Episodes
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In todayâs 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 theyâve implemented, and how theyâre deciding which parts transition from the Brother machines to the new five-axis setup.
He discusses the pros and cons of the MXâs 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 theyâre maximizing the Matsuuraâs production capabilities going forward.
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Jay and Andrew discuss the value of getting your hands dirtyâand how doing so can give you fresh eyes on your business. Jay shares what itâs been like stepping back into a department he hasnât 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.
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Andrew leads Jay through the surprisingly complicated world of modular pistolsâand what it can teach us about running a lean, efficient shop. What starts as a chat about concealed carry and SIGâs 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 confusionâsomething every shop owner can learn from.
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Andrew and Jay get real about one of the biggest headaches in the shop: waiting on other people. Whether itâs parts, processes, or just plain slow responses, Other Peopleâs 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.
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Andrew and Jay dive into lessons from an improv-based leadership workshopâlike how body language and silence shape communication. They explore âlast-letter listening,â 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.
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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. Youâll 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 âstop and fix what bugs youâ can transform workflowâno 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 deliverâliterally. 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 downâsometimes literally. Plus, hear some wild manufacturing war stories, including an industry where 50% of products are thrown awayâand itâs still cheaper than domestic production.
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Installing a new CNC machine isnât 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.
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Jay and Andrew unpack the concept of âAsk for No, Donât Ask for Yes,â 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.
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In this episode, we dive deep into the value of failureâyes, failureâas a crucial tool for growth and success. Jay and Andrew discuss the difference between smart failure vs. dumb failure, how to create core values that actually shape company culture, and why embracing mistakes (the right way) leads to continuous improvement. They even have a friendly debate about how much pain you should feel when you (first) make a mistake.
Book mentioned:
The Brand Gap: How to Bridge the Distance Between Business Strategy and Design by Marty Neumeier -
Whatâs harderâyour first hire or your tenth? In this episode, Jay and Andrew discuss the growing pains of hiring, when to trust your gut, and how to build a hiring process that works. They break down lean manufacturing principles, why âbusyâ doesnât mean productive, and how reducing waste can create a healthier, more profitable business.
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In this episode, Jay shares key takeaways from his visit to Gimbal Automation, giving us a behind-the-scenes look at innovation in action. We break down why job candidates who donât ask questions can be a major red flag, and we dive into the pitfalls of the pre-order trapâwhy taking money before your product is truly ready can backfire. Plus, Andrew shamelessly swipes a great idea from Jay to improve the visitor-experience to his facilityâyou might want to steal it too.
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In this episode, Jay and Andrew geek out on the power of routine, why structured days fuel creativity, and how memory palaces can turn you into a mental wizard. Plus, Jay shares a hilarious (and frustrating) story about a packaging company that somehow managed to ship his product back looking like it survived a battle. And Andrew explains why automation isnât stealing jobsâitâs setting people free.
Book mentioned:
Moonwalking with Einstein: The Art and Science of Remembering Everything by Joshua Foer.
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In this solo debrief, Andrew talks about his experiences at SHOT Show 2025, sharing reflections on industry trends, the rising costs of Vegas, trade show logistics, connecting with industry peers, the value of focused networking, and more.
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Andrew is headed to the SHOT Show, so he and Jay dive into the ins and outs of trade show culture, including the fascinating interplay between established giants and ambitious startups. Later they discuss balancing standardization with customization, and when itâs worth going the DIY route versus opting for factory solutions. Plus, hear their takes on pricing psychology, crafting an efficient workplace, and the joys of hands-on tinkering as founders.
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Andrew and Jay kick off 2025 with a wide-ranging conversation about everything from the history of urban neighborhoods and local governance, navigating customer expectations, managing inventory, and handling unexpected crises like power outages. We also dive into the importance of aligning with vendors, and the intricacies of new machine installations.
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As 2024 wraps up, Andrew and Jay reflect on the year. They discuss lessons learned in 2024, and how they're preparing for industry shifts in 2025. Plus Jay reveals an exciting new diversification venture in the tiny home industry, Piccola Tiny Homes, and how lean principles are transforming this space.
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Jay goes solo, discussing the challenges and triumphs of launching Pierson's latest product, walking listeners through the âMusk Algorithmââa five-step framework for process creation and optimization:
1. Question assumptions and requirements.2. Delete unnecessary components.
3. Optimize processes.
4. Accelerate production.
5. Automate intelligently.
And do that in them order, or else! Alongside, Jay delves into Pearsonâs philosophy of a people-centric lean company, the value of questioning long-standing practices, and how to foster a work culture where innovation thrives.
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The big reveal: Andrew finally shares which 5-axis CNC machine he chose and why it outshone other strong contenders (youâll have to tune in to find out which one made the cut). Along the way, we dive deep into the decision-making process for major shop investments, offering valuable insights for anyone facing similar choices.
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