The OnLine Kitchen

1
The On-Line Kitchen

• NAFEM 99
• October 2, 1999

2
Introductions

• Fernando Esparza McDonalds Corp.
• Mike Harlamert KFC Corp.
• Roy Hook Wendys International
• Steven Jones Triarc Restaurant Group
• John Reckert Burger King Corp.

3
Agenda

• Fernando Esparza POS Integration
• Steven Jones Back-of-House Interface
• John Reckert Labor Reduction
• Roy Hook Asset Management
• Mike Harlamert Food Safety
• Summary
• Status/Next Steps

4
TYPICAL CHAIN RESTAURANT -- TODAY
5
RESTAURANT COMMUNICATIONS -- TODAY
BACKROOM COMPUTER
KITCHEN EQUIPMENT
DRIVE-THRU POS
CENTRAL OFFICE
FRONT COUNTER POS
6
RESTAURANT COMMUNICATIONS -- TODAY

• Proprietary communications protocols
• Near Real Time communications within POS
  components
• Complex flexible configurations, i.e.
  registers, printers, video monitors,
  drive-thru systems
• Ability to communicate with back room computers

7
RESTAURANT COMMUNICATIONS -- TODAY

• Optional time clock systems integrated with POS
  and back room labor scheduling and payroll
  programs
• Available POS reports can be configured to the
  business needs of a restaurant
• Limited Projections of Product Needs

8
RESTAURANT COMMUNICATIONS -- TODAY WHATS MISSING

• Ability to easily upgrade the software and add
  components (Customer order displays, coin
  dispensers, etc.)
• Standard protocol to communicate with off-site
  computers
• Communication with kitchen equipment (fryers,
  grills, ovens and heated holding cabinets)
• Real time communication protocol to communicate
  with future automated cooking systems
• POS will be the gateway to the kitchen network
  in most restaurants

9
RESTAURANT COMMUNICATIONS -- FUTURE
Front Counter POS
Drive-Thru POS
Central Office Node
Backroom Computer
10
RESTAURANT COMMUNICATIONS -- FUTURE
Automated Beverage System
Front Counter POS
Drive-Thru POS
Central Office Node
Backroom Computer
11
RESTAURANT COMMUNICATIONS -- FUTURE
Automated Beverage System
Front Counter POS
Automated Fryer System
Drive-Thru POS
Central Office Node
Backroom Computer
12
RESTAURANT COMMUNICATIONS -- FUTURE
Automated Beverage System
Front Counter POS
Automated Fryer System
Drive-Thru POS
Central Office Node
Ice Transport
Backroom Computer
13
RESTAURANT COMMUNICATIONS -- FUTURE
Automated Drink System
Front Counter POS
Automated Fryer System
Drive-Thru POS
Central Office Node
Heated Holding Cabinet
Menu Board Systems
Backroom Computer
HVAC Controls
14
RESTAURANT COMMUNICATIONS -- FUTURE
Communication Loop for Product Projections
POS
Backroom Computer
Production Equipment
Holding Equipment
15
RESTAURANT COMMUNICATIONS Challenges to
Creating the Smart Kitchen

• How do we implement a kitchen network that will
  minimize installation costs
• How do we develop a self configuring network
  that can be embraced by the POS vendors
• How will the network deliver the bandwidth
  required to support the cooking, holding and
  all the POS components communicating in
  real- time
• Affordable --only dollars per node

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The On-Line Kitchen

• Back of the House Management System

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The On-Line KitchenBack of the House Management
System

• The On-line Kitchen should be an open, networked
  environment that allows information to be shared
  between different types of systems operating with
  various operating platforms and protocols
• The On-line Kitchen concept offers the capacity
  to link several systems together so that data is
  shared and analyzed
• P.O.S.
• Process Controllers on cooking and preparation
  equipment
• Production/Projection Monitors/printers
• Energy management
• Secondary peripherals-Order Confirmation, etc.
• Back of the House System

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The On-Line KitchenBack of the House Management
System

• The back of the House system is the Brains for
  the Conduit of a linked kitchen system
• It is where information is sent to, analyzed,
  updated and then sent back to the other elements
  in the linked system
• This linkage allows several functions to be
  connected so that each system in the link is
  getting pertinent data that affects its operation
  and or processes

