Lean Built: Manufacturing Freedom

In this episode, Jay recounts recounts the story of a stolen trailer from his tiny home business, leading into a broader discussion on trust, theft, and logistics nightmares. Andrew follows with reflections on manufacturing safety, freight failures, and the unexpected lessons of customer service—both good and bad.

Jay and Andrew kick off with a quick story about “the yips” — that sudden moment when everything you know just disappears — and use it to launch into a deeper discussion about what makes great shops tick.

They unpack why even pros break down under pressure, how systems and habits keep you grounded, and why finishing what you start matters more than chasing shiny new projects. From compressor failures to confusing control panels to the “95% Rule,” this episode is packed with real shop-floor lessons on leadership, lean thinking, and culture.

Running a business means living in the tension between control and chaos—and this week, Jay and Andrew talk about both. From tariffs and supply chain headaches to the quirks of wire EDM and CO₂ lasers, they explore how  shops adapt when material costs, sourcing, and technology throw curveballs. Along the way, they swap stories about spotless autobody shops, frustrating e-commerce platforms, website crashes, and even backup internet solutions.

Whether it’s stocking obscure steels, streamlining websites for Black Friday, planning redundancies that actually matter, or rethinking lean practices like “water spiders,” Jay and Andrew show...

This episode of the Lean Built Podcast starts in the shop but ends up on stage. Andrew  and Jay begin by discussing machining decisions—when to model details in CAD versus when to let CAM and shop standards handle them, edge breaks, chamfers, and the balance between aesthetics and efficiency.

But midway, the conversation takes a turn into music...concert stories, 90s Christian rock, ska bands, artistry, and musical creativity. Along the way, they draw parallels between toolpath textures and vinyl warmth, and talk about some of the influences that formed them into the men...

What’s better: a locked-down, push-button system or total control over every parameter? In this episode, Andrew and Jay wrestle with that question across the shop floor and beyond. They start with Haas’ robotic pallet loader and the limits of locked waypoints, then branch into the bigger design dilemma—do customers really want simplicity, or do they crave flexibility? Along the way they swap stories about return policies that backfired, the surprising psychology of premium pricing, whether renting high-dollar workholding could make sense, and why clear communication matters more than working faster. It’s a conversation about autonomy, design trade-of...

Jay and Andrew unpack the recent sale of Heller to DN Solutions and what it reveals about brand value, culture shifts, and the economics of high-ticket, low-volume machines. They move from industry news to the shop floor, comparing palletized workholding with soft jaws, weighing costs against flexibility, and sharing how small changes can unlock significant productivity gains.

Along the way, they discuss intellectual property fears, the reality of knockoffs, and why continual improvement is often the best defense. Jay shares behind-the-scenes lessons from developing new vise palettes and running beta tests, while Andrew emphasizes...

Scarcity sells. But at what cost? In this episode of Lean Built, Jay and Andrew dig into the world of false urgency, hype marketing, and smoke-and-mirrors business tactics. From eBay nostalgia to NFT mania, they unpack how artificial scarcity (and a lot of other practices) can undermine trust while genuine value builds it.

Along the way, they share stories of radical honesty in business, saying no to misaligned customers, and why investing in truth creates stronger companies than any short-term marketing trick.

This week’s conversation covers a little bit of everything. Andrew shares stories from his trip to Japan, including what he noticed at Matsuura’s factory and a clever little chip briquetting machine that has everyone asking questions. Jay talks about viral video surprises on Instagram and YouTube, and the two compare notes on carts, pallet wrapping, and what lean looks like in real shops versus theory.

They also touch on shop culture: why hospitality matters as much as process, and the challenges of keeping things moving when the boss is out of town.

In this solo debrief, Andrew recounts his visit to Matsuura’s plants in Japan, where he observed firsthand the discipline and detail that define Japanese manufacturing. He describes how Matsuura trains new employees years in advance, the precision of their hand-scraping process, and the consistency achieved by grinding every pallet on a single master machine.

He also discusses the innovations he saw in Matsuura’s hybrid LUMEX metal 3D printing and machining technology, spindle balancing rigs, and integrated chip briquetting systems. Beyond the machines themselves, he reflects on Matsuura’s culture of multi-generational leadership, long-t...

Jay and Andrew swap stories about the constant balancing act between buying, making, renting, borrowing, and outsourcing. From renting camera lenses for product shoots to resisting the emotional pull of a first CNC machine, they dig into the real-life decision-making that keeps a shop lean (or clutters it up). You’ll hear about scissor lift negotiations, the pain and payoff of liquidating unused gear, the “what if” trap that fills shelves with obsolete parts, and the unexpected warranty calls that arrive the day after you throw something away. Along the way, they share practical takeaways on optioning machines, standardizing tools...

