Every machine shop reaches a point where production feels maxed out. The schedule is full, the machines are running, and yet the numbers still aren’t where they need to be. The truth? Many shops are leaving hours of hidden capacity untapped — and that’s where OPTO comes in.

Our OPTO Applications Engineers work side by side with machinists and shop leaders to uncover inefficiencies, optimize processes, and create measurable results. Here are five signs it’s time to bring OPTO back into your shop.

1- Cycle Times That Creep Up Over Time

Jobs that once ran smoothly may now take longer than expected. New materials, tooling wear, or small process changes can add minutes per cycle — costing you hours over the course of a shift.
➡️ OPTO has helped customers cut cycle times by 30–60%, adding up to four extra hours of capacity per shift.

2- Machines Sitting Idle Between Jobs

Underutilization is one of the most expensive problems on a shop floor. You’ve invested in Haas machines — now make sure they’re earning for you.
➡️ Custom OPTO training ensures operators are confident in using every capability your machines offer.

3- A Growing Backlog And Overtime Costs

If your team is staying late or you’re struggling to keep up with orders, it’s time to rethink the process.
➡️ OPTO automation solutions, like robotic tending, have eliminated overtime for customers while paying for themselves in as little as six months.

4-Scrap Piling Up 

High scrap rates don’t just hurt profitability — they drain morale too.
➡️ With OPTO’s first-part qualification and advanced software strategies, shops have dramatically reduced waste and improved consistency.

5- A Skills Gap In The Shop

Whether you’re onboarding new employees or upskilling experienced machinists, the knowledge gap can slow everything down.
➡️ OPTO’s hands-on training makes shops more self-sufficient and less dependent on outside troubleshooting.

Your machines are only as profitable as the processes behind them. If you’ve seen any of these warning signs, it’s time to unlock the hidden capacity in your shop.

📈 Most OPTO customers see full ROI in 6–12 months — some in as little as three.

👉 Don’t leave capacity on the table.

Book your next OPTO process improvement session today.

Rusty’s Machine & Tool is a one-man, high-mix, low-volume job shop. Most runs are fewer than 500 pieces, often in different materials and configurations. That variety keeps things interesting — but it also kept Rusty from running more than 8–10 hours a day. 

Every part change required him to be at the machine. That meant the spindle stopped whenever he left, and lights-out production wasn’t even on the table. 

Rusty partnered with Phillips OPTO, our team of Application Engineers, to change that. The solution was a UR VersaBuilt automation system — a collaborative cobot platform that uses the shop’s existing workholding to load and unload parts. With quick-change end-of-arm tooling, switching jobs is simple and fast, even with varied part designs. 

The transformation was immediate. Rusty can now load the table with material, start the cobot, and step away to set up other jobs. The cobot runs the job unattended and even continues after the shop is closed. 

The results speak for themselves: production doubled — and sometimes tripled — depending on the job. The system’s ROI is projected at about a year, and Rusty now has the flexibility to add new part programs without disrupting production. 

“I would recommend Phillips OPTO to anyone looking to bring automation into their operations because of the knowledge of the team, the service after the sale, and just all-around good folks to deal with.” – Rusty Sampson 

Rusty’s Machine & Tool proves that automation isn’t just for high-volume plants. With the right system and partner, even a small job shop can scale output, keep flexibility, and run around the clock. 

“Now we go home on time, orders are caught up, and the robot paid for itself in six months.” – L&W Fab 

L&W Fab set out to become the largest UTV aftermarket parts producer in the U.S., while keeping every product made in America. But like many job shops, they faced serious challenges as demand grew. Employees were working 60–65 hours a week, the backlog had grown to more than 150 orders, and scaling up seemed impossible without adding staff or floor space. Something had to change. 

Partnering with the Phillips OPTO team of Application Engineers, L&W Fab installed a collaborative robot for CNC machine tending. The integration was quick—just forty-eight hours from delivery to production—and required no floorplan changes or major reprogramming. From day one, the robot began running two extra shifts overnight, producing two days’ worth of parts while the shop was empty. By morning, orders were ready for downstream work, the backlog disappeared, and operators were able to focus on higher-value tasks. 

