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Process Control Lessons
from a Macaron Factory
Process Control Lessons
from a Macaron Factory
20 May 2025
In engineering and manufacturing, process control is critical for ensuring product quality and consistency. Recently, I had a unique opportunity to observe these principles in action at a local macaron company and its manufacturing facility. This visit, stemming from a connection made at a networking event, offered a fresh perspective on the parallels between high-reliability engineering and artisanal food production.
My initial encounter with Michael, the founder and CEO (who wears many hats!), at a professional networking gathering proved fortuitous. Recognizing a shared interest in operational excellence and process control, Michael invited me and a guest for an on-site visit. As a fan of macarons with experience making these finicky cookies in my own kitchen, I couldn't pass up an invitation to visit a factory focused on their production! Accompanied by my colleague Reehana, a manufacturing engineer specializing in aerospace vehicle fabrication and assembly, we aimed to explore the operations and intricacies of macaron production. See Figures 1 and 2.
Figures 1 and 2: Packaged macarons from Michael's small business Macadons. Macrons are tricky products that are sensitive to mixing, starting materials, baking temperatures, baking times, and technique. Mastery of them takes practice and a good understanding of process. Polaroids of Michael, Reehana, and me at dinner after our factory visit.
After our visit, I realized that the controls classic to precision, high-risk engineered products had made their way to Michael's operations, too. I was surprised to see process control best practices familiar to the many special process suppliers I've audited across the US and overseas. Just a week before, I had completed a visit to a carbon fiber composite prepreg supplier (materials typical in airframes) in Utah with a colleague of mine, Erin, and I was surprised to see similar controls in local food production operations right at home (See Figures 3 and 4). I was so intrigued by what I realized that I was inspired to share my experiences and insights in this writing to convey the importance of process control when it comes making dependable and successful products.
Special Processes
Special Processes
Similar to engineered materials requiring stringent specifications, macaron production demands a clear and well-controlled process. Unlike certain manufactured outputs where quality can be readily ascertained, the true measure of a macaron lies in its sensory attributes—taste and texture—aspects not immediately quantifiable through visual inspection or other external measurements. This characteristic mirrors challenges encountered in aerospace processes, such as composite prepreg manufacturing done at Hexcel, where process control becomes paramount to ensure desired material properties are achieved.
These kinds of processes, termed special processes in my line of work, are those that cannot be readily inspected without subsequent monitoring or measurement. Special processes produce outcomes that are tricky and challenging to detect, usually requiring destructive evaluation. This differs from outcomes of other manufacturing processes that are inspectable, like dimensions, which can be measured with calibrated tools and equipment. To avoid the risk of a malfunctioning product, controlling the inputs and the process itself is the only means to control the outcome and ensuring the product's reliability and integrity for the end customer.
For the macaron case, taste and texture cannot be assessed by direct measurement without destructive sampling. Rather than eating cookies from each lot, the emphasis in manufacturing is on the inputs and the process itself to guarantee a dependable product. Similarly, for high-precision prepreg composite materials where thousands of square feet are produced at a time, the control of the manufacturing process and parameters that go into the composite fabrication are of focus to control the resultant materials for reliable product performance (provided they are designed correctly).
Figures 3 and 4: At the front of Hexcel Corp in Salt Lake City, UT with colleague, Erin, for a special process audit. Hexcel Corp is a world-renowned supplier of composite materials used in a variety of applications spanning from aerospace, automotive, sports, and marine applications (Reference: NASA 20140002810), employing special process controls to produce reliable materials for all of their customers. Special process audits are conducted by engineering companies to verify if sufficient controls are in place to ensure predictable and reliable materials and processes for use in engineered products.
Factory Tour and Applications of Process Control
Factory Tour and Applications of Process Control
Reehana and I had a great time checking out Michael's operation. With a large part of my career spent performing supplier audits and inspections, I was pleased to report the institution of process control and quality measures throughout Michael's factory. Our observations of his macaron production process revealed a structured approach to manufacturing, as well as a principle of quality that was part of the processing from the very beginning of fabrication. Some highlights from the visit worth sharing are as follows:
Visual Management Systems: Clearly displayed visual work instructions served as readily accessible references for production personnel, promoting standardized execution of tasks. This mirrors the use of visual aids in high-reliability manufacturing to minimize process variability.
Dimensional Inspection Practices: Recognizing the importance of consistency in high-volume production, in-process dimensional checks were implemented to control physical attributes. The use of measurement tools and defined tolerances aims to ensure uniformity, crucial for customer satisfaction, as well as consistent inputs to downstream processes, too.
Standardized Work Instructions: Comprehensive written work instructions, detailing critical parameters such as processing times and temperatures, were readily available. This accessibility empowers technicians to execute their tasks with precision and consistency, mitigating the risk of process deviations. The concise, bulleted format enhanced clarity and ease of understanding.
Technique-Specific Training Programs: Investment in thorough training programs highlighted the recognition that skilled personnel are integral to process fidelity. This aligns with the emphasis on qualified personnel in critical aerospace manufacturing processes.
Inventory and Traceability Controls: Robust inventory management practices, including tracking of material lots and adherence to expected timelines, demonstrated a commitment to traceability—a critical element in regulated industries. See Figure 5 for an example of inventory control.
5S Implementation: The adoption of 5S principles (Sort, Set in order, Shine, Standardize, Sustain) was evident in the organized and clean workspace, extending even to the arrangement of tools for subsequent production batches.
If "love is in the details," Michael's small business shows this love for their product with clear and intentional care and control throughout the macaron-making process and factory. His seriousness in his core process is evident in the stack of small, simple, and effective controls, classic to any successful production facility. I am happy to report that Michael's factory out rank many of those factories and suppliers that I have visited for both capability assessments and process control auditing in over my 15 years in engineering practice. Congratulations to Michael and the Macadon Team for a job well done!
Figure 5: Inventory control at the Macadon factory in Seattle, WA shows organized product identifying product name, date of manufacture, and lot number.
Outcome of Controlled Processes
Outcome of Controlled Processes
Michael demonstrated a commitment to controlled methodologies that were evident in our tour and are typical checkpoints in any audit visit. The visit culminated in a tasting session, where the final product could be evaluated firsthand. The products were visually appealing, uniform in presentation, and all tasted great with the notable texture signature of any high-quality artisan macaron I have had in the past.
These positive outcomes, without a doubt, are heavily dependent on the elements of process control Michael installed as part of his core macaron manufacturing process. The value they produce is clear: a successful company with several storefronts in the greater Seattle area, employing a staff of over 15 focused on serving their local communities. While the criteria of an acceptable macaron differ significantly from engineered products, the intent to meet customer expectations by achieving desired outcomes is not. One key to achieving such targets is focusing on quality through process control, a clear universal to any manufacturing environment.
Final Thoughts
Final Thoughts
This excursion into the world of macaron manufacturing underscored the universality of sound process control principles. Despite the apparent differences between manufacturing engineered products and artisanal food production, the fundamental tenets of process control and a commitment to consistent quality remain paramount. Michael’s dedication to these principles in his small business serves as a compelling example of how robust control of special processes can drive success across diverse industries. It was a privilege to witness these practices in action and to forge a connection with a fellow entrepreneur dedicated to excellence.
For those in the Seattle area seeking high-quality macarons, Michael's establishment warrants consideration. This experiential assessment, coupled with the insights into the manufacturing controls, provided a holistic understanding of Michael’s operation--he's got something good going! If you ever run into his products, I highly recommend you give them a try—you won't be disappointed by Macadons.
Thx, m
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