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Ilar's IQC

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 1 I. Project SISIGma: Food Quality and Dining Improvement of Ilar’s Kitchenette II. Team Organization Dakanay, John Patrick R. ( Team Recorder ) De Jesus, Carlo Adrine B. ( Team Leader ) Mabanglo, Samuel Benedict B. ( Open minded and Creative) Reguyal, Ardreen B. ( Open minded and Creative) Romero, Ericka Patricia D. ( Process Observer ) San Juan, Joseph H. ( Team Recorder ) III. Project Background: Ilar’s Kitchenette is a “carenderia” restaurant that is known for their silogs and sizzling dishes. The top selling tapsilog and pork sisig will make you an everyday diner at Ilar’s. Also, Ilar’s is famous to UST students because of their affordable prices ranging from 50 to 80 pesos. This comes with a free drink and free extra rice for students. You can access the three branches of Ilar’s, one in Piy Margal St., Jhocson St., and the other in Lacson. Being one of Ilar’s customers, we students have experienced good and bad qualities of the restaurant as well. As for the quality management is concerned, the researchers are focusing on processes that can be improved by using techniques that we have learned in Industrial Quality and Control. The group hasdecided to work on two perspectives: the customer’s and the service
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8/10/2019 Ilar's IQC

http://slidepdf.com/reader/full/ilars-iqc 1/15

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I. Project SISIGma: Food Quality and Dining Improvement of Ilar’s

Kitchenette

II. Team Organization

Dakanay, John Patrick R. (Team Recorder )

De Jesus, Carlo Adrine B. (Team Leader )

Mabanglo, Samuel Benedict B. (Open minded and Creative)

Reguyal, Ardreen B. (Open minded and Creative)

Romero, Ericka Patricia D. (Process Observer )

San Juan, Joseph H. (Team Recorder )

III. Project Background:

Ilar’s Kitchenette is a “carenderia” restaurant that is known for their

silogs and sizzling dishes. The top selling tapsilog and pork sisig will make you

an everyday diner at Ilar’s. Also, Ilar’s is famous to UST students because of

their affordable prices ranging from 50 to 80 pesos. This comes with a free drink

and free extra rice for students. You can access the three branches of Ilar’s, one

in Piy Margal St., Jhocson St., and the other in Lacson.

Being one of Ilar’s customers, we students have experienced good and

bad qualities of the restaurant as well. As for the quality management is

concerned, the researchers are focusing on processes that can be improved by

using techniques that we have learned in Industrial Quality and Control. The

group hasdecided to work on two perspectives: the customer’s and the service

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crew itself. The study will revolve around the qual ity of food the customer’s

receive and the quality of service they have been experienced. Also, the group is

aiming for the service crew’s standpoint on how they render services. The

researchers are also making improvements on some factors such as food waste.

Through the help of some IQC tools, the group is able to identify some

of the problems and propose a solution to solve them.

Here is the SIPOC of Ilar ’s. Through this tool the researchers will understand

better the process in providing food.

1. SIPOC (Current State)

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2. Flow Process Diagram- Food Deployment

This is the FPD of Ilar’s. The group focused on food deployment because this

is where the “bottleneck” takes place. Foods are being deployed one by one

because the silogs (pre-cooked meals which are ready to be plated) are

deployed earlier than the sizzling (cooked in sizzling plates), which requires more

time to cook.

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3. Affinity Diagram

Unsatisfied Customers of Ilar’s Kitchenette 

4. Voice of the Customer (Critical to Quality)

Quality Dining experience Wasted foodDelivery

Food is cold

Food waits

and therefore

it affects the

taste.

Food is

sometimes

undercooked

Orders do not

arrive at the

table at the

same time

Makes the

food cold

Some orders

take a long

time to be

delivered

Lack of

synchronizati

on in

deployment

of orders

Customers

wait for a long

time to be

seated

Many wasted

“free” rice. 

Not all eats

the free extra

rice.

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IV. Problem Statement

Why, Why, Why Diagram

*Food is cold, below 41 °F, not safe for food consumption

Why? It is not heated

Why? It is pre-cooked

*Food is cold, below 41 °F, not safe for food consumption

Why? Food waits.

Why? It is delivered early.

Why? Other orders on the table are not complete.

Why? Other orders are still cooking.

Why? Lack of synchronization in deployment of orders.

*Customers are waiting for available seats.

Why? All seats are occupied.

Why? Layout is not optimized.

*Too many “free” excess extra rice.

Why? Number of requests is not accurate.

Why? Extra rice is given by number of orders.

*Free Extra Rice contributes to food wastage.

Why? Other customers do not consume the free extra rice.

Hot foods need to be kept above 151oF to prevent bacteria build up. Food is

considered cold if it is below 41oF. Also, below 41oF, bacteria growth is present.

Problem #1: Food is cold and not safe to be consumed.

Problem #2: Food waste.

