Shows
Lean Built: Manufacturing FreedomFlexibility vs. Control | Lean Built - Manufacturing Freedom E112What’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...
2025-09-1558 minLean Built: Manufacturing FreedomDefending Against Knockoffs | Lean Built - Manufacturing Freedom E111Jay 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...
2025-09-0853 minLean Built: Manufacturing FreedomInbox Zero is a Trap (+ Vacuum Workholding Deep Dive) | Lean Built - Manufacturing Freedom E101The 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.
2025-06-3045 minLean Built: Manufacturing FreedomYellow Tags and Micro Frustrations | Lean Built - Manufacturing Freedom E99Jay 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...
2025-06-1643 minLean Built: Manufacturing FreedomYellow Tags and Micro Frustrations | Lean Built - Manufacturing Freedom E99Jay 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...
2025-06-1643 minLean Built: Manufacturing FreedomYellow Tags and Micro Frustrations | Lean Built - Manufacturing Freedom E99Jay 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...
2025-06-1643 minLean Built: Manufacturing FreedomYour Lean Is Not My Lean | Lean Built - Manufacturing Freedom E98Is 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
2025-06-0947 minLean Built: Manufacturing FreedomMatsuura MX Update: Why We Chose It, How It’s Going, and What We’ve Learned | Lean Built - Manufacturing Freedom E92In 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...
2025-04-2832 minLean Built: Manufacturing FreedomMatsuura MX Update: Why We Chose It, How It’s Going, and What We’ve Learned | Lean Built - Manufacturing Freedom E92In 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...
2025-04-2832 minLean Built: Manufacturing FreedomModular Mayhem: What Holsters Teach Us About Lean Manufacturing | Lean Built - Manufacturing Freedom E90Andrew 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.
2025-04-1446 minLean Built: Manufacturing FreedomOther People’s Lead Times Are Killing Me | Lean Built - Manufacturing Freedom E89Andrew 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.
2025-04-071h 01Lean Built: Manufacturing FreedomImprov and the Art of Listening | Lean Built - Manufacturing Freedom E88Andrew 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.
2025-03-3153 minLean Built: Manufacturing FreedomStop and Fix: Building a Culture of Lean Accountability | Lean Built - Manufacturing Freedom E87How 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
2025-03-2431 minLean Built: Manufacturing FreedomShipping Woes & Business Wins: A Lean Approach to Logistics | Lean Built - Manufacturing Freedom E86When 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...
2025-03-1746 minLean Built: Manufacturing FreedomSurviving the Install: The High-Stakes World of CNC Machine Setup | Lean Built - Manufacturing Freedom E85Installing 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...
2025-03-1043 minLean Built: Manufacturing FreedomThe Decision-Making Hack That Frees Up Time | Lean Built - Manufacturing Freedom E84Jay 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.
2025-03-0350 minLean Built: Manufacturing FreedomSmart Failure vs. Dumb Failure | Lean Built - Manufacturing Freedom E83In 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
2025-02-2448 minLean Built: Manufacturing FreedomThe Art of Hiring: Finding the Right Fit Without Micromanaging | Lean Built - Manufacturing Freedom E82What’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.
2025-02-1846 minLean Built: Manufacturing FreedomThe Art of Hiring: Finding the Right Fit Without Micromanaging | Lean Built - Manufacturing Freedom E82What’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.
2025-02-1746 minLean Built: Manufacturing FreedomNo Questions? No Job! Why Incurious People Are Bad Employees | Lean Built - Manufacturing Freedom E81In 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.
2025-02-1057 minLean Built: Manufacturing FreedomHack Your Business With Automation, Routine, & Memory | Lean Built - Manufacturing Freedom E80In this episode, Jay and Andrew geek out on the power of routine, why structured days fuel creativity, and how memory palaces can turn you into a mental wizard. Plus, Jay shares a hilarious (and frustrating) story about a packaging company that somehow managed to ship his product back looking like it survived a battle. And Andrew explains why automation isn’t stealing jobs—it’s setting people free.Book mentioned:Moonwalking with Einstein: The Art and Science of Remembering Everything by Joshua Foer.
2025-02-0345 minLean Built: Manufacturing FreedomSHOT Show 2025 Debrief | Lean Built - Manufacturing Freedom E79In this solo debrief, Andrew talks about his experiences at SHOT Show 2025, sharing reflections on industry trends, the rising costs of Vegas, trade show logistics, connecting with industry peers, the value of focused networking, and more.
2025-01-2719 minLean Built: Manufacturing FreedomLoathing Las Vegas (Or How I Learned To Stop Worrying and Love The Trade Show) | Lean Built - Manufacturing Freedom E78Andrew is headed to the SHOT Show, so he and Jay dive into the ins and outs of trade show culture, including the fascinating interplay between established giants and ambitious startups. Later they discuss balancing standardization with customization, and when it’s worth going the DIY route versus opting for factory solutions. Plus, hear their takes on pricing psychology, crafting an efficient workplace, and the joys of hands-on tinkering as founders.