The results were immediate and sustained. Overtime has been at zero for more than eighteen months. The same output is achieved across three shifts with two fewer operators. The return on investment came in just six months through labor savings and increased throughput, all while keeping production consistent and reliable. 

“It’s changed everything. We still hit our numbers, but now we have our weekends back.” – L&W Fab 

For job shops facing backlogs, labor strain, and long hours, L&W Fab’s story proves that targeted automation can be the difference between falling behind and running ahead — without outsourcing overseas.

The Institute for Advanced Learning and Research (IALR) has officially doubled down on its investment in hybrid manufacturing with the purchase of two additional Phillips Additive Hybrid systems to pair with their original UMC-750 Hybrid, installed in 2022 and integrated with Meltio’s laser-wire DED metal 3D printing technology.  

Following their success with the first unit, IALR decided to purchase two additional systems, set to be installed later this year. With these integrations, IALR solidifies its workforce training and research leadership in Southern Virginia and supports its growing partnerships with defense and manufacturing sectors, including workforce and technology development efforts for the U.S. Navy. 

“Hybrid manufacturing technology is breaking boundaries that were once thought impossible.,” said Wesley Cifers, Assistant Director of Advanced Training & Operations at IALR. “At IALR, we firmly believe that this is a key component in the future of manufacturing. By uniting cutting-edge research, accelerated workforce training, and deep industry collaboration, we are shaping a new realm of possibility.” 

“Our partnership with IALR has been inspiring from the start,” said Dan Insogna, Regional Account Manager for Additive Manufacturing at Phillips Corporation. “Their dedication to training the next generation of manufacturing professionals and supporting the defense sector makes them an ideal partner for Phillips Additive Hybrid. We’re excited to support their mission with a platform that delivers real-world, cutting-edge capability.” 

A Unified Platform For Research, Training, And Defence

Powered by Meltio’s multi-laser, wire-fed deposition head, IALR’s hybrid systems allow users to create complex metal parts using materials like stainless steel and Inconel — all while retaining the proven reliability and control interface of a 5-axis Haas UMC-750 mill. This integration delivers the dual benefit of world-class subtractive machining with advanced additive capabilities in one compact system. 

• Integrated metal part production — combining additive and subtractive processes in one setup 

• Hands-on workforce development for advanced manufacturing careers 

• Support for defense-sector projects, including shipbuilding, Navy-related repair, and prototyping work 

• Collaborative research with academic and industry partners in material science, part design, and production runs.   

About The Phillips Additive Hybrid

• Affordable and compact — a fraction of the cost of competing hybrid systems and reduced footprint via integration 

• Safe and clean — laser-wire DED is proven safe and cuts waste with near-net shape printing 

• Training-ready — includes onsite training and curriculum support from Phillips Hybrid experts 
• Flexible — compatible with a variety of Haas CNC vertical mills and additive materials 

About The Institute For Advanced Learning And Research(IALR)

The Institute for Advanced Learning and Research serves Virginia as a regional catalyst for economic transformation with applied research, advanced learning, manufacturing advancement, conference center services and economic development efforts.  Located in Danville, Virginia, IALR offers workforce training and technology services to prepare communities for the future of industry. Learn more at www.ialr.org.  

About Phillips Corporation

Phillips Corporation has been solving manufacturing challenges for over 60 years. Its Additive Hybrid division helps industry and education integrate cutting-edge 3D metal printing into Haas CNC platforms, delivering world-class support, service, and training. Learn more at www.phillipscorp.com/hybrid.  

Media Contact:

Lauren Ramsey 
VP, US Marketing 
Phillips Corporation 
LaurenR@phillipscorp.com 

Manufacturing is undergoing a transformation driven by a familiar challenge: not enough skilled labor, and rising pressure to maintain productivity and competitiveness. Robotics and automation have quickly become key solutions—not just for big players, but across machine shops and mid-size operations as well. 

Phillips Corporation recognized this shift early and launched its OPTO Automation & Applications Division in 2019. Their mission was clear: support manufacturers who wanted to scale but couldn’t find the workforce to match. 

“Customers told us they wanted more machines but didn’t have people to run them,” says Shane LeCroix, Automation Solutions Engineer at Phillips. “So we created a team that could help close that gap with automation.” 

