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Lean Management Principles

Brief

In Assignment 1, you are to take the role of a lean consultant. You will identify a business process, analyse it, apply the tools and techniques you have learned and provide recommendations for its improvement. You may build upon the work you have done in the Challenge activities of Weeks 3 and 4 of the module.

What you need to do:

  1. Identify a business process to consider. You may choose anything appropriate, providing you can get the information you need about it. You may consider your assignment on the process of either a manufacturing, service or internal business type organisation. For example; your process might be the preparation of coffee in a busy café, manufacturing bespoke bicycles, the processing of library books, applying for an extension to a deadline, or any other area of endeavour about which you can get information.

  2. Use the lean tools and techniques you have learned in this module to analyse the process. Show its current state, the desired state, and propose a plan for transition.

  3. Produce a report clearly summarising your analysis, findings and recommendations for transforming the process. Present information professionally using relevant graphs, charts and diagrams where appropriate.

Your report must be no more than 2000 words long (excluding charts and diagrams).

  • Considering the following assessment criteria:

  • Clear presentation and analysis of the target process

  • Discussion of the process flaws and their causes

  • Application of the principles of lean to the process

  • Clear, realistic recommendations of potential further improvements

  • Appropriate professional presentation of report

Important notes:

  • Use Harvard-style citations and references.

  • Add charts and designs workflow and ..etc

  • Create a details Appendices

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Sample Answer

Improving Coffee Preparation Efficiency in a Café Using Lean Management Principles

Introduction

In today’s fast-paced service environment, efficiency and customer satisfaction are critical for small businesses to remain competitive. This report analyses the coffee preparation process in a busy independent café, aiming to reduce waste, improve service flow, and enhance overall customer experience through the application of Lean principles. Acting as a Lean consultant, this report examines the current state of operations, identifies inefficiencies, and proposes a structured plan for improvement using proven Lean tools such as Value Stream Mapping (VSM), 5S, and Kaizen.

Current Process Overview

The selected café operates daily from 7:00 a.m. to 6:00 p.m. and experiences its peak hours between 8:00–10:00 a.m. The process under review is the coffee preparation and delivery workflow, from order placement to service.

Current workflow:

  1. Customer places order at the counter.

  2. Cashier enters the order into the POS system.

  3. Barista prepares the coffee (grinding beans, steaming milk, pouring espresso, etc.).

  4. Order is placed on the counter for pickup.

  5. Customer collects their coffee.

Analysis of Process Flaws

A detailed observation revealed several inefficiencies, or "muda" (wastes), within the workflow:

  1. Motion Waste: Baristas frequently move between separate stations for grinding, milk steaming, and serving, wasting several seconds per drink.

  2. Waiting Time: Orders queue up due to uneven workload distribution between the cashier and barista.

  3. Overproduction: Extra milk or coffee is sometimes prepared “just in case,” leading to spillage or waste.

  4. Inventory Waste: Ingredients like milk and syrups are not stored near the preparation area, leading to time lost during retrieval.

  5. Defects: Occasional incorrect orders result from communication gaps between cashier and barista.

The root causes of these problems can be summarised using an Ishikawa (Fishbone) Diagram analysis:

  • Methods: No clear standardised workflow.

  • Manpower: Lack of cross-training between cashier and barista.

  • Machines: Inefficient layout of coffee machines and POS system.

  • Materials: Poor stock placement.

  • Environment: Crowded workspace during busy hours.

Application of Lean Tools and Techniques

Value Stream Mapping (VSM)

A VSM was created to visualise the current and future state.
Current State: Average lead time = 4.5 mins, value-added time = 2.5 mins.
Future State Goal: Reduce lead time to 3 mins by eliminating motion and waiting waste.

5S Methodology

Applying 5S principles (Sort, Set in Order, Shine, Standardise, Sustain) helps organise the workspace efficiently.

  • Sort: Remove unused tools and ingredients from the prep counter.

  • Set in Order: Place essential items (milk, syrups, beans) within arm’s reach.

  • Shine: Keep workstations clean at all times.

  • Standardise: Develop a uniform process for drink preparation.

  • Sustain: Schedule weekly checks to maintain the standard.

Kaizen (Continuous Improvement)

Staff meetings at the end of each week encourage feedback on bottlenecks and solutions. For instance, the café could introduce a secondary espresso machine during rush hours to balance workload.

Just-in-Time (JIT)

Orders are prepared only when placed, eliminating overproduction. Digital order tickets reduce verbal miscommunication.

Standard Work and Visual Controls

Clear signage, recipe sheets, and visual order screens can help standardise tasks and reduce errors. Visual cues for milk containers and cup sizes streamline workflow and avoid confusion.

Lean aims to eliminate waste and create more value for customers by improving efficiency and reducing unnecessary steps.

Tools like 5S, Kaizen, and Value Stream Mapping are highly effective for cafés, restaurants, and other service-based processes.

Resistance to change, lack of training, and inconsistent follow-up can hinder successful adoption.

Kaizen encourages small, consistent improvements that keep processes efficient and adaptable over time.

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