts to massive additive weld builds handled by 30-ton cranes, it’s a fascinating look at how scale transforms every aspect of the job. If you’ve ever wondered how much machining can vary across the industry, this conversation will expand your view. Whether you're cutting parts measured in microns or managing five-ton setups, one thing remains constant: it’s all about having the right people who love the craft. Segments (0:00) Why the people behind the process matter most—no matter the scale (0:26) How Paperless Parts can simplify quoting in your shop (2:16) Comparing the biggest and smallest jobs in machining (4:30) Josh Hacko’s background in watchmaking and micro part production (6:03) Jerry Kablak’s work on large-scale machining for aerospace, energy, and defense (6:51) Part sizes: from sub-millimeter to over 70 feet long (8:38) How Josh got into contract micro-manufacturing by accident (11:53) Handling tiny parts: bar diameters under 2mm and parts smaller than a fingerprint (13:45) How Jerry and his team navigate some of the largest projects in the world (19:28) Josh’s creative solutions: glue workholding, sieves, acetone, and hand-ground tweezers (22:19) Logistics challenges in big machining: setup time, crane handling, and laser tracking (26:16) Leverage Hire MFG Leaders to equip your shop (28:22) Handling and inspection of tiny parts: from tea strainers to plastic tweezers (32:16) Overproduction and scrap on both sides of the spectrum (33:54) Inspection: From laser trackers to 700x optical zoom on a Zeiss CMM (36:14) Tolerances: Josh works in single-digit microns; Jerry works in 10–20 thou over 40 feet (44:05) Drilling a 20-micron hole and the tools it takes to do it (45:29) Your success depends on the skill and resilience of your people (47:34) From rocket hardware to medical implants to lunar landers (51:08) Mutual respect across the size divide (54:11) Listen to Machine Shop Mastery if you’re serious about growing your shop  Resources mentioned on this episode Josh Hacko on LinkedIn NH Micro  Nicholas Hacko Watches Jerry Kablak on LinkedIn Baker Industries Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