2025-01-2050 minLean Built: Manufacturing FreedomBuy The Machine, Buy The Culture | Lean Built - Manufacturing Freedom E77Andrew and Jay kick off 2025 with a wide-ranging conversation about everything from the history of urban neighborhoods and local governance, navigating customer expectations, managing inventory, and handling unexpected crises like power outages. We also dive into the importance of aligning with vendors, and the intricacies of new machine installations.
2025-01-1356 minLean Built: Manufacturing FreedomShop Insights with John Saunders| Lean Built - Manufacturing Freedom E76Andrew sits down with John Saunders of Saunders Machine Works for a candid discussion about their John's visit to Andrew's shop, lessons in lean manufacturing, and the challenges of running a small business.
2025-01-0633 minLean Built: Manufacturing FreedomLessons from 2024 and Exciting Ventures for 2025 | Lean Built - Manufacturing Freedom E75As 2024 wraps up, Andrew and Jay reflect on the year. They discuss lessons learned in 2024, and how they're preparing for industry shifts in 2025. Plus Jay reveals an exciting new diversification venture in the tiny home industry, Piccola Tiny Homes, and how lean principles are transforming this space.
2024-12-3040 minLean Built: Manufacturing FreedomThe 5-Step Innovation Process | Lean Built - Manufacturing Freedom E74Jay goes solo, discussing the challenges and triumphs of launching Pierson's latest product, walking listeners through the “Musk Algorithm”—a five-step framework for process creation and optimization: 1. Question assumptions and requirements. 2. Delete unnecessary components. 3. Optimize processes. 4. Accelerate production. 5. Automate intelligently.And do that in them order, or else! Alongside, Jay delves into Pearson’s philosophy of a people-centric lean company, the value of questioning long-standing practices, and how to foster a work culture where innovation thrives.
2024-12-2326 minLean Built: Manufacturing Freedom5-Axis CNC Showdown: The Machine That Won the Day| Lean Built - Manufacturing Freedom E73The big reveal: Andrew finally shares which 5-axis CNC machine he chose and why it outshone other strong contenders (you’ll have to tune in to find out which one made the cut). Along the way, we dive deep into the decision-making process for major shop investments, offering valuable insights for anyone facing similar choices.
2024-12-1644 minLean Built: Manufacturing FreedomCraftsmanship, Innovation, and Lean: From Electric Bass Design to Everyday Efficiency | Lean Built - Manufacturing Freedom E72How about something a little different? Andrew and Jay take a detour through the world of craftsmanship, innovation, and efficiency by way of music. They discuss the evolution of electric bass designs, the nuances of machining and guitar manufacturing, and how lean principles can be applied not only to manufacturing processes but also to everyday life, from jiu-jitsu to efficient workspace setups. Along the way, they share stories about their newest equipment, the challenges of expanding their businesses, and the balancing act of maintaining quality while maximizing efficiency.
2024-12-091h 07Lean Built: Manufacturing FreedomSales That Don't Cheapen Your Brand | Lean Built - Manufacturing Freedom E71This week, we dive into the madness of Cyber Monday, Black Friday, and the whole crazy sales season. Ever wondered if discounts are really worth it? We’re talking about the psychology of sales—why free stuff beats discounts, how to build customer loyalty (shoutout to Gary Vee and John Taffer), and why one of us is over Black Friday sales. We also share behind-the-scenes stories of shipping blunders that’ll make you cringe. Plus, the thrill of new machines arriving at the shop.Don’t miss:Why “pre-sales” are the worst.How to make your customers lo...
2024-12-0249 minLean Built: Manufacturing FreedomShould You Bet On Yourself Or Somebody Else? | Lean Built - Manufacturing Freedom E70Both Jay and Andrew have made some big purchases lately, including Andrew's final decision on a 5-axis machine. In this episode, they share candid stories about navigating those choices. Just what kind of thought do you put into a six-figure decision? Do you trust your gut, do you rationalize, or what? Oh, and they also discuss battling gophers (yes, really).
2024-11-2550 minLean Built: Manufacturing FreedomDo You Get Paid By Ideas or Hours? | Lean Built - Manufacturing Freedom E69Jay and Andrew talk about getting paid by ideas versus getting paid by hours, passing the right kind of physical legacy on to your kids, the purposes of reserve cash, and more.
2024-11-1848 minLean Built: Manufacturing FreedomNumbers Without Decisions Are Noise | Lean Built - Manufacturing Freedom E68Jay and Andrew start by discussing what they will focus on as business owners coming out of this election. (Hint: focus on what you can control, which, it turns out, is actually quite a lot.) Then they talk about numbers. Some business owners run their operations based on a thorough understanding of all the relevant numbers. For some, this can lead to wonderful results; for others, it can be incredibly stifling. How do you use numbers to your advantage?
