Learning Lean Through Making Coffee
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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.
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Learning Lean Through Making Coffee
- 1. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Learning Lean Through Making Coffee Presented by Jeff Hajek Gotta Go Lean Tim McMahon A Lean Journey Version 11/18/2010
- 2. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Image courtesy of Wikimedia commons http://commons.wikimedia.org/wiki/File:%5E-%5E_coffee.jpg
- 3. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Which Would You Prefer?
- 4. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. What Do Customers Want? Value Speed FreshnessFlavor Service
- 5. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. The Problems With Batching
- 6. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Inconsistent Processes = Inconsistent Results
- 7. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Improving Quality
- 8. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Building Quality In (Poka Yoke and Jidoka)
- 9. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. FIFO / First-In, First-Out
- 10. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Pull
- 11. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Visual Instructions
- 12. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. 5S
- 13. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Follow-up Information A Lean Journey Blog http://leanjourneytruenorth. blogspot.com • What is Lean? • Mistake Proofing Help • Quick Changeover• Over 350 terms • Over 20 Forms and Tools http://www.Velaction.com
- 14. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Questions • Jeff Hajek – Info@Velaction.com – www.GottaGoLean.com – 1.800.670.5805 • Tim McMahon – http://linkedin.com/in/timothyfmcmahon – 860-469-LEAN (5326)
- 15. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Copyright Terms • You may modify this presentation for use within your own organization. • You may distribute this presentation within your own organization. • You may not distribute this presentation, its derivative works, or images contained within it outside of your own organization.
Notas do Editor
- 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