What does it take to run one of the top-performing machine shops in the country? In this episode of MakingChips, we sit down with Kevin Bowling, COO of Major Tool & Machine, to find out exactly what drives their success—and why it all starts with people. Kevin isn’t just leading a massive operation with 670,000 square feet of manufacturing space and machines that can turn parts up to 40 feet in diameter—he’s cultivating a culture of excellence, servant leadership, and continuous improvement. From daily standups to custom-built software tools that empower employees to submit (and track) improvement ideas, Kevin shares how his team fuels a winning environment. We talk about how Major Tool keeps scrap rates under 1.6%, mitigates multi-million dollar risks, and engages machinists in everything from quoting to process design. But more than that, Kevin reveals why trust, gratitude, action, growth, and excellence aren’t just words on a wall—they’re the foundation for shop floor performance. Whether you're running a 3-person shop or leading hundreds, this conversation is packed with ideas you can apply to raise the bar. Because when leadership is intentional and people are empowered, that’s when you start making chips—and making money. Segments (0:00) Nick ditches the t-shirt to interview like an adult (0:47) Will we see you at Top Shops 2025? (1:51) Paul shares insights from a woodworking leadership forum (3:50) Introducing Kevin Bowling from Major Tool & Machine (7:40) Overview of Major Tool’s massive facility and machine capabilities (12:41) Building culture through employee-led process design and daily Kaizen (16:24) How culture drives retention—Kevin's team gives Cadillacs at 50 years (18:00) Inverted org charts and servant leadership in practice (19:32) Custom software and dashboards built around the floor’s needs (22:39) Grow your top and bottom line with CLA (25:05) Aligning improvement ideas with key business KPIs (26:50) Making the scoreboard visible: everyone should know if they won today (29:48) KPIs that drive engagement and performance (31:25) Major Tool’s five core values: Trust, Gratitude, Action, Growth, Excellence (35:08) Managing massive parts and multi-million dollar risk (39:45) Everything is scalable—even if you’re just starting out (41:13) Real-world Kaizen: from newspaper boards to software tickets (44:25) Why every initiative must start with defining the current state (46:21) Sustaining improvements through standard work (47:39) Integrated systems, employee engagement, and long-term culture (50:22) Let Hire MFG Leaders make your next hire smooth and seamless Resources mentioned on this episode Will we see you at Top Shops 2025? Grow your top and bottom line with CLA Let Hire MFG Leaders make your next hire smooth Major Tool & Machine Virtual Tour of Major Tool Connect with Kevin on LinkedIn PFMEA risk management Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Planning a job is one thing—getting it through the shop without chaos is something else entirely. In part two of our Managing Orders series, we move beyond quoting and scheduling to the messy reality of production: where kitting falls short, setups go long, expectations don’t match reality, and quality gets squeezed when time runs out. We’ve seen it happen. A setup that was budgeted for two hours takes six. Why? Because the job wasn’t kitted right. Because the estimator used wishful thinking. Because no one raised their hand when they knew the target was off. It’s not just frustrating—it’s a breakdown in accountability and trust across your team. This episode is about fixing those breakdowns. We unpack how better handoffs, clearer documentation, and stronger internal service mindsets can completely transform your process. From shift tie-ins and floor leads to process development and postmortems, we share how to build a shop where problems get solved before they become expensive. Because making chips isn’t just about getting to the spindle—it’s about building a culture where everyone owns their part of the process, and where your systems hold up even when the pressure’s on. Segments (0:00) Why planning isn’t enough—execution is where things break (0:43) Grow your top and bottom-line with CLA (2:00) The dangers of “sharpening the pencil” on setup time (5:25) Why you must separate first-time setup from recurring setup targets (6:35) The hidden costs of poor kitting and missing tools at setup (11:21) Tribal knowledge, shift leads, and how to monitor execution in real time (14:08) Creating a culture where machinists feel safe to speak up (17:58) “Tiger Teams” and how to solve setup issues in the moment (20:56) Top Shops (21:22) Documenting feedback through process development and tying it to improvement (24:20) Using shift tie-ins and handoffs to reduce lost context (25:40) Rethinking quality: from bottleneck to built-in step (34:08) Treating vendors like internal customers and setting them up for success (38:15) The final handoff: why packaging, paperwork, and delivery are part of your brand (43:45) Final takeaways: document your process, eliminate failure points, and keep improving (47:46) Why you need to listen to the Lights Out Podcast  Resources mentioned on this episode The Automation Trap: Why Automating Chaos Won’t Save You, Ep #18  Vericut Hexagon Maestro The E Myth Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Once the PO comes in, it’s easy to fall into the trap of “just get it done.” But if we don’t manage orders with intention and clarity, we’re setting ourselves—and our teams—up for chaos. In this episode of the Machine Shop MBA series, we break down what it really takes to run a smooth, efficient production floor. This isn’t just about buying software or printing a checklist. It’s about building a culture where planning is seen as an act of leadership, not overhead. We share lessons from our own experiences—like rebuilding internal systems from scratch and learning the hard way that quoting means nothing if we can’t deliver on time. We explore how order management touches everything: lead times, stress levels, team morale, and profit margins. We talk about what it means to serve internal customers, how to build standards everyone can actually follow, and why checklists might just be the most underrated tool in your shop. If we want to stop firefighting, reduce turnover, and grow a business that lasts, we need to start treating order management like the strategic function it is. Because without a plan, even good shops fall short. Segments (1:39) Stay tuned: Top Shops 2025 registration coming soon! (2:40) Paul’s early lessons from Pro CNC (4:59) The role of ERP systems and process discipline—even for small shops (8:18) Why you need a detailed process for making parts (with associated timing) (12:04) Identifying bottlenecks early: the Herbie analogy and long lead-time items (15:19) Planning as leadership: how we reduce chaos and stress for our teams (17:12) What “kind leadership” actually looks like (18:49) The power of checklists for staying on-track (21:25) Grow your top and bottom-line with CLA (23:02) Defining complete and accurate: internal customers and downstream clarity (27:40) Scheduling mistakes: why poor input ruins even the best software (31:06) How we build lead-time buffers and deal with vendor risk (35:37) Letting ERP guide quoting, planning, and scheduling (38:51) Investing time to save time: building in space for continuous improvement (43:30) What great kitting actually looks like—and how it cuts setup time (47:47) Wrapping up Part 1—with a joke, of course (48:47) Why investing in ProShop ERP is investing in your business Resources mentioned on this episode Stay tuned: Top Shops 2025 registration coming soon! The Tech Stack Advantage Profit Starts with the Quote “The Goal” By Eliyahu Goldratt “The Checklist Manifesto” by Atul Gawande The KAIZEN™ methodology ProShop Setup Reduction Guide Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

Discover how outdated quoting methods could be costing your manufacturing shop! Learn about the importance of accurate cost modeling, including activity-based pricing and true cost evaluations. Hear real-world tactics for confidently walking away from unprofitable jobs. Explore how speed in quoting can boost profitability and align with client needs. Dive into pricing strategies that drive sales success while managing risks. This engaging discussion highlights quoting as a key leadership decision for the future of your shop.