2024-11-1135 minLean Built: Manufacturing FreedomStandards Are Gorgeous | Lean Built - Manufacturing Freedom E67You know what's really nice? When standards are, y'know, standardized. As in...widely accepted and widely implemented. As opposed to changing between different companies, regions, and manufacturers. This is just one topic Jay and Andrew tackle in this episode on standards, simplicity, and solving problems before they happen. Books mentioned:Lean Made Simple - 12 Proven Steps for Creating a Vibrant Lean Culture Kindle Edition by Ryan Tierney.Who Not How: The Formula to Achieve Bigger Goals Through Accelerating Teamwork by Dan Sullivan and Dr. Benjamin Hardy.
2024-11-0443 minLean Built: Manufacturing FreedomEffort Doesn't Equal Output | Lean Built - Manufacturing Freedom E66Andrew talks about some really valuable things he's learned from Who Not How: The Formula to Achieve Bigger Goals Through Accelerating Teamwork by Dan Sullivan and Dr. Benjamin Hardy, including the importance of making fewer, better decisions and living in the results economy, not the effort economy.
2024-10-2820 minLean Built: Manufacturing FreedomAnything Worth Doing is Worth Doing Poorly? | Lean Built - Manufacturing Freedom E65Anything worth doing is worth doing well, right? Well, yes! Of course. But, in another sense, anything worth doing is worth doing poorly. Find out the distinction in this episode. You'll also hear Jay ponder the fact that when he doesn't review things with his employees, they tend to forget them. Which may sound like an obvious truth, but who among us couldn't profit from keeping it in mind?Andrew and Jay also talk about the morality of money, the search for a good salesman, and when to trade money for time or energy (and vice versa).
2024-10-2151 minLean Built: Manufacturing FreedomSelf-Limitation for Success | Lean Built - Manufacturing Freedom E64In this week's episode, Andrew and Jay delve into:Choosing the Right Machinery: How do you decide on the best equipment for your needs, not other people's?Strategic Purchasing for Tax Benefits: Is NOW always the right time to buy equipment to leverage tax advantages?The Owner's Mindset: Exploring how an owner's mindset can be the largest barrier to business growth.Self-Limitation for Success: Identifying areas where business owners should set boundaries for themselves to ensure the company's prosperity.Running a sale: when and how is it actually advantageous to run a sale?Book discussed: Who N...
2024-10-1456 minLean Built: Manufacturing FreedomIs Clean Lean? (The Aesthetics of Efficiency) | Lean Built - Manufacturing Freedom E63Join Jay and Andrew as they explore:The Aesthetics of Efficiency: Does a clean environment make for a more productive shop? Or is a bit of mess the price of lean?Fresh Perspectives: The importance of bringing new eyes to old processes for innovation and improvement.Actually Testing Things: Why testing ideas and methods is crucial for true productivity, and how assumptions can lead us astray.Plus ... Jay and Andrew disagree on something! Sort of. For a minute. Maybe.
2024-10-0749 minLean Built: Manufacturing FreedomWhat Makes More Money—Spindles or Pallets? (Plus More IMTS Followup) | Lean Built - Manufacturing Freedom E62It's a jam-packed episode of Lean Built as Jay and Andrew kick things off with a head-to-head: spindles versus pallet pools. Which one packs the bigger profit punch? From there, they steer back into the world of IMTS, and especially how bringing your team and employing them strategically can yield big results. But that's not all. They tackle machine aesthetics—does beauty equal beast in manufacturing? They also dissect the double-edged sword of automation, and the art of slashing unnecessary steps to streamline your operations like a pro. All that...
2024-09-2350 minLean Built: Manufacturing FreedomEliminate Choices, Solve ACTUAL Problems | Lean Built - Manufacturing Freedom E61Andrew and Jay come back from IMTS with plenty on their minds. They talk about salespeople who want to solve your problems vs. ones who just want to make a sale, the pros and cons of using products from new companies, getting up and close with machines, knowing what problem a particular machine you're considering actually solves, ending choice paralysis, and more.
2024-09-161h 17Lean Built: Manufacturing FreedomLive from IMTS 2024 | Lean Built - Manufacturing Freedom E60Jay and Andrew check in from IMTS.
2024-09-1117 minLean Built: Manufacturing FreedomIMTS Trick 'n' Tips | Lean Built - Manufacturing Freedom E59As Jay and Andrew prepare to go to IMTS 2024, they talk trade show tricks and tips. How do you approach events like this? How do you make the most of them for your company and your own personal growth? When should you take pictures? How should you treat competitors? Is it better to be honest with a salesperson if you're not interested in buying something? They talk everything from comfortable footwear to staying hydrated to seeing friends to how to schedule your time for maximum benefit.
