What a 10-Micron Aerospace Defect Taught Me About Manufacturing

What a 10-Micron Aerospace Defect Taught Me About Manufacturing

How can a defect smaller than a human hair cause an aircraft system to fail? In this episode of Manufacturing Runs The World, Justin Schnor sits down with Tessa Axsom, Product Marketing Manager at Fictiv, mechanical engineer, manufacturing expert, and metallurgy enthusiast. Tessa shares her unique journey through aerospace manufacturing, metallurgy, CNC machining, product development, failure analysis, and advanced manufacturing. One of the most fascinating stories from this conversation involves a microscopic defect measuring only ten microns that affected a critical electrical contact used in an aircraft communication system. The investigation revealed how an incredibly small manufacturing issue could have enormous consequences for an entire aerospace system. This episode explores: • Metallurgy and the science of metals • Aerospace manufacturing challenges • Failure analysis and root cause investigations • Why small defects create major system failures • CNC machining and manufacturing processes • Product development and prototyping • Manufacturing innovation • Engineering careers • Mentorship in manufacturing • Why hands-on experience matters for engineers • Design for manufacturing principles • The future of advanced manufacturing ABOUT THE GUEST Tessa Axsom is the Product Marketing Manager at Fictiv and a mechanical engineer with experience in aerospace manufacturing, metallurgy, CNC machining, finishing processes, product development, and failure analysis. hroughout her career, she has worked on aerospace components, medical applications, manufacturing processes, and engineering investigations involving material performance and failure mechanisms. ABOUT FICTIV Fictiv is a global manufacturing and supply chain technology company helping innovators accelerate product development from prototype to production.Fictiv supports customers across aerospace, robotics, medical devices, consumer products, industrial equipment, and advanced manufacturing through a global network of manufacturing partners and engineering expertise. FEATURED GUESTS Tessa Axsom — Product Marketing Manager, Fictiv Featuring: Rachael Brownell — Content Marketing Manager, FictivWhile Tessa leads most of the conversation, Rachael joins the discussion representing Fictiv's content and manufacturing storytelling efforts. CHAPTERS 00:00 Meet Tessa Axsom 00:38 Why Manufacturing Is Misunderstood 01:15 Engineering, Marketing & Manufacturing 02:30 Falling In Love With Metallurgy 03:13 What Metallurgy Actually Is 03:44 Investigating Manufacturing Failures 05:20 The 10-Micron Aircraft Defect 06:41 Why Tiny Defects Cause Huge Problems 07:02 Working Across Aerospace, Robotics & Medical 08:13 Helping Innovators Build Products 09:41 From Idea To Production 11:31 Why Companies Switch Manufacturing Partners 12:14 How Fictiv Supports Different Industries 14:00 Mentorship For Young Engineers 15:00 Why Hands-On Experience Matters Join the Manufacturing Runs The World community: https://manufacturingrunstheworld.com/join-the-community/ Follow Manufacturing Runs The World: YouTube: https://www.youtube.com/@ManufacturingRunsTheWorld LinkedIn: https://www.linkedin.com/company/manufacturing-runs-the-world Facebook: https://www.facebook.com/people/Manufacturing-Runs-The-World/61576240361119/ Instagram: https://www.instagram.com/mfgrunstheworld TikTok: https://www.tiktok.com/@mfgrunstheworld A Big Thank You to our Sponsors! 🔹 Ellison Technologies Ellison Technologies empowers manufacturers with advanced CNC machines, automation, and expert support—helping shops work smarter, faster, and more competitively.👉 https://ellisontechnologies.com 🔹 GSC – 3D & Automation GSC is one of the nation’s leading resellers of SOLIDWORKS CAD software and Markforged industrial 3D printers, empowering engineers and manufacturers with cutting-edge design, simulation, and additive manufacturing solutions.👉 https://gsc-3d.com