19
The On-Line KitchenBack of the House Management
System

• This linkage allows an operator or chain to give
  and get information on a variety of operational
  and equipment functions
• Operators have the flexibility within the BOH
  system to extract and generate information and
  reports on a variety of areas based on the
  software employed
• Based on the parameters and functionality of the
  software used in the BOH system it potentially
  allows multi-tasking processes to operate

20
The On-Line KitchenBack of the House Management
System

• These sub-systems can include
• Cash Management
• Product Projection-To Prepare To Cook
• Menu Inventory Management
• Sales/Menu Mix
• Inventory tracking monitoring
• HACCP Tracking Monitoring
• Labor Management -Tracking, Forecasting
  Scheduling
• Asset Management-Tracking Diagnostics
• Energy Management-Control Diagnostics

21
The On-Line KitchenBack of the House Management
System

• The utilization of an On-line Kitchen system
  reduces restaurant management's manual tasking to
  get useable information on
• Product preparation amounts
• Product holding on hand amounts
• Product to be cooked amounts
• Labor required for food sales and preparation
• Labor scheduling
• Inventory administration
• This in turn offers management the freedom to
  focus on Customer Service Operational execution

22
The On-Line KitchenBack of the House Management
System

• It also offers the potential for increased
  efficiency at the work station level by allowing
  an hourly employee to function at a higher level
  of productivity by supplying product ordered info
  directly to the station
• It can also reduce the level of verbal
  communication direction needed between
  management and hourly employees by supplying
  product production data directly to the employee
  via monitors or printers
• It can facilitate improvement in work/product
  process flow by orienting data to the proper end
  user (work station, product assembly, expediter,
  etc.)

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The On-Line KitchenBack of the House Management
System

• The BOH system can also offer external
  interaction via a modem allowing remote access to
  data and equipment performance
• Linked to HQ or Regional HQ
• Sales Menu Mix polling
• Automated Product Ordering
• Equipment Diagnostics - Internal or External
  Service
• Equipment calls for service based on diagnostic
  or PM schedule
• Downloads to Equipment process controllers - Cook
  Time or Temperature Changes
• Energy Management diagnostics

24
The On-Line KitchenBack of the House Management
System

• The BOH system is the core of the communication
  between different elements within the Kitchen and
  the front of the house
• With the variety and different capabilities of
  P.O.S. systems and Process Controllers that are
  currently available the ideal BOH system must be
  designed with an open connectivity that accepts
  any protocol
• Hardware and software must be able to communicate
  on a basic or higher level to facilitate the
  exchange of information needed

25
The On-Line KitchenBack of the House Management
System

• The Back of the House Management System is the
  critical element in the design of an On-Line
  Kitchen
• Based on the software and the functionality that
  is designed into it, the BOH will allow the
  interchange of information to flow freely between
  the P.O.S., the equipment and other peripheral
  hardware
• The key in designing an a system is to determine
  what data needs to be exchanged and what the
  output is going to be and how that will be
  presented to the end user

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The On-Line Kitchen

• Labor Implications

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The Industries Labor Problems...

• Cost
• Quality
• Availability
• In the Market to work at any cost!
• To work when we have the business

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Labor Availability

• We cant always get labor when our business calls
  for it

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Labor Availability

• We cant always get labor when our business calls
  for it
• For the Sales shown, this would be the ideal use
  of labor

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Labor Availability

• We cant always get labor when our business calls
  for it
• For the Sales shown, this would be the ideal use
  of labor
• This is how we staff in reality

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Labor Availability
Flattened Labor Line

• Why?
• More availability of Full Time employees

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Labor Availability
2 - 3 hour shifts

• Why?
• More availability of Full Time employees
• Ideal staffing calls for many 2 - 3 hour shifts

33
Labor Availability
Understaffed

• Why?
• More availability of Full Time employees
• Ideal staffing calls for many 2 - 3 hour shifts
• As more full time employees are hired, off peak
  times are overstaffed and peak times are
  understaffed

Overstaffed
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Labor Availability
Not providing service

• The result
• Not delivering optimal service during our peak
  periods
• Overspending on labor during our off peak periods
• Sales and costs are not optimized

Inefficient use of labor
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The On Line Kitchen can...