2024-09-0943 minLean Built: Manufacturing FreedomThe Bullet Tells The Truth | Lean Built - Manufacturing Freedom E58Andrew and Jay discuss several key principles this week that can help your business grow, including:The Bullet Tells the Truth: It doesn't matter how well something works in theory; it must work in practice.Avoid Delusional Leadership: Understand the real workings and needs of your company.AI as Homework: Using AI can be beneficial if you use it wisely, much like looking at someone else's homework.Customer Alignment: Recognize that your business goals won't align with every customer, and that's sometimes okay.Exploring Other Shops: Visiting other businesses can provide valuable insights into different operational methods.Keep...
2024-09-0253 minLean Built: Manufacturing FreedomThe Dark Side of Lean | Lean Built - Manufacturing Freedom E57Andrew and Jay continue their discussion of what kind of 5-axis machine should Andrew buy and how to think ahead in making big decisions. Then they shift gears into the art of crafting a mission statement that doesn't just gather dust on a plaque. What makes a mission statement not just good, but galvanizing? What is a good mission statement is even meant to accomplish? Finally, they discuss the "dark side" of lean methodology, when it begins to consume your life outside the shop.
2024-08-2647 minLean Built: Manufacturing FreedomThe Power of Staying In Your Lane | Lean Built - Manufacturing Freedom E56Join Jay and Andrew as they dive deep into the challenges of using Fusion, the nuances of fair use in copyright law, and the art of dressing to impress in the business world (it's actually a thing!). We're picking up where we left off from our future discussion on Andrew's journey in scaling up his business and investing in new equipment. As we do, we'll explore why sometimes staying in your lane can be the most strategic move for growth.
2024-08-191h 04Lean Built: Manufacturing FreedomCrossroads & Clarity: Navigating Big Decisions in Business | Lean Built - Manufacturing Freedom E55Andrew is at a crossroads, weighing the decision to expand or relocate his shop, along with the potential purchase of a 5-axis machine. In this episode, Jay helps Andrew navigate the complexities of these big decisions. They delve into how a firm "no" on one major issue brought Andrew much-needed clarity. They explore the emotional investment required when thinking about the future. They talk a lot about what kind of machine Andrew should actually buy. And more. There's plenty to learn as they discuss the challenges and rewards of making big decisions in business.Here’s the li...
2024-08-1256 minLean Built: Manufacturing FreedomDon't Be Blind To The Future | Lean Built - Manufacturing Freedom E54Andrew and Jay talk about automation (Jay's buying another robot!), solving unexpected space problems, how to not be myopic about the future, and more.
2024-08-0547 minLean Built: Manufacturing FreedomCreating A Company You Can Sell One Day | Lean Built - Manufacturing Freedom E53Andrew and Jay talk about the necessity of vacation, why math SHOULD be (somewhat) emotional, known cost versus unknown upside, upscaling so you can do a job versus getting a job and then upscaling, bringing remote workers in, and things you can be doing right now to create a company with real value, the kind of value you can sell (even if you're not planning to do so for years or ever).
2024-07-2944 minLean Built: Manufacturing FreedomWhen Saving Money Costs Too Much | Lean Built - Manufacturing Freedom E52Join Jay and Andrew as they delve into their deep-seated skepticism towards multipurpose products, discuss why some cost-cutting measures can be counterproductive, and explore the concept of (imagining) scaling their business tenfold to uncover hidden bottlenecks. They also examine the importance of hiring individuals who elevate the team, the strategic use of loss leaders, the fine line between effective and off-putting advertising, and the right time to attend trade shows.
2024-07-221h 04Lean Built: Manufacturing FreedomHow Companies Die | Lean Built - Manufacturing Freedom E51What is the lifespan of a company? What should be the lifespan of a company? How long should you want your company to last? Are you trying to build the next Samsung/Apple/whatever or something that lasts a single lifetime? Jay visited the Haas facility recently, and Andrew toured some shops as well. In this episode, they talk about what they learned.
2024-07-1542 minLean Built: Manufacturing FreedomJust Try It | Lean Built - Manufacturing Freedom E50Andrew and Jay discuss the art of identifying true anomalies in your business ... when is something worth pivoting for and when is it not? They also talk about tradeoffs and how to keep your eye on long-term goals, some hands-on tips for working Fusion, and the "just try it" mindset, encouraging a spirit of experimentation that can lead to innovative breakthroughs.
2024-07-0138 minLean Built: Manufacturing FreedomThe Art of Customer Disappointment | Lean Built - Manufacturing Freedom E49Jay and Andrew dive into the secrets of maintaining productivity amidst workplace interruptions, mastering remote collaboration, and leveraging tools like Slack and Signal for seamless communication. They also talk about the surprising benefits of groupthink, and the art of knowing when it's actually beneficial to disappoint customers—and when it's critical not to.
