Lean Built: Manufacturing Freedom

Jay and Andrew kick off with a quick story about “the yips” — that sudden moment when everything you know just disappears — and use it to launch into a deeper discussion about what makes great shops tick.They unpack why even pros break down under pressure, how systems and habits keep you grounded, and why finishing what you start matters more than chasing shiny new projects. From compressor failures to confusing control panels to the “95% Rule,” this episode is packed with real shop-floor lessons on leadership, lean thinking, and culture.

Running a business means living in the tension between control and chaos—and this week, Jay and Andrew talk about both. From tariffs and supply chain headaches to the quirks of wire EDM and CO₂ lasers, they explore how  shops adapt when material costs, sourcing, and technology throw curveballs. Along the way, they swap stories about spotless autobody shops, frustrating e-commerce platforms, website crashes, and even backup internet solutions.Whether it’s stocking obscure steels, streamlining websites for Black Friday, planning redundancies that actually matter, or rethinking lean practices like “water spiders,” Jay and Andrew show how business owners can navigate uncertainty without losing sight of customer experience.

This episode of the Lean Built Podcast starts in the shop but ends up on stage. Andrew  and Jay begin by discussing machining decisions—when to model details in CAD versus when to let CAM and shop standards handle them, edge breaks, chamfers, and the balance between aesthetics and efficiency.But midway, the conversation takes a turn into music...concert stories, 90s Christian rock, ska bands, artistry, and musical creativity. Along the way, they draw parallels between toolpath textures and vinyl warmth, and talk about some of the influences that formed them into the men they would become. 

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

Jay and Andrew unpack the recent sale of Heller to DN Solutions and what it reveals about brand value, culture shifts, and the economics of high-ticket, low-volume machines. They move from industry news to the shop floor, comparing palletized workholding with soft jaws, weighing costs against flexibility, and sharing how small changes can unlock significant productivity gains.Along the way, they discuss intellectual property fears, the reality of knockoffs, and why continual improvement is often the best defense. Jay shares behind-the-scenes lessons from developing new vise palettes and running beta tests, while Andrew emphasizes the importance of building trusted feedback networks. They also look ahead at sensor-driven machining, acoustic analysis, and AI applications that could reshape how shops optimize tool life and performance.

Scarcity sells. But at what cost? In this episode of Lean Built, Jay and Andrew dig into the world of false urgency, hype marketing, and smoke-and-mirrors business tactics. From eBay nostalgia to NFT mania, they unpack how artificial scarcity (and a lot of other practices) can undermine trust while genuine value builds it.Along the way, they share stories of radical honesty in business, saying no to misaligned customers, and why investing in truth creates stronger companies than any short-term marketing trick.

This week’s conversation covers a little bit of everything. Andrew shares stories from his trip to Japan, including what he noticed at Matsuura’s factory and a clever little chip briquetting machine that has everyone asking questions. Jay talks about viral video surprises on Instagram and YouTube, and the two compare notes on carts, pallet wrapping, and what lean looks like in real shops versus theory.They also touch on shop culture: why hospitality matters as much as process, and the challenges of keeping things moving when the boss is out of town.

In this solo debrief, Andrew recounts his visit to Matsuura’s plants in Japan, where he observed firsthand the discipline and detail that define Japanese manufacturing. He describes how Matsuura trains new employees years in advance, the precision of their hand-scraping process, and the consistency achieved by grinding every pallet on a single master machine.He also discusses the innovations he saw in Matsuura’s hybrid LUMEX metal 3D printing and machining technology, spindle balancing rigs, and integrated chip briquetting systems. Beyond the machines themselves, he reflects on Matsuura’s culture of multi-generational leadership, long-tenured employees, and a genuine curiosity about how customers use their equipment.Andrew explains the real opportunities in palletized five-axis automation, from reducing setups to unlocking flexible, high-mix production. He emphasizes that these machines require not just investment, but vision and continuous learning to realize their full potential.

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

Andrew and Jay unpack a thought-provoking article from The Systems Thinker on the tension between learning and performance. How do you actually learn from failure? Is it a given that you will? The conversation ranges from morning meeting rituals and positive failure culture to the dangers of over-relying on data.Along the way, they talk chipped tools, misordered pipe, customized packaging, AI-assisted KPI dashboards, Harbor Freight, and more.