Process Engineering

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Process Engineering
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Overview

• Process Engineering
• Process Mapping
• HW 5 7 and Taco Bell Example

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Engineering and Process Engineering

• Engineering often involves building a model of an
  entity
• Stresses on a bridge (Civil Engineering)
• Flow of electricity in a circuit (Electrical
  Engineering)
• Process Engineering involves building a model of
  a process (usually multi-step, parallel or series
  operations) (Industrial/Management Engineering)

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A Process

• A good definition of a process describes it as a
  series of connected steps or actions to achieve
  an outcome.
• A process has the following characteristics
• a starting point and an end point. This is the
  scope
• a purpose or aim for the outcome
• rules governing the standard or quality of inputs
  throughout the process
• it is usually linked to other processes
• it can be simple and short, or complex and long

From NHS, UK
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Examples of different processes

• From ordering a taco to receiving it.
• From first developing symptoms of a gastric ulcer
  to being discharged as fit
• From the doctor saying that you need a chest
  x-ray to knowing the results

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Process Map

• A flow diagram to help create a better
  understanding of the processes.
• Can model each process.
• Can eliminate or improve each process.

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Process Mapping

• Use to graphically show the processes involved
• Allows for examination of processes (elimination
  or improvement)
• Used in manufacturing, logistics, and medical
  areas

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HW5-7 Fast Food Systems

• Aims
• Work as a team
• Examine an application of process engineering to
  see how an example restaurant operates
• Give presentation on your results
• Select fast food restaurant.
• Visit and examine their operation.

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HW5-7 Fast Food Systems

• How does the restaurant handle product variety?
• Examine menu of restaurant (ignore minor items)
• Identify the food inputs for the main menu items
  (again, ignore minor items)
• How does the restaurant handle speed of delivery?
• Produce a process map using IDEF3
• How is customer wait time reduced?
• How does it handle bulges in demand?

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Fast Food Providers

• Customer requirements
• Low cost
• Fast
• Variety
• Consistency
• Safe, clean, convenient, pleasant surroundings
• HW5-7 will mainly examine how a fast food
  restaurant meets these requirements

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Two Main Approaches to Making Items for Customers

• Make in advance of customer order (Push)
• Examples car dealers lot, McDonalds standard
  items.
• Make to Customer Order (Pull)
• Make after customer has ordered.
• Examples Taco Bell, Dell computers
• What are advantages/disadvantages of each for
  fast food restaurants?

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Taco Bell (think outside the bun)

• Products include burritos,  tacos, gorditas,
  chalupas, nachos and quesadillas
• Some background Taco Bell have re-engineered
  their operations to a k-minus (kitchenless)
  operation, meaning that most food preparation
  operations were taken from the stores to
  centralized facilities.
• This has resulted in significant cost savings,
  reduced space requirements and increased quality
  control. They also eliminated middle-management
  layers and implemented  the TACO (Total
  Automation of Company Operations) program  to
  give an integrated information system.

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• These changes have had a huge impact on the
  company -- Taco Bell went from a failing regional
  Mexican -American fast food chain with 500
  million in sales in 1982, to a 3 billion
  national company 10 years later
• The K-Minus program, or kitchenless- restaurant,
  established a system where the large majority of
  food preparation occurs at central commissaries
  rather than in the restaurant, pushing 15 hours
  of work a day out of the restaurant, improving
  quality control and employee morale, reducing
  employee accidents and injuries, and resulting in
  substantial savings on utilities.

From http//future500.org/case_02.php
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Main Menu Items

• Burritos
• Bean Burrito
• 7-Layer Burrito
• Chili Cheese Burrito
• Burrito Supreme
• Fiesta Burrito
• Grilled Stuft Burrito
• Gordita
• Gordita Supreme
• Gordita Baja
• Gordita Nacho Cheese
• Chalupa
• Chalupa Supreme
• Chalupa Baja
• Chalupa Nacho Cheese

• Value
• Spicy Chicken Soft Taco
• Spicy Chicken Burrito
• Grande Soft Taco
• Double Decker Taco
• 1/2 lb Bean Burrito Especial
• 1/2 lb Beef Combo Burrito
• 1/2 lb Beef and Potato Burrito
• Tacos
• Original Taco
• Taco Supreme
• Soft Taco
• Ranchero Chicken Soft Taco
• Soft Taco Supreme
• Grilled Steak Soft Taco
• Double Decker Taco
• Double Decker Taco Supreme

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Main Ingredients

• Wraps
• Soft tortilla
• Hard taco shell
• Flatbread (Gordita)
• Chalupa
• Meats
• Chicken
• Beef
• Steak

• Other
• Beans
• Lettuce
• Onions
• Cheese
• Red sauce
• Potatoes
• Sour cream
• Tomatoes
• Rice
• Guacamole

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Taco Bell

• How does the restaurant handle product variety?

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Simplified Taco Bell Process Map
Ingredients Prepared 1
Number shows worker ID
Customer Orders
Order Entered 2
Order Assembled 3,4
Customer Waits
Order Delivered
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Taco Bell

• How does the restaurant handle speed of delivery?
• How is customer wait time reduced?
• Where does it use Pull and/or Push approaches?
• How does it handle bulges in demand?

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Taco Bell

• How does Taco-Bell meet other customer
  requirements?
• Low cost
• Ingredients, central preparation of food, small
  site, low wage labor
• Consistency
• Training, uniform measures
• Safe, clean, convenient, pleasant surroundings
• Well?
• How can operations be improved?