Why Most Machine Shops FAIL at Efficiency - Feat. Chris Zappettini | 19

Explicit content warning

03/18/25 • 88 min

What if you could shave hours off cycle times, optimize your machining strategies, and get your entire shop on board with process improvements—without the usual resistance?

In this episode of the Impractical Machinists Podcast, we sit down with Chris Zappettini, owner of Zappettini Consulting and co-host of Within Tolerance. Chris has spent years inside machine shops across the U.S., helping businesses cut waste, improve workflows, and implement smarter machining strategies. But as he explains, real improvement isn’t just about faster cycle times—it’s about getting everyone from the shop floor to management to buy in.

Chris shares a behind-the-scenes look at a recent project where rethinking material selection, tooling, and machining strategies slashed cycle times from 15 hours down to just 7 or 8. He also dives into the power of five-axis machining, custom G-code macros, and how well-organized CAM systems and fixture libraries can transform efficiency.

But this conversation isn’t just for shop owners—programmers, operators, and anyone who’s ever fought against change on the floor will get valuable insights on making processes smarter, not harder. Chris also opens up about life as a consultant, from navigating difficult customers to ensuring shops stay competitive in an ever-evolving industry.

🔔 Subscribe, Rate, and Review to never miss an episode. Your feedback helps us bring you the content you love!
Drop your comments or topic ideas in the forum here:
https://www.practicalmachinist.com/forum/categories/the-impractical-machinists-podcast.102/
Or listen to our podcast on YouTube: https://www.youtube.com/playlist?list=PLxzIM06jyJCYTCMGUQLgKXNtpq-HqvV2Q
Connect with the hosts on Instagram:
Patrick Mcclintock: IG: https://www.instagram.com/job_shopper_tn/ or PM@Job Shopper TN
Cameron Graves: IG: https://www.instagram.com/machiningiscool/ or PM@Machiningiscool
Bradley Thomas: IG: https://www.instagram.com/marvelmachining/ or PM@Marvel
Thanks for listening!!!

What if you could shave hours off cycle times, optimize your machining strategies, and get your entire shop on board with process improvements—without the usual resistance?

Previous Episode

Biggest Risks in Machining, Tools, and Burnout | 18

Machining is more than just making parts—it’s stress, tight deadlines, and trying to balance work and life without losing your mind. In this episode, we talk about the reality of burnout in the trade, handling overwhelming RFQs, and when taking big risks actually pays off.

And much more! Stick around to the end for a big announcement from Patrick!

Next Episode

I Didn’t Realize What I Was Missing - Until I Left this Shop | 20

When the job starts draining you, sometimes the best move is walking away. Here’s what happened next.
Burnout doesn’t hit all at once — it builds slowly, especially in high-pressure work environments. In this episode, we talk about what it really feels like to hit that point, why one of us finally decided to leave a demanding job, and what life is like on the other side.
We also dive into bigger questions:
– What makes a healthy work culture?
– How do you keep a team motivated without burning them out?
– And how can leaders build shops people actually want to work in?
This isn’t just a story about machining — it’s about finding balance, building better workplaces, and making hard choices for the right reasons.