Lunch Order Cycle Time Project Storyboard

Bahama Bistro Example

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Executive Summary

Key Words(Specific to Bahama Bistro)

• Order Lead Time: Total cycle time from the moment the customer places their order to the moment they receive their food.

• Lunch Time: Key lunch ordering hours from 11am to 2pm• Customers: Business people and vacationers• Packaging Process: All tasks related to placing food into take-out

containers, selecting utensils, napkins and condiments and then placing them all into a bag

• Stock Items: All raw food items and food packaging items• Condiments: Mini-bottles of hot sauce, limes, salt and pepper

Project Charter

VOC Translation Matrix

Key Take Away: Project needs to address overall Lead time which will impact customer wait time as well as food temperature

SIPOC – Lunch Order to Delivery

Key Take Away: The scope of this project goes from the point of receiving the lunch order to the point at which food is delivered or picked up

“As Is” Spaghetti Map

Key Take Away: Prep area setup leads to a lot of wasted motion

Data Collection Plan

Key Take Away: Data collection was spread out among the staff and covered a 6-week period – Back-up help was provided for kitchen staff

Baseline Data –Lead Time

Key Take Away: The baseline shows that for many orders, both the Order Lead Time and the Sandwich Order Lead time were well beyond the requirement.

Order Lead Time

Sandwich Order Lead Time

Fishbone Diagram

Key Take Away: Initial brainstorming indicates that packaging and wait staff might be potential root causes

5 Whys

Key Take Away: Root Cause Analysis will focus on verifying how much packing layout and wait staff habits are impacting Order Lean Time

Process Analysis

Key Take Away: The majority of the steps are non- value adding or non-value-adding but required – lots of opportunity to remove waste

Hypothesis Confirmations

Key Take Away: Data shows sandwich prep takes up to 13 min., cook times are <20 min., prep area is issue & servers don’t delay orders

Histogram of Sandwich Prep Time Histogram of Cooking Time

Impact Effort Matrix

Key Take Away: The team left condiments out of the pick-up orders, switched vendors, labeled the bins and studied X-training options

Risk Management

Key Take Away: Having the vendor call to confirm quantities would lead to lower risk of running out of key menu items

To Be Spaghetti Map

Key Take Away: New layout reduces waste of motion and cuts process time in half

Before & After Time Data

Key Take Away: Implemented solutions significantly decreased both Sandwich and Order Lead Time

Order Lead Time – Before and After

Sandwich Order Lead Time – Before and After

Monitoring & Response Plan

Key Take Away: The monitoring plan factors in both the leading indicators of packaging and prep time along with the project “Y” of Order Lead Time

Innovation Transfer Opportunities

Key Take Away: Most of the improvements can be immediately transferred to other bistro locations for immediate time savings