Download - Lean Six Sigma: Reducing Wasted Time
Lean Six Sigma: Reduce Wasted Time at
Coal BenCorbin Gett, Neill Thoreson, Max Picard
Background❖ Originally housed coal
fire boilers for the University
❖ Converted into a bar style eatery where students could eat, drink, and socialize
❖ Diverse menu featuring burgers, chicken sandwiches, quesadillas, halal specials and more
❖ Beer available after 12:00 pm
Define Phase
Coal Ben SIPOC Diagram
Coal Ben VOC
Quick Wins
Project Champion’s Role❖ Frank Budig was supportive of the project and
sought our opinions and conclusions on possible Coal Ben business opportunities
❖ Main concern is to determine the ideal time to allow Meal Swipes
Interaction between Krasa and Coal Ben → Reducing Bottleneck
Coal Ben❖ Hours of Operation:
➢ Monday - Friday: 11:30 a.m. - 11:00 p.m.
➢ Saturday: 2:00 p.m. - 11:00 p.m.
➢ Sunday: 2:00 p.m. - 8:00 p.m.
❖ Equivalency Hours:
➢ Monday - Friday: 6:30 p.m. - 9:00 p.m.
➢ Saturday and Sunday: 5:00 p.m. - 8:00 p.m.
Krasa Dining Hall❖ Hours of Operation (Equivalency
Hours):
➢ Monday - Friday: 7:30 a.m. - 11:00 p.m.
11:15 p.m. - 3:00 p.m.
5:00 p.m. - 6:30 p.m.
➢ Saturday/Sunday: 9:00 a.m. - 11:00 p.m.
11:15 p.m. - 1:00 p.m.
Measure Phase
Tickets
Data Collection❖ We received tickets from Tuesday, March 1st❖ 71 orders were taken containing 108 menu items❖ Combo orders → multiple menu items ordered to
one ticket❖ The average wait time for non-combo orders was
5.86 minutes❖ The average wait time for combo orders was
7.457 minutes
Kitchen Tour
Analyze Phase
Redefine Problem❖ Fried meals vs non-Fried meals
➢ Most noticeable during non-Rush Hour times■ Not as many orders placed → the need to
constantly fry food not the same as Rush Hour
❖ Rush Hour (6:30 pm - 7:00 pm) vs non-Rush Hour➢ High volume of orders in a small time frame
■ Majority of wait time due to the time spent preparing earlier orders (prepare all orders as they come in)
Standard Times
Ticket Analysis
Ticket Analysis
Fried Results❖ Non-Combo Orders
➢ Average wait for Fried meal = 5.56 minutes
➢ Average wait for non-Fried meal = 6.78 minutes
➢ There is NO reason for the non-Fried orders to take longer than the Fried order as they aren’t dependant on the standard frying times
❖ Combo Orders➢ Average wait for meals with Fried component = 7.53 minutes
➢ Average wait for meals without Fried component = 5 minutes
Rush Hour Results❖ Non-Combo Orders
➢ 48% of the orders received during Rush Hour were sent out late
➢ ZERO orders received outside of Rush Hour were sent out late and all of these meals were Fried
❖ Combo Orders➢ 81% of the orders received during Rush Hour were sent out late
➢ 22% of the orders received outside of Rush Hour were sent out late
■ All these orders contained a Fried component
■ (one of which was 2 orders of boneless wings and French Toast Sticks)
Transaction Analysis
Sunday → Meals 5 pm - 8 pm
❖ Lowest amount of transactions occurs just before meal times begin at 5:00 pm
❖ The goal is to even-out the spike in transactions at lunch and dinner to maintain a more steady flow of customers instead of a dinner rush at 5:00 pm
Wednesday → Meals 6:30 pm - 9 pm
❖ Very low number of transactions throughout the day
❖ The inability to use Meal Swipes before 6:30 pm leads to a drastic rise in transactions and a rush hour that causes much longer wait times
Saturday → Meals 5 pm - 8 pm❖ Large dropoff in transactions
after the initial meal time (5:00 pm), perhaps due to students eating earlier in order to start their drinking and partying
❖ If happy hour or other beer specials were offered, there may be a smaller rush hour and a more steady flow of customers willing to stay later into the night
Improve Phase
Fryer Limitations❖ 3 Fryers each equipped
with 2 baskets
❖ 1 Fryer is only used for potato products and halal meats
❖ The other 2 Fryers cook everything else
❖ It isn’t possible to purchase additional Fryers
➢ No where to place them
Fried Food Solution
❖ Separate the tickets as they are received → Meals with a Fried component on the left and Meals without a Fried component on the right
❖ Will eliminate the dead time waiting for Fried components
❖ Allows Coal Ben to send out non-Fried meals without this added time
Rush Hour Solutions❖ Increase the amount of
time that Meal Swipes are offered ➢ Instead of weekday Meal Swipes
beginning at 6:30 pm, Meal Swipes would now begin at 5:00 pm
❖ Implement Happy Hour and other beer specials on weekends➢ Avoiding a large rush at 5:00
pm and encouraging students to stay later
Control Phase
Project Champion’s Role ❖ Frank will implement our solutions starting Fall
2016❖ He is continually searching for ways to make Coal
Ben more cost efficient, thus he will determine whether or not our solutions were effective and adjust accordingly
Lean Components
Lean Components❖Fryer Solution
➢ Eliminates the time lost while waiting for Fried meals
➢ Reduces the wait time for customers → Increases the business for Coal Ben ($$)
❖Rush Hour Solution➢ Current Schedule @ $8.25 per hour
■ 11 am - 6 pm 2 workers
■ 6 pm - 9 pm 5 workers
■ 9 pm - 11 pm 3 workers
■ $288.75 in wages for kitchen workers
➢ New Schedule @ $8.25 per hour
■ 11 am - 5 pm 2 workers
■ 5 pm - 9 pm 4 workers
■ 9 pm - 11 pm 2 workers
■ $264 in wages for kitchen workers → $24.75 in saving per day
ResultsPending