2024-06-241h 00Lean Built: Manufacturing FreedomEat, Sleep, Succeed | Lean Built - Manufacturing Freedom E48You may or may not like it, but it turns out food and sleep are both an important part of your strategy for succeeding at any type of business. In this episode, Andrew and Jay give their thoughts.
2024-06-1730 minLean Built: Manufacturing FreedomDocument or Die | Lean Built - Manufacturing Freedom E47Join Andrew and Jay as they talk companies that couldn't make the cut and uncover why sometimes taking the passenger seat can be the smartest move. Andrew shares his concept of digital office hours—a game changer for remote workers. Plus, learn why meticulous documentation is not just a growth catalyst but also your golden ticket to a successful exit strategy.
2024-06-1051 minLean Built: Manufacturing FreedomDays Off That Are Days On | Lean Built - Manufacturing Freedom E46Jay begins by talking about taking multiple weeks off...as a highly recommended strategic way to help his business. Then Andrew and Jay talk about fusion file management, team meetings, onboarding remote workers, and why you can't "delegate your gut."Books mentioned:Poka-Yoke: Improving Product Quality by Preventing Defects.Poka-Yoke: Mistake-Proofing for Zero Defects by Hiroyuki Hirano.
2024-06-0352 minLean Built: Manufacturing FreedomLayout Or Location? | Lean Built - Manufacturing Freedom E45Jay and Andrew talk building for growth, shop layout, removing unnecessary items, morning meetings, and more.
2024-05-2736 minLean Built: Manufacturing FreedomMorning Meetings That Actually Work | Lean Built - Manufacturing Freedom E44Jay and Andrew talk about the Remarkable tablet and effective idea dumping. Then they both describe their morning meetings and talk about how you inspire people with your company culture ... without reducing it to a bunch of corporate gobbledegook. Books discussed:Extreme Ownership by Jocko Willink and Leif Babin.The Design of Everyday Things by Don Norman.
2024-05-2052 minLean Built: Manufacturing FreedomTerrible Design That MAKES You Mess Up | Lean Built - Manufacturing Freedom E43"When I lay in bed at night as a young, hungry, naive entrepreneur, I could barely contain my joy at the thought of filing sales tax forms with a dozen states every month."—Andrew on the joy of state taxes, one of a few subjects he and Jay cover in this week's episode. Mostly, they talk about design. Good, intuitive design that takes into account the way real people think and work. And bad, terrible design that sometimes literally leads to death.Book mentioned:The Design of Everyday Things by Don Norman.
2024-05-1344 minLean Built: Manufacturing FreedomDon't Hire Too Quickly | Lean Built - Manufacturing Freedom E42Andrew and Jay talk about whether they would ever purchase housing for out-of-town workers or clients, why most problems are math problems, how to inculcate company culture in remote workers, why you shouldn't hire too quickly, slips vs mistakes, design that you shouldn't notice, "Swiss cheese problems", and thoughtless outsourcing. In other words, there's plenty to chew on in this episode of Lean Built.Book mentioned:The Design of Everyday Things by Don Norman.Article mentioned:"Boeing and the Dark Age of American Manufacturing" by Jerry Useem.
2024-05-0647 minLean Built: Manufacturing FreedomPrioritize Finishing Before Starting | Lean Built - Manufacturing Freedom E41Andrew and Jay continue to explore the challenges they're facing, including website woes, and brainstorming solutions for keeping customers in the loop about new projects and product releases.
2024-04-2929 minLean Built: Manufacturing FreedomBuy Machines the Smart Way | Lean Built - Manufacturing Freedom E40Jay and Andrew talk the eclipse, the joys of 3d printing, and the thought process behind what machines they own.
2024-04-2241 minLean Built: Manufacturing FreedomI'm The One Who Sets Me Up To Fail | Lean Built - Manufacturing Freedom E39This episode starts on a somber note as Jay and Andrew both had deaths of people they loved. This leads to a discussion of legacy and what they want to leave behind as shop owners and men. They also discuss Andrew's new idea of dedicated "improvement time", hiring and onboarding remote workers, and Jay's idea for a Gordon Ramsey like show about improving shops (it would be awesome).
2024-04-0845 minLean Built: Manufacturing FreedomAvoiding Decision Fatigue | Lean Built - Manufacturing Freedom E38How do you avoid decision fatigue? How many good decisions can you make in one day? How can you make your decisions ahead of time? How can you brainstorm effectively? These are a few of the important issues Jay and Andrew tackle in this episode of "Lean Built."