Rethinking the Role of Automation 

When people think automation, they often picture a robotic arm. But automation includes far more—bar feeders, pallet systems, rotary tables, and more—all working to streamline repetitive processes. 

Importantly, automation isn’t about eliminating jobs. As Dave Cirilo, Senior Applications Engineer, explains: “It replaces repetitive tasks, not people. It allows skilled workers to shift into more valuable roles—like programming, setup, or troubleshooting.” 

Operational Gains from Even Small Changes

The impact of automation doesn’t require a massive overhaul. Many shops see significant production increases from relatively small investments. For instance, gaining two extra hours of runtime per day adds up to 10 hours of production weekly—without adding labor. 

One real-world case involved a shop eliminating overtime demands on weekends thanks to automation. Workers benefited from better schedules and even raises, while the shop increased throughput. 

Process First, Then Automation

Phillips OPTO emphasizes that automation works best when built on strong, efficient processes. “If the process isn’t stable, you won’t get the ROI you expect,” says LeCroix. That’s why their approach starts with evaluating current workflows and refining them before layering in automation. 

Automation, in this sense, becomes part of a larger effort toward continuous improvement—not just a tech upgrade. 

Adoption Is Getting Easier

What’s helping drive adoption now is how much more user-friendly automation technology has become. Programming and setup are far simpler than even a decade ago, and integration is more standardized. 

As Cirilo puts it: “The learning curve is flattening. Automation is becoming just another tool in the shop—like probing or 5-axis machining did 20 years ago.” 

Manufacturers who’ve embraced automation are already seeing real returns—in productivity, employee satisfaction, and operational resilience. And as the technology becomes more accessible, the shift toward smart, automated production will only continue to grow. 

Biography

Shane LeCroix 
Automation Solutions Engineer 
Phillips OPTO – Automation & Applications Division 

Based in Athens, Alabama, Shane LeCroix brings over 30 years of industrial manufacturing experience to his role as Automation Solutions Engineer. His distinguished career includes impactful work as a Manufacturing Engineer at NASA’s Marshall Space Flight Center, where he supported critical Human Space Flight projects. 

Shane’s technical foundation began with a degree in Machine Tool Technologies from Calhoun Community College, leading to successful positions as both an Applications Engineer and Sales Engineer. Today, he combines deep industry knowledge with a passion for innovation to deliver customized automation solutions that help manufacturers optimize processes, increase productivity, and stay competitive. 

Rooted in the Tennessee Valley region, Shane shares his life with his wife Suzanne, daughter Olivia, and their beloved pets. His local ties give him a strong understanding of the challenges regional businesses face, allowing him to connect with customers and deliver results that truly matter. 

Dave Cirilo 
Senior Applications Engineer 
Phillips OPTO – Automation & Applications Division 

With 22 years of experience, Dave Cirilo, Senior Applications Engineer at Phillips, is a problem-solver in tooling design, toolpath generation, and advanced macro logic. From integrating robots into CNC machines to developing high-performance software, his innovative solutions boost productivity for customers across industries. 

Outside of work, he’s a holiday lights enthusiast, renowned for choreographed displays, and enjoys woodworking and coding custom websites for his community. 

In modern manufacturing, CNC vertical machining plays a pivotal role in achieving precision and efficiency. The Haas VF Series stands out as a trusted solution for offering versatile and high-performance CNC vertical machining centers that streamline production processes.

This article explores how Haas VF CNC machine features can optimize CNC manufacturing workflows.

Understanding CNC Vertical Machining

CNC vertical machining involves the use of computer-controlled vertical milling machines where the spindle axis is vertically oriented. These machines are essential in manufacturing for their ability to perform precise milling, drilling, and cutting operations on various materials.

Vertical Machining Centers (VMCs) operate by moving the cutting tool vertically along the Z-axis while the workpiece remains stationary on the table. This allows for intricate and accurate material removal.

Overview of Haas VF Series

The Haas VF Series offers a comprehensive lineup of CNC vertical machining centers, renowned for their reliability and performance in CNC manufacturing workflows.