Andrew and Jay unpack a thought-provoking article from The Systems Thinker on the tension between learning and performance. How do you actually learn from failure? Is it a given that you will? The conversation ranges from morning meeting rituals and positive failure culture to the dangers of over-relying on data.

Along the way, they talk chipped tools, misordered pipe, customized packaging, AI-assisted KPI dashboards, Harbor Freight, and more. 

Jay and Andrew discuss the true cost of doing business with “big name” clients who act like bullies. You know the ones. They demand unfair terms, they're slow to pay, they're quick to add red tape. Jay shares a personal story about walking away from a prestige customer that wasn’t worth the stress, cost, or collection headaches. Andrew adds cautionary tales, including lessons from a fellow shop owner who took the bait on a massive PO and paid the price in blood, sweat, and sleepless nights.

They also talk about the power of peer a...

Jay and Andrew dig into the difference between organization and orderliness, unpack how simply arranging clutter isn't true organization, and how failing to eliminate what’s unnecessary leads to inefficiency, wasted time, and blocked flow.

From red-tagging unused bandsaws to preserving museum-worthy prototypes, the conversation explores the emotional and practical side of decluttering. Jay shares a maintenance wake-up call involving a long-forgotten gearbox and walks through how proactive systems (like Trello and SOPs) can prevent downtime disasters. Then the duo touch on their favorite tools, ranging from $20 Japanese nippers to precision CMMs.

You can get th...

As this episode begins, Andrew shares the lessons learned from a recent Matsuura mishap—how a forgotten chip fan caused an unexpected repairs and expensel—and how these bumps in the road are part of owning the machine, not just using it.

This leads to Andrew and Jay digging into the balance between pushing limits and preventing crashes, using real-life examples of breaking tools (sometimes on purpose) to discover the edge of performance. The conversation also touches on company culture and the psychology of failure in machine shops, including the value of giving employees perm...

Andrew and Jay trade stories and strategies around one of the most pivotal parts of entrepreneurship: risk.

Jay recounts signing the papers for a commercial building just weeks before the world shut down in 2020—and how faith, clarity, and conviction helped him stay the course. Andrew reflects on leaving his teaching job, taking out his first major equipment loan, and learning to distinguish between high-stakes risks and small, reversible bets.

Together, they explore:

The first half of this episode is all about Inbox Zero (riffing on this blog post): what it really means, why it might not matter, and how to manage information overload without wasting time or energy.

From there, Jay and Andrew dig into tool change times, Matsuura automation quirks, solenoid-driven air savings, and the oft-overlooked cost of compressed air. They also get nerdy about vacuum workholding—explaining the science behind efficient setups, the inevitability of leaks, and why not all vacuum systems are created equal.

In our 100th episode special, we take listener questions including:

Whether yo...

Jay walks listeners through how Trello has become the backbone of Pierson's documentation and digital workflow system—replacing binders, Dropbox links, and scattered storage with an integrated, accessible, and collaborative project management setup. Andrew offers a comparison with Asana and how they track product development through value/difficulty filters.

Then the episode shifts toward lean factory layout, as Andrew details a recent consultation that helped him rethink mold storage, tool access, and workspace flow. The episode wraps with a conversation about leadership—highlighting how small process frustrations, when voiced and owned by proactive team memb...

Jay walks listeners through how Trello has become the backbone of Pierson's documentation and digital workflow system—replacing binders, Dropbox links, and scattered storage with an integrated, accessible, and collaborative project management setup. Andrew offers a comparison with Asana and how they track product development through value/difficulty filters.

Then the episode shifts toward lean factory layout, as Andrew details a recent consultation that helped him rethink mold storage, tool access, and workspace flow. The episode wraps with a conversation about leadership—highlighting how small process frustrations, when voiced and owned by proactive team memb...

Jay walks listeners through how Trello has become the backbone of Pierson's documentation and digital workflow system—replacing binders, Dropbox links, and scattered storage with an integrated, accessible, and collaborative project management setup. Andrew offers a comparison with Asana and how they track product development through value/difficulty filters.

Then the episode shifts toward lean factory layout, as Andrew details a recent consultation that helped him rethink mold storage, tool access, and workspace flow. The episode wraps with a conversation about leadership—highlighting how small process frustrations, when voiced and owned by proactive team memb...

