© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Learning Lean Through Making
Coffee
Presented by
Jeff ...
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Image courtesy of Wikimedia commons
http://commons.wik...
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Which Would You Prefer?
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
What Do Customers Want?
Value Speed
FreshnessFlavor
Se...
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
The Problems With Batching
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Inconsistent Processes = Inconsistent Results
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Improving Quality
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Building Quality In
(Poka Yoke and Jidoka)
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
FIFO / First-In, First-Out
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Pull
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Visual Instructions
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
5S
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Follow-up Information
A Lean Journey Blog
http://leanj...
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Questions
• Jeff Hajek
– Info@Velaction.com
– www.Gott...
© 2010, Velaction Continuous Improvement, LLC.
All rights reserved.
Copyright Terms
• You may modify this presentation for...
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Learning Lean Through Making Coffee

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In our first live show, we discuss how Lean lessons stick best when people can relate to them through every day examples. Many of us practice Lean thinking in our lives without recognizing it. Since most people already know how to make coffee, this provides a perfect backdrop to teach a variety of Lean concepts.

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  • 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
  • Learning Lean Through Making Coffee

    1. 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. 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. 3. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Which Would You Prefer?
    4. 4. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. What Do Customers Want? Value Speed FreshnessFlavor Service
    5. 5. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. The Problems With Batching
    6. 6. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Inconsistent Processes = Inconsistent Results
    7. 7. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Improving Quality
    8. 8. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Building Quality In (Poka Yoke and Jidoka)
    9. 9. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. FIFO / First-In, First-Out
    10. 10. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Pull
    11. 11. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. Visual Instructions
    12. 12. © 2010, Velaction Continuous Improvement, LLC. All rights reserved. 5S
    13. 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. 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. 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.
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