• Provide Productivity Improvements to flatten out
  the labor line needs by providing additional
  efficiency to our labor force during peak periods

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Productivity / Labor Reductions

• Productivity - Improving the capability of
  producing product with given labor
• Decrease tasks
• Decrease time to perform individual tasks
• Combine tasks into the same time frame
• Increase output of doing a task
• Given enough productivity improvements, labor
  reductions may be a result

37
Productivity / Labor Reductions

• Labor Reductions - The ability to reduce head
  count at given production levels
• We have not experienced enough gains in
  productivity to substantially reduce our labor
  requirements during peak periods

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The On-Line kitchen could...

• Drive Automation that eliminates appropriate
  tasks to reduce staff needs
• Anticipate Tasks at optimal times to make our
  current labor more efficient
• How much to cook and when
• How much to prep and when
• Monitor work loads within the kitchen
• Balancing the work loads of our staff

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Indirect Labor

• Additionally, the on line kitchen could help to
  reduce indirect labor by
• Scheduling equipment maintenance cleaning of
  equipment by monitoring use and performing these
  tasks more efficiently or less frequently
• Give us exact usage per time periods of products
  that require pre preparation

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In Summary...

• The on line kitchen presents many opportunities,
  some yet unidentified, to improve
• Staffing Requirements, especially at peak
• Productivity of existing labor
• Utilization of labor required for equipment
  maintenance and cleaning

41
The On-Line Kitchen

• What isAsset Management?

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Asset Management

• Service and Maintenance
• Tracking of equipment assets
• Energy use optimization

43
Service and Maintenance

• Detecting Performance Degradation
• Early Warning of Failures
• Preliminary Diagnostics
• Preventative Maintenance

44
Service and Maintenance

• Detecting Performance Degradation
• based on known performance standard
• initial heat up times
• compressor run times

45
Service and Maintenance

• Early Warning of Failures
• performance degradation a signal
• non critical function failures

46
Service and Maintenance

• Preliminary Diagnostics
• correlate historic cause and effect
• Reduce trips to location
• take the right parts on the first trip

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Service and Maintenance

• Preventative Maintenance
• tracking reduces missed scheduled PM
• Management tool to optimize PM based on
• current equipment performance
• specific location history

48
Tracking Equipment Assets

• Identify Specific Equipment by Location
• Update Equipment Operating Parameters
• Tabulate Abnormal Operating Events

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Tracking Equipment Assets

• Identify Specific Equipment by Location
• for accounting purposes
• warranty administration

50
Tracking Equipment Assets

• Identify equipment for recalls
• locate equipment for improvements
• identify location of recalled equipment
• know when recall service has been completed

51
Update Equipment Operating Parameters

• Identify operating parameter issues
• Directly make equipment changes to
• Accommodate new menu items
• React to product improvements
• Insure adherence to operational standards

52
Tabulate Abnormal Events

• Use as an operational tool
• determine the magnitude of operational issues
• correlate issues with other events
• aid in resolving causes of issues

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Energy and Labor

• Tracking use of energy
• Optimizing energy use
• Reducing labor dependency

54
Tracking Use of Energy

• Know what items are contributing to
• energy used
• demand charges

55
Optimizing Energy Use

• Adjust equipment operating times to maximize
  energy efficiency
• Stager turn on to reduce demand

56
Reduce Labor Dependency

• Automatic turn on and off of equipment
• based on time of day
• relationship to other equipment
• relationship to business/operations activity
• Reduces need for personal attention
• Eliminate requirement to schedule labor in time
  to turn on equipment

57
The On-line Kitchen

• Food Safety Implications

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The On-line KitchenFood Safety Implications

• Food safety is one of the most important issues
  facing the industry today

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The On-line KitchenFood Safety Implications

• Food safety is one of the most important issues
  facing the industry today
• Affects 6 to 80 million persons annually

60
The On-line KitchenFood Safety Implications

• Food safety is one of the most important issues
  facing the industry today
• Affects 6 to 80 million persons annually
• Causes 9,000 deaths

