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

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 workholding—explaining the science behind efficient setups, the inevitability of leaks, and why not all vacuum systems are created equal.

In our 100th episode special, we take listener questions including:How to retain capital and make smart reinvestment decisionsLife expectancy of CNC machines and why not to be a machine collectorThe blessing (and curse) of early adoptionWhat really sparked our motivation to make our own productsHow we each implemented Lean without killing moraleRaising kids while running a shop—and how to inspire the next generation of makersA look behind the curtain at our most game-changing lean hacks, and what we’ve “borrowed” from each otherWhy you don’t need a business plan to start—and what matters moreWhether you’re new to the Lean Built community or you’ve been with us from episode 1, thank you for listening. Here’s to 100 more episodes of building freedom—one lean improvement at a time.Book mentioned: The E-Myth Revisited by Michael E. Gerber

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)

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