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

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.

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Connect with the hosts on Instagram:
Patrick Mcclintock: IG or PM@Job Shopper TN
Cameron Graves: IG or PM@Machiningiscool
Bradley Thomas: IG or PM@Marvel

Thanks for listening!!!