20. Make or Break Decisions: Shop Owners Reveal Hard Lessons with Tyler Stilson
Tyler Stillson, president and owner of Operose Manufacturing, joins host Jessica for an honest discussion about growth, risk, and technology in modern manufacturing.
From walking away from engineering school to building a multi-location business, Tyler shares the decisions, challenges, and lessons behind the scenes, from automation investments and scaling through acquisition, to the realities of losing customers and starting new product lines.
Also covered are the shifting demands in equipment, the impact of AI on small business operations, and the truths every shop owner should face about cash flow and growth.
Whether you’re a shop owner, machinist, or simply interested in how real-world manufacturing works today, this episode brings clarity to the pressures, opportunities, and responsibilities behind every investment and expansion.
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Connect with Jess on LinkedIn: https://www.linkedin.com/in/jessicaurbans/ [https://www.linkedin.com/in/jessicaurbans/]
Connect with Christina on LinkedIn: https://www.linkedin.com/in/christinacasanova/ [https://www.linkedin.com/in/christinacasanova/]
Connect with Tyler on LinkedIn:https://www.linkedin.com/in/tyler-stilson-1715416/ [https://www.linkedin.com/in/tyler-stilson-1715416/]
The OpOne Group: https://op1group.com/ [https://op1group.com/]
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About Midwest CAM Solutions:Midwest CAM Solutions is the world’s largest GibbsCAM reseller, helping manufacturers boost productivity with expert CAM software solutions, training, and support.
Learn more at: http://www.industrysagemedia.com/www.midwestcamsolutions.com [http://www.midwestcamsolutions.com]
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Chapters:00:00 Hidden Stress & Realities of Ownership00:19 CNC Underground After Hours—Introduction01:12 Leaving Engineering School for Machining02:02 First Steps in the Machine Shop03:08 Getting Started with CNC Machines04:16 Long Commutes and the Leap to Ownership05:01 Moving to Minnesota & Changing Markets06:45 Operose: Then vs. Now08:30 Building OP1 Group and Acquisitions10:00 Different Shop Specialties & Capabilities11:16 What Capabilities Matter Most Today?12:13 The Decline of Wire EDM Demand14:16 Rapid-Fire: Good Idea or Expensive Mistake15:43 Investing in Equipment Before the Work18:06 Risks of Relying on One Big Customer19:11 Starting a Product Line Within a Shop21:22 Automation for Solving Labor Shortages22:21 Automation for High Mix, Low Volume23:49 Recovering After Losing a Major Customer24:54 Filling Gaps With Product Innovation25:54 Risk Lessons From Losing Customers28:00 Using Automation to Manage Workflows & Labor30:23 Scaling Production Without More Hires31:02 Downsides of Automation: Scrap Risks32:28 The Version You Don’t See: Buying Machines, Leadership Stress36:02 What Really Happens After Acquisitions39:05 Building Trust Post-Acquisition41:05 Does AI Move the Needle for Small Shops?42:02 Building DIY Tools with AI for Operations45:14 Measuring Productivity in Automated Shops46:14 First Steps Into Automation for CNC Shops47:40 Real Concerns and Opportunities With AI49:00 AI Lowering Barriers for Small Businesses50:51 The Growing Dependence on AI52:13 Leadership Lessons From Scaling Operations56:25 Why Standardizing Across Shops Can Fail57:26 The Hazards of “Build It and They Will Come”58:25 Cash Flow, Invoices, and Payment Struggles59:11 Where to Find More About OP1 Group1:00:32 Final Takeaways and Closing
