Date post: | 23-Jun-2015 |
Category: |
Design |
Upload: | haris-ackerman |
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Optimization of the Livingston Sub Line
By:Salvatore Scrudato
Kenneth Haury Haris Ackerman
Larry KadriuAlex Small
Unit Name
Livingston Dining Commons (Takeout)
Hours of Operation (Dinner): 5:30pm –
12am
Located on Livingston Campus, on the side of
main Dining Hall Entrance
Unit Name
Our Goals and Agenda
• Increase the productivity• Optimize the flow• Create consistent sub quality
Unit Name
Sub Knight at Livingston Monday Nights
Meat Choices include: Turkey, Roast Beef, Ham, Tuna, Salami, Peperoni, and Meat Balls
Condiments such as lettuce, tomato, various cheeses, mayo, salt, pepper, etc.
Aside from subs, students can also elect to have a premade pizza for dinner
Unit Name
Overview of Current Process
• Student enters line • Waits in line• Hands RUID card to employee who swipes card • Student receives bag, cup, and snack from swipe
employee• Student waits in line • Student waits for free sub making worker, verbally gives
worker sub order• Student waits for sub completion • Student obtains sub, gets drink, unwraps sub to apply
salt, pepper, oil, or oregano if desired• Student exits dining hall building
Operations : 5 Delays : 3
Unit Name
Glaring Issues With Takeout
• Several Delays– Creates bottlenecks and crowds
• Crowds create hectic work environment for workers• Inefficient use of worker time (I.E. worker swiping IDs)• Variability in sub quality
– Too much/little meat, cheese, etc
• Poor Location of salt, pepper, oil/vinegar, etc
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Proposed Improvements
• New method of entering take out line and swiping for meal
• Layout Improvements• Relocation of some items• Elimination of non-value added worker tasks
Unit Name
Overview of Changes
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Current Method of Entry and RUID Meal Swipe
1. Student hands RUID card to employee2. Employee swipes card3. Employee gives student bag, cup and napkins.
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Current Method of Swiping (MOST Evaluation)
For Student• Reach, give, wait, grab• A1+G1+P1+(70TMU
Wait) = 100 TMU Total
For Card Swiper• Current method
includes: 2 Reaches, 3 grabs, and a swipe for each cycle
• A1+G1+G1+P1+M1+X1
+A1 = 70 TMU
Unit Name
New Entry Method
This new method will free up labor hours, maintain order in the takeout area, and allow for a more organized calling system.
Unit Name
New Entry Method
• Student waits for “Please Wait” light to turn off
• “Please wait” light is on when there are at least 9 students inside that have not yet received their subs
• Once light is off, student swipes RUID card and receives ticket
• Ticket has unique daily number, and sub number.
• Sub number resets after 99
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Proposed “Waiting” Area
Once the student gets their ticket, they enter this waiting area. The students would wait here until they hear their number called.
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Push Button to signal end of sub time
The button is there to signal that the worker has finished making the sub. This tells us :
Worker is ready for another customer Another customer has left the system Time it took to make the sub
Unit Name
How the system works
• Student enters line• Student swipes and gets ticket (assuming it is not
full)• Student waits for number to be called• Student goes to assigned sub station• When sub is finished, sub-maker hits button• This allows for another student to go to that sub
station• This also allows for another student to get ticket
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Proposed Method
• The Proposed method removes the card swiper, and leaves the student to the self swiping entry method which includes: Reach, Swipe, and Return
• A1+X1+A1 = 30 TMU
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Benefits of a “Network”
• Everything will be hooked up to a centralized network
• This reduces the need for labor hours put towards: swiping students in, collecting data, and calling for the next customer.
• All the data can be analyzed on a computer.
• Some examples of useful data are: how long it takes to finish making a sub, how many students come for a sub, and the rate at which students come in for subs.
