Lightning Strikes

Taking a Product from Innovation to Manufacturing

Reality

Introduction

• Innovation

• Passion

• Concept to Production

• Challenges

• Rebecca Reynolds & Ashley Truax

2

Innovation Process

3

• Ideation

• Research and Development

• Pilot Manufacturing

• Production Ramp

• Continuous Improvement

Ideation

4

Financial AnalysisBusiness

CaseStrategic

AlignmentExecute

IDEA

Market ResearchTechnical

Research

Outside Sources

& Suppliers

Research & Development

5

– Dark & Light Roasts

– Grinding and Roast

Requirements

– Consistency

Research and Development

6

Tertiary – Cardboard Box

Shipping

Secondary - Carton

ShelfPrimary – Portion Pack

Ingredient

Research and Development

7

• Appliance

• Brewer- Portion Pack Interaction

Pilot Manufacturing

Alpha – 4 Cups per Cycle

8

Pilot – 1 Cup per Cycle

Pilot Manufacturing

9

Designers Support

Staff

Production Ramp

10

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• Production Requirement– Forecasted Portion Pack & and Brewer Sales

– Planned Portion Pack Inventory

Pilo

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Sta

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Pilo

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Time

Qu

an

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Production Plan

Alp

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Sta

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Run O

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Capcity

Alp

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Large Scale Production - Stabilization

11

Yie

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Spe

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Uptim

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Ide

al/T

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ore

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100% Downtime

Reduced Speed

Poor Quality

Overall

Equipment

Efficiency

12

Large Scale Production - Stabilization

Key Performance

Indicators

Goals

Safety

Quality

Delivery

Cost

Corporate Social

Responsibility

Team

Challenges & Success

13

Manufacturing

R & D

MarketingStrategic Alignment

Appeal & Function

Evolution of Design

Knowledge Transfer

Balanced Goals & Metrics

GMCR Keurig bios

• Rebecca Reynolds

• Rebecca has worked for

GMCR Keurig almost 2 years.

She has concentrated in the

procurement, installation and

startup of manufacturing

production lines. She

graduated with a bachelors

degree in Mechanical

Engineering from Washington

State University.

• Ashley Truax

• Ashley started as an intern for

GMCR Keurig and has been a full

time employee for three years.

She has had various roles,

including Project Engineer,

supporting installation of

production equipment to

manufacturing engineer, improving

GMCR’s equipment and

processes. She graduated with a

Bachelors Degree in Mechanical

Engineering and a Bachelors in

Applied Mathematics from

University of Vermont.

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