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Control Chart

Time X1 X2 X3 Average Range

11:00AM 9.75 9.75 10.25 9.92 0.50

11:30AM 10 10.25 10.5 10.25 0.50

12:00NN 10.2 10.5 9.75 10.15 0.7512:30PM 10.2 10.4 10.1 10.23 0.30

1:00PM 9.75 10 10 9.92 0.25

10.09 0.46

Computation: Upper Class Limit (Mean)

UCL = Xdbar + A2*R

= 10.09 + 1.023*0.46

= 10.56

Lower Class Limit (Mean)UCL = Xdbar - A2*R

= 10.09 - 1.023*0.46

= 9.62

9.00

9.20

9.40

9.60

9.80

10.00

10.20

10.40

10.60

10.80

1 2 3 4 5

X Chart

Central Limit Upper Control Limit Lower Control Limit Data

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Time RangeLCL(Range)

UCL(Range)

11:00AM 0.50 0.00 1.18

11:30AM 0.50 0.00 1.18

12:00NN 0.75 0.00 1.18

12:30PM 0.30 0.00 1.181:00PM 0.25 0.00 1.18

Computation: Upper Class Limit (Range)

UCL = D4*Rbar

= 2.574*0.46

= 1.18

Lower Class Limit (Range)

UCL = D3*Rbar= 0

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1 2 3 4 5

R Chart

Range Upper Class Limit Lower Class Limit Data

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There are no outliers. Therefore, the process is statistically stable. Also,

the researchers computed for the Z, which is the probability of having good

service. The researchers assumed that the population mean of waiting time for

an order is ten minutes, which is also supported by the survey conducted.

 

 

 

 

P(Z<2.02) = 98%

Therefore, 98% of the time, Ilar’s serve the food well (below 10 minutes).

However, the researcher aims to lessen this waiting time of 10 minutes.

Problem #3: Lengthy waiting time.

 

Xbar = 10.56

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Cause and Effect Diagram

0

20

40

60

80

100

120

Pre-Cooked Unsynchronized

Deployment 

Late

Consumption

Weather is Cold

(Ambient 

Temperature)

Others

Histogram and Pareto Diagram

Frequency Pareto Diagram

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V. Objectives:

1. To deliver food at 165 °F for silogs and 390 °F for sizzling.

*Pre cooked food (silogs) are cold when served.

2. To reduce food waste (excess extra rice) by 100%.

*Voluntary giving of free extra rice in every customer leads to food

waste.

3. To reduce customer waiting time by at least 20%.

*Average waiting time is 10 minutes.

VI. Recommended Solutions

DECISION MATRIX

-Solution for re-heating or keeping precooked meals (silogs) above 135 °F.

COST (5) RESULT

IMPACT(15)

PROBABILITY

SUCCESS (10)

TOTAL

POINTS

SOLUTION A

Food Warmers

High

3x5=15

High

3x15=45

High

3x10=30

90

SOLUTION B

Microwave

Low

1x5=5

Medium

2x15=30

Medium

2x10=20

55

SOLUTION C

Heat Lamp

Medium

2x5=10

Low

1x15=15

Medium

2x10=20

45

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SOLUTION #1

*Sizzling meals are always above 390 °F because it is the standard

temperature in order to make the “sizzling” sound. Every meal are cooked and

served on the sizzling plate.

 According to the USDA's rules regarding food-safe temperatures, all

cooked foods should be held at a minimum of 135 degrees Fahrenheit after

cooking. Temperatures at or above this level have been scientifically proven to

eliminate the growth of bacteria that cause foodborne illnesses. In order to make

the food safe and warm for human consumption, the group proposed a fire-

warmed type food warmer; these are the warmers that use steam as source of

heat. Water that become steam is heated by a chamber that is fueled by

denatured alcohol. This can last for hours depending on the usage. This kind of

food warmer is durable and made of stainless steel.

Source:  http://www.ehow.com/facts_5825763_food-warmer_.html

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SOLUTION #2

SIPOC (Future State)

Supplier

  Market

  GasCompany

  ElectricCompany

  WaterCompany

  EquipmentStore

Input

  Waiter/Server

  Cook

  Rice

  Fish

  Pork

  Beef

  Vegetable

  Oil

  Seasoning

  Sauce  Gasoline

  LPG

  Water

  Electricity

  PlasticCups

  Spoons

  Forks

  Plates

  ToothPick

  CookingEquipment

  Canister

  TissuePaper

  RiceJug

  FoodWarmer s 

Output

  Food

  Services

Customer

  Employees

  Students

  Professors

  Residents

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New Process

 

Prepare the food

and wait for it to

be ready to serve

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The investigators have eliminated the voluntary giving of extra rice

because this is where the food waste is generated. Different customers have

different preferences on whether they will avail the free extra rice or not.

Because of this, the group came up with a new process: to make the

customers ask for extra rice. By this, we can know if the customers want another

cup of rice. Also, the proposal will eliminate food waste because the Ilar’s’ rice

server will only serve customers that will ask for the extra rice. It is also efficient

to use the “rice jug” as an alternative (like in Mang Inasal) because it will keep

the rice warm because of its insulation, and it will be agile to serve customers. It

will also be economical because it will eliminate the number of dishes used in

serving extra rice.

Through this process the deployment of food will be synchronize. Cooking

the egg while waiting for the sizzling to be ready will make both orders deployed

simultaneously. (Refer to flowchart)

SOLUTION #3

The researchers have found out that it takes about 2 minutes to heat a

sizzling plate. The team proposed that during peak hours, 11:00AM  –  1:00PM

and 5:00PM  – 7:00PM, the staff should pre-heat the sizzling plates to eliminate

the delay caused by heating. Pre-heating the sizzling plates will make the cycle

time of cooking faster by 20%.

The group also proposed the use of the readily available landline

telephones; to easily coordinate with the other branch located one street away.

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Through this the management can maximize their capacity and increase their

profit by properly allocating and accommodating the waiting customers of each

branch. 

VII. Pilot Study Project Implementation

a. Budget Proposal

b. Gantt Chart

CASH

OUTFLOW QUANTITY AMOUNT EXPENSES SUBTOTAL

Food

Warmers 4 1,500 6,000 6,000

"Rice Jug" 1 270 270 270

Total P6, 270


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