IMTS 2026 Conference: Lights-Out Manufacturing Without the Robot: Practical Engineering Lessons from In-Spindle Automation


Lights-Out Manufacturing Without the Robot: Practical Engineering Lessons from In-Spindle Automation

GIE Media's Manufacturing Group

Posted by

[Justin McCombs](https://www.aerospacemanufacturinganddesign.com/author/justin-mccombs/)

Published August 14, 2026 \| Updated May 20, 2026

[Listen to article](https://www.aerospacemanufacturinganddesign.com/news/imts-2026-conference-lights-out-manufacturing-without-the-robot-practical-engineering-lessons-from-in-spindle-automation/#)

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_Monday, September 14, 2:15 P.M._ _IMTS10 Room W193-A_

Learn about the presentation

Many shops assume automation means buying a robot, but that jump often adds unnecessary cost, complexity, and risk. Between manual loading and full robotic cells is a practical middle ground that can deliver real productivity gains without six-figure investments. This session explores that space using in-spindle automation as a case study.

The session takes a failure-first, engineering-driven approach, breaking down real implementations that did not work, analyzing the root causes, and explaining what should have been evaluated earlier.

Attendees will learn how to calculate required gripping forces, understand actuation tradeoffs, and identify part and machine compatibility issues. The session also addresses hidden integration costs, which can increase total project cost by 150–200%.

The session introduces a quantitative decision framework that compares manual, in-spindle, and robotic automation options side-by-side. Clear "walk-away" criteria are included to help prevent over-automation and protect ROI.

Attendees will leave with practical tools they can use immediately: a part compatibility checklist, engineering calculation sheets, and a five-year total cost model. The overarching goal is to give manufacturers honest, vendor-neutral guidance so they can choose the right level of automation for their operations.

Meet your presenter

John Olenik is an Industrial and Systems Engineering graduate from The Ohio State University and currently serves as Partner Success Manager at Jergens Inc. He works directly with machine tool builders, integrators, and manufacturers to implement practical automation solutions through workholding, supporting turnkey and retrofit projects across a wide range of applications.

His focus is helping shops reduce setup time, increase spindle utilization, and adopt the right level of automation without unnecessary complexity or cost. John takes an engineering-first approach, combining hands-on testing with ROI analysis to validate solutions before implementation. He is passionate about building strong partnerships with trusted integrators and machine tool dealers to deliver automation that works reliably on the shop floor.