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