Industrial AI Isn’t What You Think — And It’s Not Replacing Workers

Everyone thinks AI is coming to replace workers.But according to one of the leaders building industrial AI systems today — that’s not what’s happening at all.In this episode of Manufacturing Runs The World, we sit down with Bryan DeBois, a veteran engineer and technology leader who has spent nearly 25 years helping manufacturers solve complex production challenges using automation, machine learning, and data-driven decision-making.Bryan explains why AI isn’t replacing people — and why the real problem in manufacturing is actually a labor shortage. Companies are turning to automation not to eliminate jobs, but to keep production running when skilled workers are hard to find.He also breaks down one of the most misunderstood truths about artificial intelligence:AI is incredibly powerful — but only within a narrow task. Move it slightly outside that task, and performance drops dramatically.This conversation reveals how modern factories are evolving, why reshoring is creating new opportunities, and what manufacturers must do today to prepare for the future of industrial AI.About the Guest Bryan DeBois is a recognized leader in applying artificial intelligence to manufacturing and industrial automation.He serves as the Director of Industrial AI at RoviSys, a global systems integrator specializing in:Industrial automationArtificial intelligenceMachine learningManufacturing data systemsDigital transformationBryan DeBois holds a degree in Computer Science from the University of Akron and has spent decades working directly with manufacturers to implement advanced technologies that improve productivity, reliability, and operational efficiency.His work focuses on solving real-world manufacturing problems using:Predictive analyticsIndustrial AI systemsData strategy and integrationWorkforce knowledge captureAutomation and roboticsToday, Bryan helps companies modernize their factories, improve production performance, and prepare for the next generation of manufacturing technology.What You’ll Learn in This EpisodeThe biggest misconceptions about industrial AIWhy AI is not replacing manufacturing workersThe real reason companies invest in automationHow reshoring is changing manufacturingWhy data readiness is critical before AI adoptionHow modern factories are being redesignedThe future of workforce training in manufacturingWhat industrial AI can and cannot doWhy automation increases productivityHow manufacturers solve complex production problemsThe role of machine learning in factoriesWhat the future of manufacturing looks likeCHAPTERS 00:00 The Biggest Misconceptions About Industrial AI01:02 How Bryan DeBois Built a Career in Industrial AI02:24 Why Companies Started Investing in AI Before ChatGPT03:01 The Real Problems AI Solves in Manufacturing03:48 Why Workforce Shortages Are Driving Automation04:13 The Opportunity Created by Reshoring05:06 What Modern Factories Actually Look Like05:23 Why AI Is Not Skynet06:00 What AI Can Do — And What It Can’t06:39 The Truth About Robots Replacing Workers07:47 How Data Strategy Drives AI Success08:59 Why Clean Data Is the Foundation of AITHANK YOU TO OUR SPONSORSEllison TechnologiesEllison Technologies helps manufacturers stay competitive through advanced machining, automation, and engineering expertise.GSC – 3D & AutomationGSC supports engineers and manufacturers with design software, additive manufacturing, and technical expertise.Do you think AI will replace manufacturing jobs — or create new ones?

