This document presents an overview of lean principles and how they can be applied to coffee making. It discusses key lean concepts like pull systems, first-in first-out inventory, visual instructions, 5S, and mistake proofing. The goals of a lean approach are to provide customers with value through speed, freshness, flavor and service by eliminating waste and inconsistencies compared to traditional batching methods. Contact information is provided for Jeff Hajek and Tim McMahon to learn more about lean tools and consulting services.
Intro slide
Talk about using real-world examples to show Lean points
Helps dilute the emotion people feel about their jobs
Lean is common sense—just applied in areas where we normally don’t use common sense
Talk about which would be easier to sell.
Most processes are set up the way they are for the company’s benefit, not the customer
Have to understand what customer needs, and then break down obstacles that prevent you from delivering
Often tradeoff—batch increases speed for coffee (not always), but limits flexibility and freshness
Talk about the problems associated with batching
Predicting demand
Spoilage/obsolescence
Amplified quality problems (use that as transition)
If the grounds are not consistent, hard to get same flavor
Varying batch sizes (i.e. 6 cup vs 8 cup) changes process
When there is a problem, waste is larger—6+ cups ruined vs 1 cup if using flow production
Often gauges used—these are system gauges (not output related) but same principle applies
These both prevent problems
Mechanical stop on drip
Float linked with electronic to prevent machine from processing (jidoka also)
Grinder pulls beans in the order they were filled
In this case, the button sends the signal to the grinder to start. No WIP in subsequent processes, but could be.
Alternate signals—light system, colored pull balls, and most common--kanban
Differentiate between this and visual controls where there is a action built in
5S isn’t just cleaning—also preventing waste
Bins/trays prevent waste, but also make cleanup easier