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Making Chips Podcast for Manufacturing Leaders

MakingChips LLC
Making Chips Podcast for Manufacturing Leaders
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  • Shop Floor Greatness Starts at the Top: Inside the Top Shops Culture at Major Tool, 471
    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
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  • Managing Orders From Setup to Shipment—Without Losing Control, 470
    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
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  • Managing Orders: Planning for Precision on the Shop Floor, 469
    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
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  • Profit Starts with the Quote: Estimating Smarter for a Stronger Shop, 468
    Are you losing money before the job even hits the floor? If your quotes are based on outdated spreadsheets, rough guesses, or a “that’s what we’ve always charged” mindset, you might be setting your shop up to fail—before the first chip falls. In this episode of the Machine Shop MBA series, we tackle one of the most common (and costly) problems in manufacturing: bad quoting. Mike shares lessons from five shop acquisitions—each one quoting the wrong way. Paul lays out a clear framework for cost modeling, from flat-rate estimating to activity-based precision. And Nick brings it all home with real-world strategies for walking away from unprofitable jobs and quoting with confidence. You’ll learn how to: Break down your true cost per hour (and why most shops get it wrong) Quote faster and win better work Tie quoting to sales strategy and customer fit Eliminate jobs that quietly kill your margin Because quoting isn’t just a math problem. It’s a leadership decision—and the future of your shop depends on getting it right. Segments (0:00) Friday energy, name mispronunciations, and intro banter (1:01) Why ProShop can help you achieve on-time delivery (2:34) Common quoting mistakes usually stem from broken models (6:25) Scarcity mindset vs. abundance mindset in quoting decisions (7:45) The four cost buckets you need to understand (9:22) Estimating 101, 201, and 301: building smarter quoting systems (12:58) How automation changes the math (or does it…?) (16:20) Value-based pricing: how some shops quote with confidence and win (18:00) Customer transparency: when it helps, and when it hurts (19:50) Sales pressure and quoting leverage: why quoting ties back to marketing (21:05) Calculating machine rates: depreciation, utilization, and more (24:30) Overhead, tooling, scrap—when to include it, and how (25:22) Stay tuned for Top Shops 2025 registration!  (27:45) Quoting efficiency: Don’t win everything—win smart (30:42) Win rates: Why 100% is a red flag, and 40% might be just right (34:20) Speed-to-quote: The biggest untapped quoting advantage (37:43) Don’t forget to charge for review, prep, and inspection (39:32) Kill the losers: How to identify and eliminate unprofitable jobs (44:38) Use quoting as a filter for new customer relationships (46:15) Knowing your limits and stretching your niche (51:17) Recap and preview: How quoting connects to sales, strategy, and growth  (55:30) Grow your top and bottom line with CLA Resources mentioned on this episode ProShop can help you achieve on-time delivery Episode #73: A Recipe for Winning High-Volume Work Stay tuned for Top Shops 2025 registration!  Machine Rate Spreadsheet FedEx French Benefits Commercial Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube
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    56:42
  • From Invisible to Irresistible: Marketing That Actually Attracts Work, 467
    Before you spend a dime on advertising—or hire a marketing agency—you need to answer one foundational question: Who exactly are you trying to reach?  In this episode of the Machine Shop MBA series, Nick, Mike, and Paul sit down with Joe Sullivan, co-founder of Gorilla 76 and host of The Manufacturing Executive podcast, to break down the strategy behind smart marketing for job shops. Joe makes one thing clear from the jump: marketing isn’t just sales turned up louder. Instead, it’s about building trust before the buying conversation even starts. That means identifying your ideal customer profile (ICP), understanding their pain points, and crafting messages that speak directly to them—so when they’re triggered to buy, they already know who you are. The conversation dives into the practical side of marketing strategy: defining your total addressable market, publishing your ICP, understanding buyer personas, and turning a few high-quality content pieces into lead-generating machines. Joe also shares real-world tips for measuring ROI, why your content distribution matters more than volume, and how even a 10-person shop can build a consistent, credible marketing engine. Whether you’re starting your marketing journey or rethinking your current efforts, this episode gives you the roadmap to go from aimless activity to strategic growth. Stop being invisible—and start being the shop your best-fit customers call first. Segments (0:37) Grow your top and bottom line with CLA (2:50) Capturing demand vs. creating demand: Where shops go wrong (5:40) Defining and scoring ideal customers by fit and behavior (7:24) Why publishing your ideal client criteria helps filter leads (8:57) Step #1: Sizing your market realistically (13:00) “Riches are in the niches”: How tight positioning builds credibility (16:52) ICP vs. persona: company fit vs. human influencers (20:08) Foundational marketing steps to complete before execution (26:27) Moving from research to messaging: Strategy before tactics (30:15) Stay tuned: Top Shops 2025 registration coming soon (31:30) Playing the long game: Becoming next in line when a vendor fails (33:44) Content campaign thinking: Repurposing and repeating your core message (39:20) How to position your machine shop online (i.e. equipment list) (43:27) Bad blogs and lorem ipsum: When marketing is clearly an afterthought (44:43) Diving intro distribution—How to make content work for sales enablement (47:22) How do I know if it’s working? Metrics that matter. (50:10) The real role of marketing vs. sales (54:17) The shift from reactive to proactive: Marketing as a strategic function (58:57) Closing thoughts: Play the long game, be specific, stay consistent (1:03:57) Bonus question: The importance of personal branding vs. company branding (1:08:05) Why you need to listen to the Lights Out Podcast  Resources mentioned on this episode The Tech Stack Advantage The Manufacturing Marketer podcast Building a StoryBrand Obviously Awesome New Sales. Simplified.  [email protected] The Manufacturing Culture Podcast Rapidfire Manufacturing  Next Gen MFG Connect With MakingChips www.MakingChips.com On Facebook On LinkedIn On Instagram On Twitter On YouTube
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About Making Chips Podcast for Manufacturing Leaders

Manufacturing is tough—but you don’t have to go it alone. If you're leading a manufacturing business, you face constant pressure: staying competitive, adopting new tech, managing people, and driving growth. MakingChips helps you tackle those challenges head-on. Since 2014, we’ve been equipping manufacturing leaders with the knowledge and inspiration they need to succeed. With hundreds of episodes and over a million downloads, MakingChips is a top resource for the metalworking nation—covering leadership, operations, technology, and workforce development. If making chips is part of your daily grind, this is your podcast. Join hosts Nick Goellner, Mike Payne, and Paul Van Metre for real talk on the issues that matter most.
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