Haas VF CNC machine features:

• High-Speed Spindle Options: Models like the VF-2SS come equipped with a 12,000-rpm inline direct-drive spindle.
• Tool Capacity and Automatic Tool Changers: Standard 20-pocket tool changers, with options for 24+1 side-mount versions.
• Rigid Construction for Precision and Durability:  The VF Series machines are built with robust cast-iron components for structural integrity and consistent precision over time.
• User-Friendly Haas Control System: Intuitive CNC control for varied operator expertise.

The VF Series includes a range of models:

• VF-1: 20” x 16” x 20” travel
• VF-2: 30” x 16” x 20” travel
• VF-3: 40” x 20” x 25” travel

Optimizing Workflow with Haas VF Series

Reducing Setup Time

• Quick-Change Tooling and Automatic Probing: Reduce downtime between operations.
• Advanced CNC Control Features: Program Optimizer enables real-time improvements.

Enhancing Precision and Repeatability

• High Spindle Speeds and Dynamic Toolpath Optimization: Ensures precision in complex geometry.
• Integrated Cooling Systems: Maintains cutting temperatures and improves finish/tool life.

Automating Production for Higher Efficiency

• Rotary Tables and Pallet Changers: Reduce manual handling and enable continuous machining.
• Automatic Tool Changers: Seamless transitions during complex machining tasks.

Real-World Applications of Haas VF CNC Machines

Option 1:

A notable example is Craig Machinery, a company based in Louisville, Kentucky, specializing in custom automation machines for welding plastics.

Option 2:

Leonine Engineers in Thane, India, leverage the Haas VF-2-I for producing high-precision components at scale, maintaining strict industry compliance.

Choosing the Right Haas VF Series Model for Your Needs

• Workpiece Size and Material: Match travel dimensions and power to your material and part size.
• Production Volume: Higher volumes benefit from fast spindle speeds and advanced tool setups.
• Budget and Automation Requirements: Evaluate ROI from features like 5-axis or automation tools.

Entry-level models like the VF-1 offer excellent performance for smaller parts, while higher-end models such as the VF-6/40TR provide advanced features for complex and large-scale machining needs.

Conclusion

The Haas VF Series of CNC vertical machining centers plays a crucial role in optimizing CNC manufacturing workflows by reducing setup times, enhancing precision, and automating production processes. Investing in these advanced machining solutions can lead to significant improvements in efficiency and product quality.

As a trusted Haas distributor and partner, Phillips Corporation helps businesses integrate Haas CNC solutions seamlessly into their operations. Whether you are looking to upgrade your CNC machining capabilities or need expert guidance on selecting the right Haas VF model, we are here to assist.

Introduction

In the highly competitive suppressor market, speed matters. The faster you can bring innovative products to market, the more you can capitalize on rising demand. Additive manufacturing (AM) is helping firearm manufacturers reduce time-to-market and gain a critical edge.

The Traditional Challenges of Suppressor Manufacturing

Traditional methods like CNC and welding machining have inherent bottlenecks:

• • Long lead times for prototyping and production.
  • Limited design flexibility.
  • Pinholes and weld inconsistencies
  • Expensive tooling setups.

How Additive Manufacturing Speeds Up Production

• Rapid Prototyping: With AM, suppressor designs can be tested and refined in days, not weeks.
• On-Demand Production: Skip the tooling phase and produce parts as needed.
• Streamlined Workflow: AM integrates easily into your existing operations, reducing downtime.

Example: A typical suppressor prototype might take 4-6 weeks using CNC machining. With AM, the same part can be ready in under a week.

Success Stories
Manufacturers leveraging Phillips Additive Solutions have achieved remarkable results with additive manufacturing:

• Faster Prototyping: Cutting prototyping cycles by up to 40%, enabling rapid design iterations.
• Accelerated Launch Timelines: Introducing new suppressor lines as much as 3 months ahead of schedule.
• Market Leadership: Gaining a competitive edge by capitalizing on peak buying seasons with quicker time-to-market.

By partnering with Phillips Additive Solutions, manufacturers are redefining what’s possible in suppressor production, driving innovation, and capturing growth opportunities.

Conclusion

Time is money in the firearm industry. Additive manufacturing is helping manufacturers bring products to market faster, more efficiently, and with greater innovation. Download our comprehensive firearm suppressor guide to request more information today.

Interested! Download our Firearm Suppressor Guide to learn more today?

Email: PCAM@phillipscorp.com