Is high-density workholding incompatible with single-piece flow? In this episode of Lean Built, Andrew and Jay talk about the intersection of lean manufacturing theory and real-world machining. From palletized workflows to red-tagging clutter, they cover the trade-offs between quality, speed, density, and cost. They also explore the nuanced relationship between SMED, economic lot size, and high-density fixtures—plus why your shop's application of lean principles might be a lot different from my shop.

Books mentioned:
5 Pillars of the Visual Workplace: The Sourcebook for 5S Implementation by Hiroyuki Hirano

Andrew and Jay cover everything from the real meaning of 5S (and why people forget “shine”) to the subtle art of good UI/UX—both in software and hardware. Along the way, they share lessons learned from designing better shop tools, organizing workspaces, and reducing friction in daily tasks.

Andrew recounts how a Memorial Day spent reorganizing led to a color-coded system for trash bins, while Jay explains how constraints—not extra time—often lead to better results. They also discuss bringing on high school interns, building culture through curiosity, and how thoughtful design—like a volum...

A recent EF2 tornado brushes past Andrew’s church and shop, prompting a frank conversation with Jay about what it takes to run a manufacturing business when the weather—and the insurance coverage—is uncertain. They compare real experiences with unexpected policy gaps, weak agents, and the slow process of building a trustworthy support network.

The conversation then moves to leveraging lights-out machining and pallet pool workarounds. Andrew also shares how his team is adapting to new production challenges and experimenting with lean hardware fixes.

Sound in a shop is more important than you might think, as Andrew and Jay discuss in this episode. They swap stories about soundproofing strategies, and why one bad cut can be heard across the room. Along the way, they compare notes on how tools like Plaud, ChatGPT, and Zapier are actually being used in the shop—not just as shiny toys, but as part of daily workflows that save time and reduce mental clutter.

They also get into air system upgrades, why machine noise wears you down more than you think, and what it...

Jay and Andrew dig into the evolving landscape of remote work—what’s working, what’s not, and how their companies have adapted with distributed teams. From time zone headaches and culture-building tactics to tool stacks like Trello, Asana, Signal, and Loom, they discuss the real-life challenges of managing modern manufacturing and design teams remotely.

The guys explore the balance between asynchronous freedom and real-time collaboration, debate Airbnb and tiny homes for remote worker lodging, and share their philosophies on deadlines, productivity, and internal documentation. You’ll also hear practical tips for automating daily updates...

Today we talk practical applications of lean manufacturing, including smarter air management for CNC machines, efficient shipping workflows, and the role of AI in documenting standard operating procedures. Andrew shares the highs and lows of integrating his new Matsuura—complete with GoPro hacks, networking woes, and the importance of psychological design tweaks like turning keys into knobs.

 Book Mentioned:

The Amateur’s Mind: Turning Chess Misconceptions Into Chess Mastery by Jeremy Silman

In today’s solo episode, Andrew goes deep on the new Matsuura MX installation at Henry Holsters. He answers key questions about why they chose the MX over the MAM series, the tooling strategies they’ve implemented, and how they’re deciding which parts transition from the Brother machines to the new five-axis setup.

He discusses the pros and cons of the MX’s pallet pool design, the transition to Rego-Fix PowerGrip tool holders, and how the investment in high-speed prototyping is paying off. Andrew also opens up about the long and sometimes stressful journey...

In today’s solo episode, Andrew goes deep on the new Matsura MX installation at Henry Holsters. He answers key questions about why they chose the MX over the MAM series, the tooling strategies they’ve implemented, and how they’re deciding which parts transition from the Brother machines to the new five-axis setup.

He discusses the pros and cons of the MX’s pallet pool design, the transition to Rego-Fix PowerGrip tool holders, and how the investment in high-speed prototyping is paying off. Andrew also opens up about the long and sometimes stressful journey...

Jay and Andrew discuss the value of getting your hands dirty—and how doing so can give you fresh eyes on your business. Jay shares what it’s been like stepping back into a department he hasn’t worked in for years, spotting process drift, and rediscovering the satisfaction of lean improvements. Andrew relates his own experiences revisiting old stations and realizing just how much clarity comes from reengaging directly with the work. Along the way, they talk through the pitfalls of stale systems, how to balance small improvements with big strategic goals, and why owner involvement still matters. They a...

Andrew leads Jay through the surprisingly complicated world of modular pistols—and what it can teach us about running a lean, efficient shop. What starts as a chat about concealed carry and SIG’s infamous P365 series turns into a full-blown deep dive into systems thinking, SKU overload, and why bad product naming can crush your workflow.

