Lean Built: Manufacturing Freedom
Jun 15, 2026 · 47 min · 10 segments
A single drop of coolant shut down an overnight production run that should have been making parts for hours. Nothing crashed or was broken, yet the machine stopped, production stopped, and the…
So Jay, I walked into my shop at 9.15 this morning.
to a blinking red light on the Matsuura, having hoped for a clean, multi-palette, unbroken overnight run.
Based on the amount of stock that I had scheduled, it should have still been running at 9 a.m., and I came into a blinking red light and a bean block error on the laser tool setter.
Not a broken rule.
There's nothing worse than expecting green flashing and you get red flashing.
Okay.
And nothing was wrong.
Nothing had crashed.
Nothing had broken.
The laser simply errored out because of coolant mist.
Like a coolant blocked it.
It thought it...
Something.
I don't know whether there was coolant on one of the sensors or the air was just misty at the moment, but it was trying to do a tool check.
So we're running one of our first... week-long trying to run all day, all night production jobs.
So I've got multiple pallets tooled up for this, multi-sided fixtures, trying to get all the criticals done in one, and then opt-to is just...
So main op, secondary op, strong op, weak op, you know, right op, left op, whatever you call it.
It is a...
All the criticals are done in one.
Got it.
And then op two is just... clean off some tabs and blend.
And because we're doing hundreds and hundreds of parts, I don't want to stand in front of a belt sander or a grinder and try to touch those up to taste.
I just want, we have an opt to fixture that holds 27 parts and just comes in and blends off the tabs.
It's a super short cycle.
Beautiful.
So Jay, I walked into my shop at 9.15 this morning.
to a blinking red light on the Matsuura, having hoped for a clean, multi-palette, unbroken overnight run.
Based on the amount of stock that I had scheduled, it should have still been running at 9 a.m., and I came into a blinking red light and a bean block error on the laser tool setter.
Not a broken rule.
There's nothing worse than expecting green flashing and you get red flashing.
Okay.
And nothing was wrong.
Nothing had crashed.
Nothing had broken.
The laser simply errored out because of coolant mist.
Like a coolant blocked it.
It thought it...
Something.
I don't know whether there was coolant on one of the sensors or the air was just misty at the moment, but it was trying to do a tool check.
So we're running one of our first... week-long trying to run all day, all night production jobs.
So I've got multiple pallets tooled up for this, multi-sided fixtures, trying to get all the criticals done in one, and then opt-to is just...
So main op, secondary op, strong op, weak op, you know, right op, left op, whatever you call it.
It is a...
All the criticals are done in one.
Got it.
And then op two is just... clean off some tabs and blend.
And because we're doing hundreds and hundreds of parts, I don't want to stand in front of a belt sander or a grinder and try to touch those up to taste.
I just want, we have an opt to fixture that holds 27 parts and just comes in and blends off the tabs.
It's a super short cycle.
Beautiful.
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