2024-04-0141 minLean Built: Manufacturing FreedomGrow Fast or Grow Slow? | Lean Built - Manufacturing Freedom E37From discussing the merits of expanding quickly versus gradually to exploring the pivotal role of the shop floor in fostering career development, Andrew and Jay have a lot to talk about in this episode. They tackle the idea that anything repetitive should be automatable and ponder what it takes to build a company where employees aspire to retire from. They also examine the importance of assembling a diverse team with varied skills and preferences and the potential of gamification in enhancing productivity.But it's not all about speed. Andrew and Jay emphasize the significance of b...
2024-03-2553 minLean Built: Manufacturing FreedomMachine Malfunctions to Avoid | Lean Built - Manufacturing Freedom E36In this episode of Lean Built, Andrew and Jay dive into the world of machining mishaps and shop space dreams. Andrew recounts the story of a wild thing that happened during vacuum workholding, which leads to some tips for safe vacuum hold-down machining—plus a discussion of other downright scary machine malfunctions.Plus Jay and Andrew begin to delve into the topic of planning for future shop expansion.
2024-03-1845 minLean Built: Manufacturing FreedomWhen Does Analog Beat Digital? | Lean Built - Manufacturing Freedom E35First up, Jay and Andrew dive into the art of effectively documenting workflows. How do you avoid the pitfall of keeping everything in your head?Next, they explore the world of AI and how it can be used to address frequently asked customer queries.Then Jay shares a story of transitioning a process from digital to analog, prompting a discussion on the pros and cons of both digital and analog methods. When do you embrace digital tools and when do you stick to the tried-and-true analog methods?All that a...
2024-03-1134 minLean Built: Manufacturing FreedomThe Power of Deletion | Lean Built - Manufacturing Freedom E34Jay and Andrew talk about the power of deletion and the joy of 3D printing. They discuss the importance of embracing the development process, even when it includes ideas that don't work out. They offer insights on how to effectively engage with influencer marketing (there's a way to do it and a way not to do it). Plus Andrew reveals his trade show strategies.
2024-03-0443 minLean Built: Manufacturing FreedomUsing Kanban To Expose Weaknesses | Lean Built - Manufacturing Freedom E33Andrew and Jay talk about keeping the right amount of inventory without causing a bottleneck, the awesomeness of vertical lift modules (and just generally turning square feet into cubic feet), avoiding monuments in the shop, and how kanban is not just cards ... it's a system for exposing weaknesses.Book discussed:New Manufacturing Challenge: Techniques for Continuous Improvement by Kiyoshi Suzaki.
2024-02-2640 minLean Built: Manufacturing FreedomFind the Answer Where You Ask the Question | Lean Built - Manufacturing Freedom E32Andrew and Jay delve into the depths of lean maturity (or the absence of it), discussing how small companies can avoid reinventing the wheel, skillfully use redundancy, adhere to fundamental lean principles, and deliver answers right where the questions are most likely to be asked.
2024-02-1931 minLean Built: Manufacturing FreedomLessons from a Lathe | Lean Built - Manufacturing Freedom E31Andrew's just got a new lathe and we talk about it in this episode. There are plenty of challenges, including moving the shop layout. We also talk about how new employees help you find problems, and Rock Fuel University.
2024-02-1248 minLean Built: Manufacturing FreedomMoney Buys You an Easy Button | Lean Built - Manufacturing Freedom E30Jay and Andrew talk about rigging, how money eases the way, making our environment serve us, relationships vs profit, establishing value through the right comparison, and much more.Books mentioned:Alchemy: The Surprising Power of Ideas That Don't Make Sense by Rory Sutherland.The Brand Gap: How to Bridge the Distance Between Business Strategy and Design by Marty Neumeier.New Manufacturing Challenge: Techniques for Continuous Improvement by Kiyoshi Suzaki.
2024-02-0543 minLean Built: Manufacturing FreedomTechnology Should Never Be The Bottleneck | Lean Built - Manufacturing Freedom E29Andrew and Jay talk about building in margin, feeding your interest and curiosity, doing life-giving things, why you might not want to tie up funds in overstock, why technology should never be the bottleneck, and more.Book mentioned: New Manufacturing Challenge: Techniques for Continuous Improvement by Kiyoshi Suzaki.
2024-01-2949 minLean Built: Manufacturing FreedomThe Best Expeditor is No Expeditor | Lean Built - Manufacturing Freedom E28Jay and Andrew talk leadership development, hiring when you don't need people, utility players vs bench players, where KPIs (key performance indicators) are useful and where they aren't, why the best expeditor is no expeditor, where to place a lathe, and more.Books mentioned:The New Manager's Handbook: 24 Lessons for Mastering Your New Role by Morey Sterner.How to Become a Rainmaker: The Rules for Getting and Keeping Customers and Clients by Jeffrey J. Fox.The Story of the Paratroops by George Weller.
