Lean Built: Manufacturing Freedom

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...

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 purp...

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 betwe...

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 workh...

In our 100th episode special, we take listener questions including: How to retain capital and make smart reinvestment decisions Life expectancy of CNC machines and why not to be a machine collector The blessing (and curse) of early adoption What really sparked our motivation to make our own products How we each implemented Lean without killing morale Raising kids while running a shop—and how to in...

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 fac...

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-d...

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...

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 m...

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 menta...

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 asynchr...

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...

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 Re...

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...

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 cha...

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? Plu...

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, exp...

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 visibilit...

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 pr...

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 catast...

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, s...

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 whe...

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 impr...

In 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...