Starbucks’ AI Coffee Makers: A Productivity Case Study

Henry Ford could have probably similarly kept car prices high and maintained only a small workforce to build cars with his moving assembly line. We know, however, that he reduced prices until the middle class could afford cars, which is why the automotive industry and its suppliers employ eight million Americans for relatively high wages.8

References
1. Rhone, Kailyn. “U.S. fast-food chains add automation to boost speed.” yahoo!finance. Aug. 2, 2023.
2. Casselman, Ben. “Wages Continue to Grow, Good for Workers But a Worry for the Fed.” The New York Times. April 28, 2023.
3. Emerson, Harrington. “Efficiency as a Basis for Operation and Wages.” The Engineering Magazine, 1909.
4. Ford, Henry; and Crowther, Samuel. Moving Forward. Doubleday, Doran, & Co., 1930. p. 25.
5. Marley, Brad. “The Impact of Data and Analytics on Sustainable Manufacturing.” Smart Manufacturing, June 20, 2023. pp. 25–29.
6. Fast Food. “Starbucks Menu Prices (Updated: August 2023).” Fast Food.
7. Taylor, Frederick Winslow. The Principles of Scientific Management. Harper Brothers, 1911.
8. Hill, Kim; Cooper, Adam; and Menk, Debra. “Contribution of the Automotive Industry to the Economies of All Fifty States and the United States.” Center for Automotive Research.

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Nor can the baristas expect to be paid 45 cents per drink, or $32.85 an hour, including the employer’s share of Social Security and Medicare, due to the productivity improvement. Starbucks can’t keep the same per-unit markup, either, because some of the benefits must be shared with customers to increase sales volume. If the price remains the same, the company might be able to save money by laying off half the baristas—thus proving the Luddites right with the consequences depicted by Taylor—but it will forego the opportunity to sell more than twice the current volume.

Published: Tuesday, August 29, 2023 – 12:03

This is a very strong selling point for the ISO 50001:2018 standard for energy management systems. But let’s return to the Starbucks example to illustrate the role of labor efficiency.

Starbucks’ deployment of automated coffee makers (and the referenced article cites automation in other restaurants as well) should be beneficial to all stakeholders. Higher efficiency can deliver lower prices to increase sales volume and keep the workers employed, and at higher wages because their labor is no longer being expended on inefficient or nonvalue-adding activities. The employer can accept a lower profit margin per unit but earn more per employee-hour because more items are being sold.

This is roughly a 140% productivity improvement. The price of a grande mocha Frappuccino is currently $4.45.6 Assume the baristas earn $15 an hour (the figure varies widely). Add 7.65% for the employer’s Social Security and Medicare taxes to get $16.15 an hour.

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The same exercise can be done with Frank Gilbreth’s non-stooping scaffold, which allowed masons to lay 350 rather than 125 bricks per hour, and with less physical effort. The labor cost per brick could be reduced, but as the masons were now 180% more productive, their hourly pay could be increased. The builder could accept a lower profit margin per brick, while again making more profit per hour because 180% more bricks could be laid. The masons were kept employed because the lower prices encouraged more construction.

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When automation is present, it takes 49 seconds (again assuming 13 seconds to know what the customer wants) to fill the order, so 73 can be filled every hour. Assume the barista’s pay is increased to $20 an hour, which with employment taxes comes to $21.53 or 29.5 cents per drink.

Customer Care

Starbucks’ AI Coffee Makers: A Productivity Case Study

Automation could allow baristas to be paid more and still net higher profits for company

The key takeaway regarding efficiency and productivity improvements is therefore as follows:
• The worker’s piece rate can and must be reduced, but the reduction must be such that the worker gets paid more per hour because he or she is making far more units.
• The employer’s profit margin per piece must similarly be reduced, but the reduction must be calculated so the employer earns more per employee per hour.
• The difference must be reflected in lower prices to support the higher sales volume to keep all the workers employed.

Summary

Quality professionals can help educate consumers to demand value for their money, and this will help fight inflation. But the real work must take place on the shop floor, where waste can constitute at least 75 percent of the labor costs.

Materials and energy also can be wasted, and Brad Marley5 quotes Armstrong International’s Patricia Provot as saying, “As much as 80% of the energy that is used in a manufacturing facility gets dumped before it can be recouped and used elsewhere.”

As but one example, I recently had to pick out frames for new sunglasses. I selected the Sam’s Club Member’s Mark brand, which is the generic store brand, over fancy designer labels because the eyeglass frame is worth only what it can do, namely, hold the lenses in place. A designer brand costs more but doesn’t do a better job, and the price difference is pure waste. The seller receives money without delivering genuine value or utility, which adds to the velocity of money but not to the supply of genuine goods and services.