2024-01-2242 minLean Built: Manufacturing FreedomInflexible Lean is Bad Lean | Lean Built - Manufacturing Freedom E27Andrew and Jay discuss some of the lessons from 2023. Topics include the need for lean to be flexible, how lean should align with a company's culture, the importance of intentional lean practices, setting diverse goals for different companies, establishing and executing measurable goals for employees, fostering employee ownership in their respective areas, and delegating tasks to enable more time for creative pursuits.Books mentioned:The 21 Irrefutable Laws of Leadership Workbook 25th Anniversary Edition: Follow Them and People Will Follow You Paperback by John C. Maxwell.Traction: Get a Grip on Your Business by G...
2024-01-1545 minLean Built: Manufacturing FreedomBuying Ahead can be a Big Mistake | Lean Built - Manufacturing Freedom E26Jay and Andrew discusses Andrew's new company truck (which he bought in the least lean environment possible), how buying ahead to appease short-term tax write-offs can be a long-term bad investment, avoiding long term accounts receivable, cash flow vs cash position, trusting employees with their own credit cards, same day shipping and package tracking, and how prototyping is not necessarily lean.They also begin a conversation on what they want to improve in 2024 as they look back on 2023, which will continue in next episode.
2024-01-0848 minLean Built: Manufacturing FreedomLulled in by Robots | Lean Built - Manufacturing Freedom E25Jay and Andrew talk about Andrew’s forklift and how he’s applying “digital training wheels,” how robots and automation can lead you astray, seeing how pain and expense add up, using AI to make expertise scalable to a wider audience, and much more.
2024-01-011h 11Lean Built: Manufacturing FreedomHandling a Backlog with Lean | Lean Built - Manufacturing Freedom E24How do you handle a backlog with lean? Andrew gives a little masterclass on that, since he just had to do it, thanks to the holidays and employee sickness. Then Jay talks about why he's thinking about getting a space pod (office pod or silence booth). Plus, they talk about why adding Credit Key was good for Jay, making quality of life improvements at the end of the year instead of hoarding cash, shipping in the holidays, and how to handle Christmas break.
2023-12-2536 minLean Built: Manufacturing Freedom"Use it or lose it" is a losing philosophy | Lean Built - Manufacturing Freedom E23Jay and Andrew talk about Andrew's new forklift, the pros and cons of handling inventory for other shops, tax incentive buys at the end of the year, as-needed budgets, systems vs goals, "use it or lose it" mentality in bigger companies, delaying gratification for wants (but not needs!), and how to avoid being at the mercy of the supply chain.
2023-12-1850 minLean Built: Manufacturing FreedomFree, New and NOBODY Wanted It! | Lean Built - Manufacturing Freedom E22Andrew and Jay continue to talk about what kind of lathe would Andrew like, as well as false ways of achieving economy, the drawbacks of big sales, seeing where you only partially think of things, the value of high-priced CEO meetings, and more. Books mentioned:How to Sell at Margins Higher Than Your Competitor by Lawrence Steinmetz.Alchemy: The Surprising Power of Ideas That Don't Make Sense by Rory Sutherland.
2023-12-1151 minLean Built: Manufacturing FreedomThe data is never fully pristine | Lean Built - Manufacturing Freedom E21Jay and Andrew discuss the benefits and dangers of allowing people to buy on a payment plan, nurturing good relationships with vendors, reevaluating the company after the loss of a key employee, job prioritization, custom software, and calculating true cost. Additionally, they pose an important question: Does your ERP (Enterprise Resource Planning) system truly work for you?"
2023-12-0443 minLean Built: Manufacturing Freedom'Monkey Like Shiny' Syndrome | Lean Built - Manufacturing Freedom E20Should Andrew buy a lathe? This is the question of the hour, leading to all sorts of useful discussions, such as ... do you spend money on a crummy machine just to learn? Or buy your good one first? If you have a machine, will the work come? What happens if getting use out of a machine relies on one rockstar employee? How do you play the odds in a small business? How do you avoid "monkey like shiny" syndrome? What makes a visionary, and why do Jay and Andrew both kind of hate the word? Would either of them...
2023-11-2757 minLean Built: Manufacturing FreedomWould you start over with what you know now? | Lean Built - Manufacturing Freedom E19Jay and Andrew talk 3D printers, color matching vs color coding, after-market mods, and ponder what it would take to sell their companies and start from scratch with what they know now.
2023-11-201h 16Lean Built: Manufacturing FreedomWhere are the problems happening? | Lean Built - Manufacturing Freedom E18Andrew is putting off buying a lathe, which leads to a discussion of what to prioritize in buying machines, returns and exchanges, how Amazon makes it easier for people to rip you off, and more.
