Planning a job is one thing—getting it through the shop without chaos is something else entirely. In part two of our Managing Orders series, we move beyond quoting and scheduling to the messy reality of production: where kitting falls short, setups go long, expectations don’t match reality, and quality gets squeezed when time runs out.
We’ve seen it happen. A setup that was budgeted for two hours takes six. Why? Because the job wasn’t kitted right. Because the estimator used wishful thinking. Because no one raised their hand when they knew the target was off. It’s not just frustrating—it’s a breakdown in accountability and trust across your team.
This episode is about fixing those breakdowns. We unpack how better handoffs, clearer documentation, and stronger internal service mindsets can completely transform your process. From shift tie-ins and floor leads to process development and postmortems, we share how to build a shop where problems get solved before they become expensive.
Because making chips isn’t just about getting to the spindle—it’s about building a culture where everyone owns their part of the process, and where your systems hold up even when the pressure’s on.
Segments
- (0:00) Why planning isn’t enough—execution is where things break
- (0:43) Grow your top and bottom-line with CLA
- (2:00) The dangers of “sharpening the pencil” on setup time
- (5:25) Why you must separate first-time setup from recurring setup targets
- (6:35) The hidden costs of poor kitting and missing tools at setup
- (11:21) Tribal knowledge, shift leads, and how to monitor execution in real time
- (14:08) Creating a culture where machinists feel safe to speak up
- (17:58) “Tiger Teams” and how to solve setup issues in the moment
- (20:56) Top Shops
- (21:22) Documenting feedback through process development and tying it to improvement
- (24:20) Using shift tie-ins and handoffs to reduce lost context
- (25:40) Rethinking quality: from bottleneck to built-in step
- (34:08) Treating vendors like internal customers and setting them up for success
- (38:15) The final handoff: why packaging, paperwork, and delivery are part of your brand
- (43:45) Final takeaways: document your process, eliminate failure points, and keep improving
- (47:46) Why you need to listen to the Lights Out Podcast
Resources mentioned on this episode
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