Andrew unpacks how chaos in the holster industry mirrors challenges in manufacturing. He also shares how his team is using AI and smart documentation to streamline customer service and reduce confusion—something every shop owner can learn from.<

Andrew and Jay get real about one of the biggest headaches in the shop: waiting on other people. Whether it’s parts, processes, or just plain slow responses, Other People’s Lead Times (OPLT) can absolutely wreck your schedule. They talk through the tension between outsourcing and staying lean vs. trying to control the whole process. Would Henry-Ford style vertical integration ever be worth it? Plus tariff talk, the dark side of lean, and so much more.

Andrew and Jay dive into lessons from an improv-based leadership workshop—like how body language and silence shape communication. They explore “last-letter listening,” a simple but powerful game to build better habits in conversations. Then the discussion shifts to process drift, shop floor improvements, and the ongoing battle between order and entropy. Along the way: clear bins, label makers, expanding facilities, Formula 1 fandom, and why every machinist should probably watch some racing.

How do you maintain lean principles when things are temporary? From setting up makeshift workstations to dealing with process drift and forgotten improvements, Andrew and Jay discuss the cost of cutting corners ... even in short-term production. You’ll hear real-life shop floor stories about mislabeled kits, cracked lenses, and the subtle erosion of good processes. Plus, they explore how visibility, standardization, and a culture of “stop and fix what bugs you” can transform workflow—no matter how small the task.

Book mentioned:
The Goal: A Process of Ongoing Improvement by Eliyahu M. Goldratt

When your entire shipping process is disrupted by a black hole of lost packages, what do you do? In this episode, we dive into a real-world shipping and fulfillment crisis, as a USPS hub in Indianapolis fails to deliver—literally. With potential for lost orders, frustrated customers, and rising costs, Andrew breaks down how his company pivoted their logistics strategy in real time to save their product launch.

We also explore lean manufacturing principles, the importance of process feedback loops, and why bad vendors will eventually burn themselves down—sometimes literally. Plus, hear some wild...

Installing a new CNC machine isn’t for the faint of heart, and in this episode, we dive into the process of rigging and setting up the Matsuura MX420 PC10. From nerve-wracking moments with teetering machine parts to the surprising role color plays in a shop environment, Andrew and Jay share firsthand experiences from the world of machining.

Plus, we explore: why rigging mistakes have led to catastrophic crashes in the past, how a misaligned spindle caused major headaches, the power of getting the right technicians for the job, why choosing between a Brother and a Haas CN...

Jay and Andrew unpack the concept of “Ask for No, Don’t Ask for Yes,” a strategy that flips traditional decision-making on its head. Inspired by this article from Dan Moore, they discuss how shifting from seeking approval to assuming action can streamline workflows, eliminate bottlenecks, and empower teams to make decisions with confidence. They also share insights on reducing decision fatigue, setting clear boundaries, and avoiding unnecessary delays. Plus, they do a deep dive into machining improvements, and ChatGPT for workflow automation.

In this episode, we dive deep into the value of failure—yes, failure—as a crucial tool for growth and success. Jay and Andrew discuss the difference between smart failure vs. dumb failure, how to create core values that actually shape company culture, and why embracing mistakes (the right way) leads to continuous improvement. They even have a friendly debate about how much pain you should feel when you (first) make a mistake.

Book mentioned:
The Brand Gap: How to Bridge the Distance Between Business Strategy and Design by Marty Neumeier 

What’s harder—your first hire or your tenth? In this episode, Jay and Andrew discuss the growing pains of hiring, when to trust your gut, and how to build a hiring process that works. They break down lean manufacturing principles, why “busy” doesn’t mean productive, and how reducing waste can create a healthier, more profitable business. 

What’s harder—your first hire or your tenth? In this episode, Jay and Andrew discuss the growing pains of hiring, when to trust your gut, and how to build a hiring process that works. They break down lean manufacturing principles, why “busy” doesn’t mean productive, and how reducing waste can create a healthier, more profitable business. 

In this episode, Jay shares key takeaways from his visit to Gimbal Automation, giving us a behind-the-scenes look at innovation in action. We break down why job candidates who don’t ask questions can be a major red flag, and we dive into the pitfalls of the pre-order trap—why taking money before your product is truly ready can backfire. Plus, Andrew shamelessly swipes a great idea from Jay to improve the visitor-experience to his facility—you might want to steal it too.