61
The On-line KitchenFood Safety Implications

• Food safety is one of the most important issues
  facing the industry today
• Affects 6 to 80 million persons annually
• Causes 9,000 deaths
• Cost an estimated 5 billion dollars

62
The On-line KitchenFood Safety Implications

• Food safety is one of the most important issues
  facing the industry today
• Affects 6 to 80 million persons annually
• Causes 9,000 deaths
• Cost an estimated 5 billion dollars
• Many cases can be related to improper cooking
  and/or holding conditions

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The On-line KitchenFood Safety Implications

• Food safety issue is compounded by

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The On-line KitchenFood Safety Implications

• Food safety issue is compounded by
• Increased complexity in the back-of-the-house

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The On-line KitchenFood Safety Implications

• Food safety issue is compounded by
• Increased complexity in the back-of-the-house
• Menu expansion

66
The On-line KitchenFood Safety Implications

• Food safety issue is compounded by
• Increased complexity in the back-of-the-house
• Menu expansion
• Increased equipment sophistication

67
The On-line KitchenFood Safety Implications

• Food safety issue is compounded by
• Increased complexity in the back-of-the-house
• Menu expansion
• Increased equipment sophistication
• Decreasing quality of available workforce

68
The On-line KitchenFood Safety Implications

• Proliferation of microcontroller based process
  control systems have improved the situation

69
The On-line KitchenFood Safety Implications

• Proliferation of microcontroller based process
  control systems have improved the situation
• Tighter control over time temperature

70
The On-line KitchenFood Safety Implications

• Proliferation of microcontroller based process
  control systems have improved the situation
• Tighter control over time temperature
• Load compensation algorithms

71
The On-line KitchenFood Safety Implications

• Proliferation of microcontroller based process
  control systems have improved the situation
• Tighter control over time temperature
• Load compensation algorithms
• Multiple process set points

72
The On-line KitchenFood Safety Implications

• Microcontroller based process control systems are
  only the first step, and in some cases have
  contributed to the food safety issue

73
The On-line KitchenFood Safety Implications

• Microcontroller based process control systems are
  only the first step, and in some cases have
  contributed to the food safety issue
• Increased flexibility has led to increased level
  of difficulty in programming

74
The On-line KitchenFood Safety Implications

• Microcontroller based process control systems are
  only the first step, and in some cases have
  contributed to the food safety issue
• Increased flexibility has led to increased level
  of difficulty in programming
• Increased likelihood of incorrect process set
  points in controllers

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The On-line KitchenFood Safety Implications

• How having appliances on-line can address food
  safety issues

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The On-line KitchenFood Safety Implications

• The next logical step

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The On-line KitchenFood Safety Implications

• The next logical step
• Connect all appliances to a network connected to
  the back office management system to further
  automate the back-of-house operations

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The On-line KitchenFood Safety Implications

• Process set point verification

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The On-line KitchenFood Safety Implications

• Process set point verification
• Appliance performance monitoring

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The On-line KitchenFood Safety Implications

• Process set point verification
• Appliance performance monitoring
• Automated HACCP compliance

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The On-line KitchenFood Safety Implications

• Process set point verification
• Insures cooking equipment is correctly programmed
  for the products being processed

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The On-line KitchenFood Safety Implications

• Appliance performance monitoring
• Insures cooking and holding equipment are
  performing to manufacturers specifications

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The On-line KitchenFood Safety Implications

• Appliance performance monitoring
• Insures cooking and holding equipment are
  performing to manufacturers specifications
• Notifies restaurant manager of deficiencies in
  performance

84
The On-line KitchenFood Safety Implications

• Appliance performance monitoring
• Insures cooking and holding equipment are
  performing to manufacturers specifications
• Notifies restaurant manager of deficiencies in
  performance
• Could lock out defective equipment to prevent use

85
The On-line KitchenFood Safety Implications

• Automated HACCP compliance
• Data log cooking process to insure correct
  thermal processing

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance
• Data log cooking process to insure correct
  thermal processing
• Maintain file of historical data

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance
• Data log cooking process to insure correct
  thermal processing
• Maintain file of historical data
• Notify manager of anomalies/deviations in process
  due to

