Lean Built: Manufacturing Freedom

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 members, can lead to high-impact improvements.Next up is episode 100! Got a question? Send it to the Lean Built Podcast on Instagram.Book mentioned:Getting Things Done by David Allen (Amazon)

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

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 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.

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.

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 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.

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.

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

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.

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.

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.Book mentioned:Moonwalking with Einstein: The Art and Science of Remembering Everything by Joshua Foer.

In 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.

Andrew 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.

Andrew 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.

Andrew 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. 

As 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. 

Jay 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.

The 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.

How 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.

This 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 love you without cheapening your brand.Stories from the trenches of manufacturing chaos.

Both 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).

Jay 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.

Jay 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?

You 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.

Andrew 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.

Anything 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).Books Mentioned:The E-Myth Revisited: Why Most Small Businesses Don'T Work And What To Do About It By Michael E. GerberWho Not How: The Formula to Achieve Bigger Goals Through Accelerating Teamwork by Dan Sullivan and Dr. Benjamin Hardy....and on a slightly non-business topic, check out the wit and wisdom of great Christian thinker, G. K. Chesterton!

In 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 Not How: The Formula to Achieve Bigger Goals Through Accelerating Teamwork by Dan Sullivan and Dr. Benjamin Hardy.

Join 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.

It'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 and plenty more. Thanks as always for joining us on our Lean Built journey.

Andrew 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.

Jay and Andrew check in from IMTS.

As 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.

Andrew 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 Vendors Close: There are advantages to having your vendors geographically near your business.And there's much more. Hey, if you spot us at IMTS 2024, please come over and say hello!

Andrew 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.

Join 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.

Andrew 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 link for cornhole tournament Jay mentions near the end of the episode!

Andrew and Jay talk about automation (Jay's buying another robot!), solving unexpected space problems, how to not be myopic about the future, and more.

Andrew 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).

Join 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.

What 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.

Andrew 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.