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.