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

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.