Lean Built: Manufacturing Freedom
Two successful entrepreneurs talk about manufacturing, lean principles, and the freedom they are pursuing in life and business.
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Andrew Is Fired: Letting Go of the Owner-Hero Trap | Lean Built - Manufacturing Freedom E128
<p>As 2026 begins, Andrew and Jay take a look at one of the most dangerous traps for founders and small shop owners: becoming the hero who always steps in to save the day.</p><p><br></p><p>Andrew introduces a personal document he titled “Andrew Is Fired,” a deliberate decision to remove himself from roles that feel productive but quietly limit growth. The conversation explores why constantly “going above and beyond” can actually be a form of selfishness, how undocumented processes turn leaders into bottlenecks, why clarity around ownership matters more than raw effort, and more.</p>
The Point of Lean is People | Lean Built - Manufacturing Freedom E127
<p>In this end-of-year episode, Jay and Andrew unpack all kinds of things:</p>Why business owners are wired to over-promise at the buzzerThe difference between employee thinking and owner thinkingCalendars, automation, and why “the best calendar is sometimes no calendar”Paying people well, shutting down between Christmas and New Year’s, and using PTO wiselyNet terms, cash flow, and refusing to be a bank for bigger companiesWhy some founders need to sign checks or take tech support calls to stay groundedThe danger of over-optimizing leadership—and losing the human sideTracking improvement with marbles instead of spreadsheets
When Shipping Fails, You Fly | Lean Built - Manufacturing Freedom E126
<p>What happens when a rush job collides with holiday shipping chaos and failure isn’t an option?</p><p>In this episode, Andrew walks us through a real-world manufacturing crisis involving last-minute customer demands, specialty tooling delays, weather-related shipping failures, and nonstop overtime.</p><p>Along the way, Jay and Andrew cover: the true cost of rush orders (beyond the invoice), why duplication and redundancy matter in high-stakes work, when it makes sense to say yes and when it’s wiser to walk away, managing time and expectations, customer communication under stress, and more.</p>
Running Your Shop at 100% Capacity Is a Mistake | Lean Built - Manufacturing Freedom E125
<p>Jay and Andrew discuss real-world shop challenges like air quality, ventilation, coolant selection, and bandsaw blade performance. The conversation expands into capacity planning, why running at 100% utilization is a hidden liability, and how maintaining margin and flexibility allows shops to respond quickly when customers need help.</p><p><br></p><p>Along the way, they touch on safety systems that fail when alerts are too distant from the problem, lessons from catastrophic industrial accidents, and why local, thoughtful gestures like good donuts or quality coffee build stronger vendor and customer relationships than generic (or just plain bad) corporate gifts.<...
Majoring On The Majors | Lean Built - Manufacturing Freedom E124
<p>Tiny improvements won’t move the company forward unless leaders also make the big decisions. Lean is life-changing, but you can’t lean your way into a clear vision. You have to choose it. That means looking honestly at customers, pricing, equipment, automation, space, and your team, and fixing what really bugs you at the highest level. That lesson is at the crux of this jam-packed episode which also covers: visual controls that save mental energy, smarter checklists that stop cultural drift, and a simple light-curtain jig that turns a tedious sewing task into an effortless one.</p>
Lean Saved Their Factory: Fire Prevention, Inventory Wins & Q4 Strategy | Lean Built - Manufacturing Freedom E123
<p>It's Cyber Monday, and Andrew and Jay dive into year-end strategy, the real cost of Black Friday sales, and why deep discounts often hurt more than they help. They also discuss how lean manufacturing practices literally saved an entire 60,000 sq ft facility after a major fire. </p><p><br></p><p>Elsewhere, Andrew shares the importance of using LinkedIn with intention, how handwritten notes beat (or should be combined with) AI transcription for capturing insights, and why business owners must prioritize end-of-year tasks before the December panic hits. Jay breaks down inventory strategy, shop-floor safety improvements, and the hard t...
Building a Company That Can Survive Without You | Lean Built - Manufacturing Freedom E122
<p>Andrew opens with a simple shop-floor idea that changed how their teams celebrate progress: a six-inch clear tube filled with colored marbles. That playful visual turns into a deeper conversation between Jay and Andrew about the power of collective improvement, the limits of mental capacity as organizations grow, and the art of estimating through Fermi numbers. They move from marbles to antennas, from CNC stencils to parabolic reflectors, and from daily shop habits to long-term business planning.</p><p>The episode also takes a serious turn as they take a blunt look at succession planning, wills, and preparing your...
The Best First CNC Machine | Lean Built - Manufacturing Freedom E121
<p>When Jay asks what machine someone should buy to start a small job shop, Andrew gives a direct answer: without committed, repeatable work, he wouldn’t buy anything. But both Jay and Andrew do offer their recommendations, and that opens a broader conversation about the unstable economics of prototypes, customers who send sketches instead of CAD, and why certain jobs are better routed to services like Xometry or Upwork.</p><p><br></p><p>From there, Jay and Andrew compare Haas and Brother machines—control systems, tool changers, rigidity, multi-axis capability, and real reliability differences. Andrew explains why he favo...
The Power of Looking Back | Lean Built - Manufacturing Freedom E120
<p>In this episode, Andrew and Jay take a walk down memory lane. What starts as Andrew revisiting old shop photos turns into a conversation about the hidden value of reflection in a culture obsessed with constant improvement. The two discuss how looking back fuels gratitude, strengthens company culture, and reminds teams that today’s “normal” was once hard-won progress.</p><p><br></p><p>They also share practical ideas for visualizing improvement over time, from “Lean scoreboards” to posting employee innovations without turning healthy pride into toxic competition. Later, Jay tells the story of an unexpected visit from a high-profi...
Lessons from the Gemba Summit in Belfast | Lean Built - Manufacturing Freedom E119
<p>Fresh off the Gemba Summit in Belfast, Andrew shares lessons from across the pond with Jay. What starts as a deep dive into lean culture at the Titanic Belfast turns into a candid conversation about scaling small businesses, visiting your vendors, and rethinking what it means to “fix what bugs you.”</p><p><br></p><p>Andrew and Jay unpack how lean principles evolve when your company outgrows the two-second mindset. Andrews tells about conversations with Toyota UK’s Alan Weir, British Rototherm’s Oliver Conger, and Tom Hughes of GembaDocs. They also discuss the practical takeaways from Greg Crabtree...