2023-11-1344 minLean Built: Manufacturing FreedomI Paid $3,000 for THEIR Mistake! | Lean Built - Manufacturing Freedom E17Andrew and Jay talk about teamwork, pushing a machine until you break it (to learn how far you can push it), onboarding new vendors (plus vendor management in general), over-communicating as a violation of lean principles, organizational clarity, and more.Books mentioned: The Four Obsessions of an Extraordinary Executive: A leadership Fable by Patrick LencioniRocket Fuel: The One Essential Combination That Will Get You More of What You Want from Your Business by Gino Wickman and Mark C. Winters
2023-11-0648 minLean Built: Manufacturing FreedomDon't Burn Up Goodwill | Lean Built - Manufacturing Freedom E16Jay and Andrew talk about Jay's new Zeiss CMM, how to not burn up somebody's goodwill, documenting processes, face to face versus shoulder to shoulder versus face to screen, the high cost of small errors, and the dangers of automation. Plus Jay pushes back on whether Andrew should get a lathe ... side quests are dangerous!
2023-10-301h 18Lean Built: Manufacturing FreedomConstruction, Shop Layout and Unknowns | Lean Built - Manufacturing Freedom E15Jay and Andrew talk about lean drift in other shops, waiting on other contractors, construction crews doing wrong things, shop layout improvements, inventory systems, known knowns vs. known unknowns vs. unknown unknowns, when routine becomes inhibiting, customers wanting to modify equipment, and more.
2023-10-2352 minLean Built: Manufacturing FreedomCompany Culture IS a Magnet! | Lean Built - Manufacturing Freedom E14Andrew and Jay talk a lot about the philosophy of buying machines ... do you buy a piece of junk first just to learn? Or sink money into something great when you don't know what you're doing? They also talk about hiring, finding good candidates, company culture, how the manufacturing industry is and isn't like the software industry, and much more.
2023-10-1657 minLean Built: Manufacturing FreedomRelying on memory is a process without guardrails | Lean Built - Manufacturing Freedom E13Jay has some riggers coming which leads to a discussion of memory and checklists, dealing with dishonest sales reps, give-aways and order returns, plus Andrew's new 3D printer!
2023-10-0956 minLean Built: Manufacturing FreedomOptimizing processes that shouldn't exist | Lean Built - Manufacturing Freedom E12Andrew and Jay talk updating workflow, picking battles, the "three-legged stool", optimizing processes, top line vs bottom line, the importance of trust, helping people in an efficient way, and much more.
2023-10-021h 17Lean Built: Manufacturing FreedomFixing problems, not symptoms | Lean Built - Manufacturing Freedom E11Andrew and Jay talk about fixing problems (not symptoms), teaching employees without making assumptions about what's intuitive, Fusion 360 vs Solidworks, stress and control in decision making, half measures, the 95% rule, and a lot more!
2023-09-2553 minLean Built: Manufacturing FreedomCommunicate, Communicate then Over-Communicate | Lean Built - Manufacturing Freedom E10Andrew and Jay talk about communicating lead times, managing customer expectations, the mystery of memory, malice vs. incompetence, and much more.
2023-09-201h 03Lean Built: Manufacturing FreedomReal Value vs Perceived Value | Lean Built - Manufacturing Freedom E9Jay talks about why he walked away from a big purchase because of a feeling, Andrew talks about the perils of moving shop, they both talk about perceived value versus psychological value, and a whole more.
2023-09-2053 minLean Built: Manufacturing FreedomOur Lego Test for Hiring | Lean Built - Manufacturing Freedom E8Jay and Andrew talk about customer service software, systemization, and problems with shipping, plus Jay talks about how he smokes everyone on building a lego set ... and the business application of said skill.
2023-09-2050 minLean Built: Manufacturing FreedomDo you have a Competitive Advantage? | Lean Built - Manufacturing Freedom E7Andrew and Jay talk about buying used equipment, navigating vacations, interoffice communication, the "Lego test", competitive advantage, and more.
2023-09-201h 11Lean Built: Manufacturing FreedomDon't Sell, Provide Value | Lean Built - Manufacturing Freedom E6Jay and Andrew talk about solar panels, insurance, Relevant Selling by Jaynie Smith, selling machines, minimizing decisions, and more.
2023-09-201h 09Lean Built: Manufacturing FreedomFixing what's not working | Lean Built - Manufacturing Freedom E5Andrew and Jay talk abut giving every employee the right to see what's not working, how to decide what to fix when, The Seven Habits of Highly Effective People, customer satisfaction vs company sustainability, and more.
2023-09-201h 19Lean Built: Manufacturing FreedomKeys to Resting Well | Lean Built - Manufacturing Freedom E4Jay and Andrew talk about vacations, coming back from vacations, their latest lean improvements, the great opportunity that comes with a new employee, and more.
2023-09-2034 min