Joe Sullivan, co-founder of Gorilla 76 and host of The Manufacturing Executive podcast, shares invaluable insights into smart marketing for job shops. He emphasizes that marketing is about building trust, not just louder sales pitches. Joe highlights the importance of defining your ideal customer profile, understanding pain points, and crafting targeted messages. He also discusses the significance of quality content over quantity in lead generation and practical tips for measuring ROI. Transform your marketing approach and become the go-to shop for your best-fit customers!

In this engaging discussion, Mike Fritz, host of the Machine Shop Growth podcast and sales strategist for machine shops, highlights the detrimental 'cashier model' that stunts business growth. He emphasizes the importance of proactive customer engagement and shares tactics to understand current, dormant, and new accounts. By diving into customer psychology, Mike reveals how fostering relationships and unlocking existing account value can drive revenue. Tune in for insights on rekindling dormant clients and enhancing sales strategies!

When you're launching or scaling a machine shop, it’s easy to think of software as a cost—something you "have to have" just to get by. But what if your tech stack could become your sharpest competitive edge?  In this episode of the Machine Shop MBA series, we are joined by returning guest and digital strategy expert Bryce Barnes to unpack why your software decisions might matter more than your next CNC machine purchase. They explore how an intentional, integrated digital backbone isn’t just for managing data—it’s about accelerating sales, boosting throughput, and future-proofing your shop. We share our own journeys with building digital infrastructure from scratch, transitioning off spreadsheets, and how we now see our systems as a key part of our brand. The reality is, when your systems are dialed in, they don’t just save time—they win work. We’ve seen it ourselves: customers are more confident, audits are smoother, and top talent is easier to attract when you run a modern, connected operation. We break down the key components of a modern machine shop's digital ecosystem—from ERP and QMS to CAD/CAM, CRM, and even the email domain you choose when naming your business. We explain how integrations reduce risk and waste, why starting early simplifies everything later, and how a great tech stack not only saves time but wins customers. Whether you're quoting parts on an Excel sheet, trying to choose your first ERP, or just curious how cloud, AI, and machine monitoring can fit into your daily operations, this episode is an essential listen. It's not a tech tutorial—it’s a business strategy conversation every shop owner needs to hear. The takeaway? Don’t tack on software as an afterthought. Build your shop around it. Segments (0:00) Broken spreadsheets and the hidden dangers of quoting errors (0:35) Let ProShop ERP help you achieve on-time delivery  (2:10) Why the MBA series is resonating with startup shop owners (3:26) From machines to mindsets: introducing the digital backbone (5:32) What a tech stack actually includes (and why it matters early) (6:48) How shops can and should go paperless (8:29) Email addresses, domains, and the perception of professionalism (9:10) Tech stack mindset: cost center vs. competitive advantage (13:21) CRM, marketing, and quoting: connecting the whole flow (16:54) The case for seamless data flow and integration (18:10) Human input, machine monitoring, and minimizing mistakes (20:11) Designing your workflows digitally, not retrofitting after (21:35) The value of ERP systems built specifically for machine shops (25:58) Grow your top and bottom line with CLA (27:42) A jaw-dropping machine monitoring story from aerospace (29:45) Where to start with scale: communications and safety (32:40) Matching tech stack to business model (high-mix vs. high-volume) (35:02) Involving your team in tech decisions increases buy-in and success (36:13) Choosing tools with a strong community and support ecosystem (39:00) Pros and cons of cloud infrastructure for manufacturers (43:30) The hidden cost of old tech: attracting and retaining talent (46:30) Getting IT help doesn’t mean hiring full-time staff (47:00) A lean and logical order to build your tech stack from day one (50:00) Don’t forget cybersecurity—it’s essential, not optional (51:40) Why early investment pays off more than late retrofitting (53:00) Your tech stack is also your sales pitch (54:00) The virtuous cycle of the right tools: fewer mistakes, more wins (55:35) What’s next: Building your brand and growing your sales  Resources mentioned on this episode Tech Stack Checklist  Your 6-Step Guide to Achieving Over 95% On-Time Delivery ProShop ERP Paperless Parts Grow your top and bottom line with CLA Quickbooks Xero Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

