In this special episode of Lights Out, we step away from the Automation Trap series for a special episode recorded at Hexagon Live, where the buzz wasn’t just about race car simulators—but about revolutionizing shop floor productivity. We sit down with Darren Metherell, Head of Sales for Hexagon’s Connected Worker team, to explore how modern manufacturing operations can digitize smarter, faster, and with less friction than ever before.
Hexagon may be known for metrology and measurement tech, but as you’ll hear in this conversation, they’re playing a much bigger role in the factory of the future. Darren shares how Hexagon is helping mid-sized shops unlock value from the equipment and software they already have—without the six-figure consulting bill.
From paperless travelers to real-time dashboards, from tribal knowledge capture to KPI-driven gamification, the Connected Worker platform is all about helping you run a smarter shop, not just a busier one.
The conversation hits on the deep-rooted challenges many shops face: communication gaps, generational shifts, underutilized data, and the overwhelming pressure to automate without disrupting flow. But as Darren explains, real solutions start with empathy, integration, and a roadmap—not a rip-and-replace mentality.
Whether you're a job shop looking to go paperless or a multi-plant manufacturer chasing lights-out efficiency, this episode sheds light on how digital transformation can be practical, scalable, and ROI-positive from day one.
You will want to hear this episode if you are interested in...
- (0:18) An investment in ProShop is an investment in your business
- (2:00) Introducing Darren Metherell and recapping Hexagon Live
- (5:38) Darren’s journey from VCR data collection to connected manufacturing
- (7:58) Hexagon’s dual strategy: direct sales and enabling their channel
- (9:05) The paperless traveler solution: eliminating 6 inches of paperwork per job
- (11:30) Mike explains Hill Manufacturing’s structure and core challenges
- (13:16) Tribal knowledge: Collecting data to actually using it for improvement
- (15:54) Dashboards and real-time visibility and gamifying performance
- (18:15) Breaking down OEE vs. spindle utilization
- (21:38) Grow your top and bottom-line with CLA
- (22:16) More Connected Worker workflows: quality, inventory, audits, training
- (26:51) How Hexagon tailors solutions to actual pain points
- (28:52) Capturing tribal knowledge as interactive digital checklists
- (30:14) Automating more lights-out hours: sensors, cameras, RFID
- (32:40) Bringing life to legacy equipment through smart retrofitting
- (34:10 Why time-to-value beats big custom builds every time
- (35:15) Making this tech accessible to 10-person shops—not just OEMs
- (36:32) What Darren’s most excited about: unlocking value from existing systems
- (38:44) Mike reflects on buying shops with aging tech—and scaling anyway
- (39:43) Connected workers = empowered workers = future leaders
- (40:33) Check out the Machine Shop Mastery Podcast
Resources & People Mentioned
Connect with Darren Metherell
Connect With Lights Out
Subscribe to Lights Out
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