Are Robots Taking Jobs? The Truth From a Robotics Engineer | Anjali Asar

Are robots taking people's jobs?It’s one of the most emotional and controversial questions surrounding robotics, automation, and artificial intelligence today.In this episode of Manufacturing Runs The World, we sit down with Anjali Asar, a robotics software engineer at Miso Robotics, the company behind the well-known Flippy robot used in commercial kitchens. When Anjali first took the job, she had the same concern many people have:Was she helping people — or replacing them?She openly shares that she wondered whether working on robots meant “taking people's jobs.” But after visiting restaurants and speaking directly with workers, her perspective changed completely. Many employees were relieved.They didn’t want to spend eight hours standing in front of a hot fryer. They wanted safer, more meaningful work — and robotics helped make that possible.This conversation reveals the human side of automation.Not fear.Not hype.Real stories from inside the industry. You’ll learn how robots like Flippy are designed to handle repetitive and dangerous tasks, improve safety, and help workers focus on more valuable responsibilities — not eliminate jobs entirely.This episode also explores what it’s actually like to work in robotics engineering, how robots are developed and deployed in real environments, and why the future of work will depend on people who can adapt to changing technology. If you’ve ever wondered: * Will robots replace human workers? * How automation is changing everyday jobs * Whether robotics creates or destroys opportunities * What skills the next generation needs * How technology improves workplace safety * What the future of manufacturing and service industries looks like This episode will change how you think about automation.Because the real story isn’t about robots replacing people.It’s about work evolving. ⏱ CHAPTERS 00:00 [https://www.youtube.com/watch?v=rxpCWE6ha0s] Are robots taking jobs? 00:31 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=31s] Meet a robotics engineer from Miso Robotics 01:02 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=62s] What a roboticist actually does 01:32 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=92s] Inside the Flippy robot 02:00 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=120s] The biggest mistake engineers make early 03:00 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=180s] Why asking questions builds confidence 03:18 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=198s] The truth about robots replacing workers 04:13 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=253s] Visiting restaurants using Flippy 05:06 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=306s] How automation improves work safety 06:12 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=372s] Why AI makes coding faster 07:24 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=444s] A day in the life of a robotics engineer 08:14 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=494s] The future of robotics and scaling automation 09:10 [https://www.youtube.com/watch?v=rxpCWE6ha0s&t=550s] How automation changes jobs — not eliminates them 👤 GUEST Anjali Asar Robotics Software Engineer Miso Robotics Miso Robotics develops intelligent robotic systems designed to automate kitchen operations, improve safety, and support restaurant staff using advanced robotics technology.Their flagship robot, Flippy, is used in real commercial kitchens to handle frying tasks and improve operational efficiency. THANK YOU TO OUR SPONSORS Ellison Technologies Ellison Technologies empowers manufacturers with advanced CNC machines, automation solutions, and engineering expertise to help companies work smarter and more competitively. https://ellisontechnologies.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqbXhHNWlBcEE5MV9SS0JkcHNpNlhuT1hYZ21Cd3xBQ3Jtc0ttMUZnODU5bUNhZGZDLWg5SjhWMHFmclNkOHpueS1ORzNlQkY0Y0p3Sml0NjRsNm41MXAwVFhLakR2Y2NFblpHZm1QbmV6TGdMLWRDdXdyZ29tcmh1TXh4NTl4ZU12cUt4Zm5yUndCM2tNdWl6ZXR4WQ&q=https%3A%2F%2Fellisontechnologies.com%2F&v=rxpCWE6ha0s] GSC – 3D & Automation A leading reseller of SOLIDWORKS® CAD software and Markforged® industrial 3D printers, helping engineers design and manufacture innovative products faster. https://gsc-3d.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqbjl1M2tJNlRudnJQWlNWQTUycjRuT2RiUm9mQXxBQ3Jtc0tsZ2dpeW1qdlZWRHl5T21mVG10V3gxRkgzLTZJUFRsUTlrQmVORGVmMG1leFllQkFibHVpU3BTaThmZ1ZtSzVNSGJRclZOQzZqVThwLW50ejhHczljdkxEUWxydTl2aWZJZFZZTkl1X3AwcXRzUDVPTQ&q=https%3A%2F%2Fgsc-3d.com%2F&v=rxpCWE6ha0s] Would you feel comfortable working alongside a robot at your job? Why or why not? Share in the comments below.

Why Manufacturing Scraps $40,000 in “Good Parts” Every Month | Jacob LaFlamme

Manufacturing quality control is one of the most misunderstood parts of CNC machining and precision manufacturing. Many people assume every manufactured part that works gets shipped to the customer — but in reality, thousands of dollars in perfectly functional parts are rejected every month.In this episode of Manufacturing Runs The World, Jacob LaFlamme of SwissTurn/USA explains a surprising truth about modern manufacturing quality engineering: companies sometimes scrap tens of thousands of dollars in CNC machined parts every month in order to maintain strict tolerances, product reliability, and customer trust.At many precision machining companies, even parts that technically function can still be rejected if they fall outside the required tolerance range. Jacob shares that some shops scrap around $40,000 worth of parts every month, and in industries like medical device manufacturing, aerospace manufacturing, and defense manufacturing, those numbers can easily reach millions of dollars annually.The reason is simple: the cost of shipping a defective component can be far greater than the cost of scrapping it.A single bad part can cause product failures, recalls, damaged reputation, and even lawsuits. Because of this, quality engineers must enforce strict inspection processes, ensuring that every component meets the exact specifications defined in the manufacturing print.Jacob explains that quality engineering is not just about measuring parts — it's about protecting the reputation of the entire company.Using a simple analogy, he compares manufacturing quality to ordering a custom-built car. If the car arrives on time but constantly breaks down, the customer will remember the problems forever. But if the car arrives late and works perfectly for years, the delay is quickly forgotten.In this episode, Jacob discusses:• Why millions of dollars of CNC machined parts are scrapped every year• The real pressure inside manufacturing quality control departments• How ISO 9001 manufacturing quality systems work• The role of inspection tools like micrometers and Zeiss CMM machines• How SolidWorks and ERP systems track manufacturing quality issues• Why machining experience is critical for quality engineering careers• The balance between production speed and manufacturing quality standards• Why skilled trades and CNC machining experience still matter in modern engineeringCHAPTERS00:00 [https://www.youtube.com/watch?v=_hJXBadvOOA] Why manufacturing scraps $40,000 of parts every month00:44 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=44s] Introduction to manufacturing quality engineering00:52 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=52s] Jacob’s background in medical device manufacturing01:09 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=69s] How liquid chromatography machines analyze blood samples01:27 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=87s] Transitioning to SwissTurn job shop manufacturing02:01 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=121s] Why defense manufacturing hides part applications02:14 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=134s] Why “good parts” still get rejected in quality03:16 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=196s] How scrap costs reach millions in medical manufacturing03:37 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=217s] Why reputation matters more than shipping fast04:36 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=276s] From CNC machining school to quality engineering05:48 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=348s] The pressure between production and quality06:19 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=379s] Micrometers vs Zeiss CMM inspection tools07:21 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=441s] Using SolidWorks and ERP systems for quality tracking08:31 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=511s] How ISO 9001 certification works in manufacturing09:19 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=559s] Staying ahead of automation and Industry 4.010:35 [https://www.youtube.com/watch?v=_hJXBadvOOA&t=635s] Advice for the next generation of machinists and engineersTHANK YOU TO OUR SPONSORSEllison TechnologiesEllison Technologies empowers manufacturers with advanced CNC machines, automation solutions, and engineering expertise to help companies work smarter and more competitively.https://ellisontechnologies.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqa3ZIOF9hbTUxV3Y4TXQ5dy1yb0xpWFVDYWpvd3xBQ3Jtc0tsUGVvbmtYM3ZMTEZkbjdFSmRLQXNqWFBGYjFJbHB0VHZ2MFF1V2tka1BlUWJKQUtKZnVRclNlaTZXRXU1NVZTM3VPM0hsSjFLdW1jOXJsX3l1WEd6VGl5NWFwekRLQ1NhOHhMUzgtclZWMWx1bmhUYw&q=https%3A%2F%2Fellisontechnologies.com%2F&v=_hJXBadvOOA]GSC – 3D & AutomationA leading reseller of SOLIDWORKS® CAD software and Markforged® industrial 3D printers, helping engineers design and manufacture innovative products faster.https://gsc-3d.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqblJXR0pnQ1FFNU5NNk5DX2sxamFQSW1XRVljQXxBQ3Jtc0ttVnBVdENUYW8tdTZJY3BvbFByU09iNHZldjNtX0tjSVpnMUNjVHNtd1BtTFFfd283UHI4TC01WjU3b3lvSmwyM0pjblFobEdhZmowbjhMUnRMb1ZmalBkZkJPSTlWWFc1ay1ZelUzMWs1VTc2VVhjRQ&q=https%3A%2F%2Fgsc-3d.com%2F&v=_hJXBadvOOA]

A Big Company Tracked Production on Whiteboards… For Years

Most people think modern factories are powered by advanced automation, real-time dashboards, and highly optimized digital systems.But what if a major manufacturing operation was still tracking production numbers using… whiteboards and manual data entry? In this episode of Manufacturing Runs The World, manufacturing engineer Kyle Fenstermacher of Universal Laser Systems shares one of the most surprising process discoveries from his career. When Kyle first encountered the system, production numbers were being tracked by writing hourly output on whiteboards across the shop floor. Someone would then walk around collecting the data, hand it off to another employee, and that information would finally be entered manually into Excel. For a modern manufacturing operation, the process was shocking.Kyle explains how this moment opened his eyes to one of the biggest realities inside manufacturing today: many factories are still operating with outdated processes that dramatically slow down production, limit visibility, and create unnecessary inefficiencies. Instead of accepting the status quo, Kyle worked with teammates to design and implement a digital production tracking system, allowing line leaders to enter production data directly from iPads and feed that information into a live dashboard for real-time visibility. The result? Better communication. Better production visibility. And a much smarter manufacturing process. But that story is just one part of Kyle’s journey. As a Manufacturing Technical Manager and Manufacturing Engineer at Universal Laser Systems in Scottsdale, Arizona, Kyle focuses on improving manufacturing systems, production efficiency, and process optimization across the factory floor. His work involves identifying operational inefficiencies, designing new production tooling and fixtures, and implementing automation solutions that improve both productivity and manufacturing quality. In one case, Kyle helped uncover over $1 million in margin opportunities by analyzing production processes and identifying hidden cost improvements. Throughout this conversation, Kyle shares insights into: * How modern manufacturing engineers solve real-world production problems * Why automation isn't always giant robots * How 3D printing is transforming production tooling• The hidden inefficiencies many factories still face * Why communication with vendors can make or break a project * How AI is beginning to influence engineering workflows Manufacturing today is far more technical, innovative, and impactful than most people realize.And stories like Kyle’s show why manufacturing truly runs the world. Chapters 00:00 [https://www.youtube.com/watch?v=EIIzDWzDoR8] The manufacturing system that shocked Kyle 00:36 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=36s] Why outdated factory processes still exist 01:20 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=80s] Kyle Fenstermacher’s background in manufacturing engineering 02:05 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=125s] Working at Universal Laser Systems 03:02 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=182s] How production tooling and fixtures improve manufacturing 04:12 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=252s] Designing tools directly for the production floor 05:10 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=310s] How 3D printing speeds up manufacturing improvements 06:05 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=365s] The whiteboard production tracking system discovery 07:00 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=420s] Building a digital factory dashboard system 08:05 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=485s] Why automation is more than robots 09:10 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=550s] Using AI to assist engineering workflows 10:05 [https://www.youtube.com/watch?v=EIIzDWzDoR8&t=605s] The biggest lesson about managing manufacturing projects 11:05 Why communication with vendors is critical 12:00 Changing the public perception of modern manufacturing 🙏 Thank You to Our Sponsors Ellison Technologies Ellison Technologies empowers manufacturers with advanced CNC machines, automation, and expert support — helping shops work smarter, faster, and more competitively. https://ellisontechnologies.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqbHJ0YVFrSG1LdUdtb3R2NmpoMlRVZ0hja3dpQXxBQ3Jtc0tsRHZ6UWVyS1RMTGpHNzBldFZNUDFfWVNWYzY1VTVidWFqcGpDSmxxVGZmRkNMb2lRMmRSdGtrSDB6VWxRS0pKdGJuVXlsekNtajNRRVVnTUV6YUZ5UG8wLTlHQ1pzeDVKV0xjLTAydjZzZ3V3OVFpNA&q=https%3A%2F%2Fellisontechnologies.com%2F&v=EIIzDWzDoR8] GSC – 3D & Automation A leading reseller of SOLIDWORKS® CAD software and Markforged® industrial 3D printers, empowering engineers with cutting-edge design, simulation, and additive manufacturing tools. https://gsc-3d.com [https://www.youtube.com/redirect?event=video_description&redir_token=QUFFLUhqbjBMUF93eWs3Z2RYeXdEb0hpUVhHQ0NSS09Pd3xBQ3Jtc0trajBicWEwQzBWZjRBcFZWVWYySllIZWVLUzUxT2g2YzFJTlNYY0VidXFYWm55VU1pMHY0bTJNdVNqeDByYW5GQnhsaFZEelRFX2JkNHlVYWp5WUN2dkdYWjRveWpEaHJpMkR2OGF4eTRnNUNDc3lfVQ&q=https%3A%2F%2Fgsc-3d.com%2F&v=EIIzDWzDoR8]