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New location for cups and sub toppings
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Cups and Toppings
• Putting the Oil, Vinegar, Salt, and Pepper at the end of the sub line will
optimize the process
• Students can tell the worker not to wrap the sub if they wish to put a topping on it
• Having the cups at the end of the line will eliminate the need for a worker to hand out cups
Unit Name
Arrivals in a given interval
5:00
5:15
5:30
5:45
6:00
6:15
6:30
6:45
7:00
7:15
7:30
7:45
8:00
8:15
8:30
8:45
9:00
9:15
9:30
9:45
10:0
0
10:1
50
10
20
30
40
50
60
Number of Arrivals
Number of Students
Unit Name
Data of arrivals (in 15 minute intervals)
TimeNumber of Students
Students in that interval
TimeNumber of Students
Students in that interval
5:00 0 0 7:45 317 265:15 25 25 8:00 347 305:30 46 21 8:15 391 445:45 78 32 8:30 418 276:00 100 22 8:45 439 216:15 143 43 9:00 476 376:30 184 41 9:15 518 426:45 213 29 9:30 557 397:00 244 31 9:45 602 457:15 266 22 10:00 641 397:30 291 25 10:15 697 56
• Average of 33 different students in a given 15 minute interval
• With 3 stations that represents 11 students per station
• The average total time to make a sub is 1.36 minutes or 81.81 seconds
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Current Vs. Proposed Entry Method and RUID Swipe
• Simplifies calling the preceding students to get in line for their sub
• Eliminates task of worker swiping cards manually
• Changes Layout of the assembly line
• Combines swiping the card, tallying number of students served, and allowing students in the door.
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Comparison
• Current Method: 100TMU = 3.6 Seconds/Cycle
• Proposed Method: 30 TMU = 1.08 Seconds/cycle
• And one less worker required
• Roughly 2.5 seconds saved per cycle
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Comparison Continued
• We had observed approximately 700 subs made in 1.5 hours
• Current Method: – (700 subs) (3.6 seconds per sub) = 2,520 Seconds for 700 sub
swipes
• Proposed Method: – (700 subs) (1.08 seconds per sub) = 756 Seconds for 700 sub
swipes
• This new method saves about 1,764 seconds or 29.4 minutes over 700 swipes
Unit Name
Pre-Portioning of Meat/Cheese on Wax Paper
• 4 pieces of meat and/or cheese takes 7.73 seconds
• Each sub will contain 12 pieces of meat and/or cheese (3 wax papers)
• On average meat/cheese will take 23.19 seconds to assemble
• With 2 people preparing the meats, they can make enough meat for 77.6 subs in a 15 minute interval
Unit Name
Making a Sub: 1 or 2 man job?
• 2 workers - 1 sub every 52.60 seconds
• 17.11 subs - 15 minutes
• 2 stations - 34.22 subs in a 15 minutes
• 1 workers - 1 sub every 65.72 seconds
• 13.7 subs - 15 minutes
• 3 stations - 41.1 subs in a 15 minutes
Unit Name
Reduction of time due to pre-portioned meat
• 30.72(avg) seconds to place meat on the sub
• Pre-portioned meat, 14.45(avg) seconds to place meat
• Reduces the time to make a sub by 16.27 seconds
• Time reduced from 65.72 to 49.45 seconds
• Now, with this reduced time, the 3 workers making subs can make 54.6 subs in a 15 minute interval.
• Interestingly, this is fast enough to meet the demand at the peak hour.
Unit Name
Current vs. Proposed
Current• 2 Stations• 2 Workers per station• 34.22 subs in a 15
minute interval
Proposed• 3 Stations• 1 Worker per station• 54.6 subs in a 15
minute interval
• 159.5% increase from present method
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What we learned!
• Gaining permission to perform a study on union workers is harder then expected
• How to implement relevant course work into daily life activities such as the MOST Evaluation Method and Work Sampling Techniques to obtain a higher efficiency throughout a process
• Group communication and cooperation
Unit Name
Thank you!Dr. LuxhojLivingston Dinning Hall Staff