What happens when a young marketer decides to stop chasing every client and instead zeroes in on one industry? You get Gorilla 76—a leading agency that’s spent nearly two decades helping B2B manufacturers connect, grow, and lead. In this special episode of MakingChips, the team sits down with Joe Sullivan, co-founder of Gorilla 76 and host of three powerhouse podcasts, to officially welcome him into the MakingChips Network. Joe opens up about the early missteps of trying to be everything to everyone—and how discovering a niche in mid-size manufacturers changed the game. The conversation touches on everything from how content marketing builds trust, to why ditching a break-even product line can be the smartest growth move you’ll ever make. Along the way, the hosts reflect on their own decisions to niche down, double down, and expand the MakingChips mission. But this episode isn’t just a reunion. It’s a launchpad. Joe and the team announce the addition of “The Manufacturing Executive,” “The Manufacturing Marketer,” and “The Manufacturing Employer” to the MakingChips Network—further cementing their collective goal: to equip and inspire the next generation of manufacturing leaders. If you’ve ever asked yourself how to stay relevant in an industry changing faster than ever, this one’s for you. Segments (2:38) Nick introduces Joe and how Gorilla 76 helped shape his own journey (4:28) The origin story behind the name “Gorilla 76” (6:01) Biggest early mistake: trying to serve everyone instead of niching down (7:55) Mike shares his own lesson from cutting a product line to grow faster (9:26) MakingChips’ brief foray into agency work—and why they walked away (10:32) Joe’s IMTS keynote: marketing in a changing manufacturing landscape (15:36) Introduction of Joe’s three shows joining the MakingChips Network (16:23) Overview of Joe’s podcast, “The Manufacturing Executive” (18:30) Learn about “The Manufacturing Marketer” and the Industrial Marketing Collective (20:06) Overview of “The Manufacturing Employer” and its focus on people (21:07) The real value of implementing ProShop ERP (22:42) The ROI of podcasting and learning from your audience (25:20) Rundown of other MakingChips Network shows (32:30) Why holding onto “how we’ve always done it” is a risk (36:03) The best way to gain attention is to pay attention first (37:51) Why you need to listen to Machine Shop Mastery  Resources mentioned on this episode Connect with Joe Sullivan on LinkedIn Gorilla 76 The Manufacturing Executive The Manufacturing Marketer The Manufacturing Employer The Industrial Marketing Collective The real value of implementing ProShop ERP Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube

What if every trade show, manufacturing podcast, and business resource you needed was just a few clicks away? That’s the vision behind The Home of MFG, a new online hub created by Chris Stevens—a manufacturing leader who got tired of fragmented information and decided to build a centralized, open-access platform for the industry. In this episode, we dig into Chris’s journey from sweeping shop floors to launching an ambitious initiative aimed at organizing the chaos of manufacturing content. We talk candidly about how hard it’s been to simply find the right events to attend or shows to listen to, and why the current landscape of Google searches and paywalls just isn’t cutting it. Chris shares the origin story behind The Home of MFG, his growing database of over 40 podcasts and hundreds of events, and how he’s turning feedback into new features, filters, and community-powered tools. From free templates to a future podcast of his own, Chris isn’t just curating content—he’s building a digital ecosystem that brings the manufacturing community together. Whether you’re a shop owner, engineer, marketer, or maker, this conversation will leave you feeling inspired to share, connect, and contribute. Segments (0:15) Achieve on-time delivery with ProShop ERP (2:20) Chris shares his origin story in CNC and manufacturing (4:36) The spark for “Home of Manufacturing” and the gap it aims to fill (6:00) Creating a centralized, ungated directory of events and podcasts (9:24) The overwhelming scope of manufacturing events and how to filter them (13:45) Indexing manufacturing podcasts and the potential for cross-industry insights (16:05) Why you need to listen to the Machine Shop Mastery podcast (22:00) Future plans: podcasts, tool libraries, templates, and community improvement  Resources mentioned on this episode The Home of MFG Connect with Chris on LinkedIn Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube