Actually Learning From Mistakes | Lean Built - Manufacturing Freedom E106

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. 

Jay and Andrew discuss the true cost of doing business with “big name” clients who act like bullies. You know the ones. They demand unfair terms, they're slow to pay, they're quick to add red tape. Jay shares a personal story about walking away from a prestige customer that wasn’t worth the stress, cost, or collection headaches. Andrew adds cautionary tales, including lessons from a fellow shop owner who took the bait on a massive PO and paid the price in blood, sweat, and sleepless nights.They also talk about the power of peer advisory groups like Vistage and Convene. How do you avoid flying blind in your business? Get in a room with people who’ve already made your mistakes, and who won’t let you keep making them.Plus: hear about their strategies for preventative maintenance, visual controls (including genius 3D-printed “No Touchy” signs), and the delicate balance between food trucks, team morale, and post-lunch productivity crashes.

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 a maintenance wake-up call involving a long-forgotten gearbox and walks through how proactive systems (like Trello and SOPs) can prevent downtime disasters. Then the duo touch on their favorite tools, ranging from $20 Japanese nippers to precision CMMs.You can get those amazing Fujiya pliers Andrew mentioned here and here.

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 purpose) to discover the edge of performance. The conversation also touches on company culture and the psychology of failure in machine shops, including the value of giving employees permission to experiment—and even fail—in healthy ways.Later in the episode, the discussion pivots into leadership philosophy. Drawing inspiration from Perry  Maughme's The Relentless Few podcast and Simon Sinek’s thoughts on measuring success, they challenge the traditional obsession with long-term goals. Instead, they advocate for direction, momentum, and principle-driven decision-making. The episode ends with a preview of a future conversation on healthy workplace conflict—and the importance of “normalizing awkwardness.”