Lights-Out Manufacturing Without the Robot: IMTS 2026 Session Makes the Case for In-Spindle Automation

Not every automation problem needs a robot.

A middle ground between manual and robotic

The session targets a gap many shops overlook. As the session description puts it:

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.

Learning from what didn't work

Rather than a highlight reel of success stories, the presentation takes a failure-first, engineering-driven approach — breaking down real implementations that didn't work, analyzing root causes, and explaining what should have been evaluated earlier.

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

That last figure deserves attention. Hidden integration costs capable of inflating a project by 150–200% are exactly the kind of surprise that turns a sensible automation investment into a regret.

A framework, not a sales pitch

The session introduces a quantitative decision framework that compares manual, in-spindle, and robotic automation options side-by-side.

Clear "walk-away" criteria help prevent over-automation and protect ROI.

Attendees also receive practical tools they can immediately use, including a part compatibility checklist, engineering calculation sheets, and a five-year total cost model.

The goal is to give manufacturers honest, vendor-neutral guidance so they can choose the right level of automation.

The presenter

John Olenik, Partner Success Manager at Jergens Inc., leads the session. An Industrial and Systems Engineering graduate from The Ohio State University, Olenik works with machine tool builders, integrators, and manufacturers on practical automation through workholding, supporting turnkey and retrofit projects. His emphasis: an engineering-first approach combining hands-on testing with ROI analysis before implementation.