Self-Limitation For Success | Lean Built - Manufacturing Freedom E64 Lean Built: Manufacturing Freedom podcast

47:35

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…

Lean Built: Manufacturing Freedom

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Constraints Give You More Freedom | Lean Built - Manufacturing Freedom E97 51:52

10 days ago51:52

51:52

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 volume knob that just feels right—makes work smoother and more human.…

Lean Built: Manufacturing Freedom

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What a Tornado Taught Us About Manufacturing Risk | Lean Built - Manufacturing Freedom E96 36:09

17 days ago36:09

36:09

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.…

Lean Built: Manufacturing Freedom

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The Cut Didn’t Sound Right | Lean Built - Manufacturing Freedom E95 55:55

24 days ago55:55

55:55

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 means when your team can stop a cycle just because “it doesn’t sound right.” Whether you’re chasing better processes or just trying to make your shop a little less chaotic, there’s something here for you.…

Lean Built: Manufacturing Freedom

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Remote Work That Works: Tools, Culture & Communication Tactics | Lean Built - Manufacturing Freedom E94 51:39

4 weeks ago51:39

51:39

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, managing hybrid workflows, and creating a high-trust culture.…

Lean Built: Manufacturing Freedom

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Why We’re Not Typing SOPs Anymore | Lean Built - Manufacturing Freedom E93 54:16

5 weeks ago54:16

54:16

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…

Lean Built: Manufacturing Freedom

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Matsuura MX Update: Why We Chose It, How It’s Going, and What We’ve Learned | Lean Built - Manufacturing Freedom E92 32:01

6 weeks ago32:01

32:01

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 of navigating tax abatements, government paperwork, and the logistics of installing a machine of this scale. Plus, he shares lessons learned, hidden challenges of the installation process, and how they’re maximizing the Matsuura’s production capabilities going forward.…

Lean Built: Manufacturing Freedom

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Why Smart Owners Get Their Hands Dirty | Lean Built - Manufacturing Freedom E91 48:30

7 weeks ago48:30

48:30

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 also riff on the weird dreams machinists have, poke fun at boilerplate private equity emails, and discuss the tension between freedom and cash when it comes to selling a business. The conversation wraps with thoughts on the promise of AI tools like PLAUD and Fulcrum.…

Lean Built: Manufacturing Freedom

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Modular Mayhem: What Holsters Teach Us About Lean Manufacturing | Lean Built - Manufacturing Freedom E90 46:00

8 weeks ago46:00

46:00

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.…

Lean Built: Manufacturing Freedom

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Other People’s Lead Times Are Killing Me | Lean Built - Manufacturing Freedom E89 1:01:25

9 weeks ago1:01:25

1:01:25

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.…

Lean Built: Manufacturing Freedom

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Improv and the Art of Listening | Lean Built - Manufacturing Freedom E88 53:50

10 weeks ago53:50

53:50

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.…

Lean Built: Manufacturing Freedom

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Stop and Fix: Building a Culture of Lean Accountability | Lean Built - Manufacturing Freedom E87 31:57

11 weeks ago31:57

31:57

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…

Lean Built: Manufacturing Freedom

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Shipping Woes & Business Wins: A Lean Approach to Logistics | Lean Built - Manufacturing Freedom E86 46:25

12 weeks ago46:25

46:25

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 manufacturing war stories, including an industry where 50% of products are thrown away—and it’s still cheaper than domestic production.…

Lean Built: Manufacturing Freedom

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Surviving the Install: The High-Stakes World of CNC Machine Setup | Lean Built - Manufacturing Freedom E85 43:52

13 weeks ago43:52

43:52

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 CNC is about more than just speed, insurance for machine downtime, using external expertise, and optimizing workflow tools like digital note-taking devices.…

Lean Built: Manufacturing Freedom

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The Decision-Making Hack That Frees Up Time | Lean Built - Manufacturing Freedom E84 50:24

14 weeks ago50:24