Paul Akers started FastCap in his garage with no MBA, no funding, and one simple conviction: fix what bugs you. Today FastCap ships over 2,000 products to more than 40 countries, and runs on a philosophy so simple it fits in two words — eliminate waste.

In Part 1 of this conversation, Dwayne Kerrigan sits down with Paul to unpack the Lean methodology that made it all possible, and why it has nothing to do with manufacturing.

In this episode:

Paul breaks down the eight wastes of Lean thinking — overproduction, transportation, inventory, defects, over-processing, wasted motion, customer waiting, and wasting human potential — using a Costco toilet paper run as the most memorable example you'll ever hear
Why Paul calls himself a "Lean maniac", not a lean practitioner: "How do I improve this? And how do I make it easier for everyone around me?" — the two questions that drive every decision at FastCap
The communication standard Paul holds his entire organization to: no one should ever have to ask you a question twice, and why every back-and-forth email chain is a symptom of a deeper waste problem
How FastCap documents every single process — from cleaning a toilet to setting up a $250,000 injection molding machine — using eight-step visual SOPs, QR codes, and unlisted YouTube videos that any employee can access instantly
Why Paul starts every Lean implementation the same way, regardless of company size: the bathroom. And why every visitor to FastCap — including presidents of major corporations — cleans the bathroom before they're allowed a tour
The mindset Paul refuses to argue with: if you're not ready to change, he's not interested in convincing you — and why that boundary is itself a Lean principle

Episode Highlights:

00:00 - No Questions Twice

00:22 - Podcast Welcome

00:54 - Meet Paul Akers

04:37 - FastCap Origin Story

08:31 - Lean Gospel Mindset

10:34 - Lean Maniac Defined

13:42 - Eight Wastes Explained

17:03 - Small Daily Improvements

20:10 - Hunger and Underdogs

28:31 - Lean History Lesson

31:36 - Toyota Just In Time

34:15 - Skeptic to Believer

35:25 - Lean Is People First

36:33 - Stop The Line Mindset

38:00 - Three Habits Of Toyota

40:46 - Morning Meetings

42:45 - Dialogue Not Monologue

43:26 - Keynote Agenda And Culture

48:03 - Defects And Kanban Flow

51:56 - One Hour Before Work Pays

53:59 - Ego And Leadership Growth

57:08 - How To Start

01:03:16 - Standard Work And QR Training

01:07:30 - Who Actually Changes

01:08:22 - Wrap Up And Disclaimers

Resources mentioned:

2 Second Lean — Paul Akers
Lean Health, Lean Travel, Lean Life, Banish Sloppiness — Paul Akers
The Amezawa Legacy — Paul Akers
Lean the Gospel Dressed Up in a Business Suit — Paul Akers (in progress at time of recording)
Out of the Crisis — Dr. W. Edwards Deming
Toyota Production System (TPS)
FastCap — Paul Akers' company
Bob Taylor / Taylor Guitars — referenced as Paul's early mentor
Training Within Industry (TWI) — referenced framework
FastCap YouTube channel — https://www.youtube.com/user/fastcaptv

Quotes:

"I have no time whatsoever to convince you of common sense. Zero." - Paul Akers

“ I read Dick and Jane like 10 times when I had to read it in front of the class. I had to read it over and over and over again and memorize it so I didn't screw it up when I read in front of the class.” - Paul Akers

“ But there's one thing that I've kind of realized in life is that the reason why we don't have something in our life is because of the story that we're telling ourselves.” - Dwayne Kerrigan

“Everything I look at, I'm always thinking, how do I improve? How do I increase the quality and reduce the burden on me and the people around me? So I want everything to be. Easy for everyone. No struggle in flow.” - Paul Akers

“ No one should ever ask you a question twice. If you communicate to someone, your communication should be so clear that when you say it and the words come out of your mouth, they go, I understand exactly what you want.” - Paul Akers

About Paul Akers: Paul Akers is the founder and president of FastCap, a product development company specializing in woodworking tools and hardware for professional builders, started in his garage in 1997. FastCap now has thousands of distributors in over 40 countries and launches 20–30 innovative products per year. Paul is the author of 2 Second Lean — now available in 15 languages and a Shingo Institute award winner — along with many additional books including Lean Health, Lean Travel, and Lean Life. He has won Seattle Business Magazine's Business Executive of the Year and spoken in over 34 countries.

Connect with Paul Akers: https://paulakers.net/

Connect with Dwayne Kerrigan

Disclaimer: The views, information, or opinions expressed by guests during The Dwayne Kerrigan Podcast are solely those of the individuals involved and do not necessarily represent those of Dwayne Kerrigan and his affiliates. Dwayne Kerrigan or The Dwayne Kerrigan Podcast is not responsible for and does not verify the accuracy of any of the information contained in the podcast series. The primary purpose of this podcast is to educate and inform. Listeners are advised to consult with a qualified professional or specialist before making any decisions based on the content of this podcast.

135: The Lean Maniac: Paul Akers on Eliminating Waste