88
The On-line KitchenFood Safety Implications

• Automated HACCP compliance
• Data log cooking process to insure correct
  thermal processing
• Maintain file of historical data
• Notify manager of anomalies/deviations in process
  due to
• Out of spec raw materials

89
The On-line KitchenFood Safety Implications

• Automated HACCP compliance
• Data log cooking process to insure correct
  thermal processing
• Maintain file of historical data
• Notify manager of anomalies/deviations in process
  due to
• Out of spec raw materials
• Operator aborted cooking cycles

90
The On-line KitchenFood Safety Implications

• Automated HACCP compliance ctd.
• Monitor product hold times

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance ctd.
• Monitor product hold times
• Holding timers automatically start when cooking
  process completed

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance ctd.
• Monitor product hold times
• Holding timers automatically start when cooking
  process completed
• Holding timers automatically cancel when products
  are sold

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance ctd.
• Monitor product hold times
• Holding timers automatically start when cooking
  process completed
• Holding timers automatically cancel when products
  are sold
• Holding timers could move as products move from
  one holding area to another

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The On-line KitchenFood Safety Implications

• Automated HACCP compliance ctd.
• Monitor product hold times
• Holding timers automatically start when cooking
  process completed
• Holding timers automatically cancel when products
  are sold
• Holding timers could move as products move from
  one holding area to another
• Restaurant manager notified when products are
  expired and being over held

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The On-line KitchenFood Safety Implications

• An on-line kitchen can address many of the food
  safety issues facing the industry today

96
The On-line KitchenFood Safety Implications

• An on-line kitchen can address many of the food
  safety issues facing the industry today
• Insure appliances are operating properly

97
The On-line KitchenFood Safety Implications

• An on-line kitchen can address many of the food
  safety issues facing the industry today
• Insure appliances are operating properly
• Insure correct process set points are used

98
The On-line KitchenFood Safety Implications

• An on-line kitchen can address many of the food
  safety issues facing the industry today
• Insure appliances are operating properly
• Insure correct process set points are used
• Insure cooking processes are within specifications

99
The On-line KitchenFood Safety Implications

• An on-line kitchen can address many of the food
  safety issues facing the industry today
• Insure appliances are operating properly
• Insure correct process set points are used
• Insure cooking processes are within
  specifications
• Insure hold times and conditions are within
  specifications

100
The On-line KitchenFood Safety Implications

• Product preparation decisions impacting food
  safety can be taken out of the hands of the
  operators

101
The On-line KitchenFood Safety Implications

• Product preparation decisions impacting food
  safety can be taken out of the hands of the
  operators
• The on-line kitchen can provide the restaurant
  manager with the information needed to make
  better decisions and run a safer and more
  profitable restaurant

102
SummaryBenefits of the On-Line Kitchen

• The ability to pass information between the BOH
  computer system and the kitchen appliances can
  make significant improvements in restaurant
  operations.
• Accuracy of product projections
• Labor reduction
• Improved asset management
• Improved food safety

103
SummaryCommunications can make it happen

• The key to connectivity is an open data
  communications protocol
• A non-proprietary industry accepted standard
  data communications protocol that can be
  implemented across all appliance manufacturers
  and used by all
• end users.

104
SummaryWhy is a standard open protocol important

• Lack of a standard open protocol will result in
  increased costs and increased development time.
• Multiple protocols for various customers
• Multiple software versions for the same
  applications

105
SummaryThe vision of the future

• Today
• Computer control systems are standard
  equipment for most major equipment
  manufacturers.
• Tomorrow
• A data communications port and controls
  equipped with a NAFEM endorsed protocol become
  standard equipment.

106
Status/Next Steps

• Under the direction of the TLC, and with the
  endorsement of the CAT, two working groups are
  being formed
• Group 1 - Define the requirements
• Group 2 - Explore existing protocols
• Goal - Present update with recommendations at
  COEX 2000

107
Status/Next Steps

• At COEX 99, NAFEM was challenged to define the
  protocol
• NAFEM accepted and project assigned to the
  Technical Liaison Committee (TLC)
• Exploratory meeting at NRA - May 1999
• Meeting with NAFEM Chain Advisory Task Force
  (CAT) - July 1999

108
QA