Optimization of the Livingston Sub Line

By:Salvatore Scrudato

Kenneth Haury Haris Ackerman

Larry KadriuAlex Small

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Livingston Dining Commons (Takeout)

Hours of Operation (Dinner): 5:30pm –

12am

Located on Livingston Campus, on the side of

main Dining Hall Entrance

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Our Goals and Agenda

• Increase the productivity• Optimize the flow• Create consistent sub quality

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Sub Knight at Livingston Monday Nights

Meat Choices include: Turkey, Roast Beef, Ham, Tuna, Salami, Peperoni, and Meat Balls

Condiments such as lettuce, tomato, various cheeses, mayo, salt, pepper, etc.

Aside from subs, students can also elect to have a premade pizza for dinner

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Overview of Current Process

• Student enters line • Waits in line• Hands RUID card to employee who swipes card • Student receives bag, cup, and snack from swipe

employee• Student waits in line • Student waits for free sub making worker, verbally gives

worker sub order• Student waits for sub completion • Student obtains sub, gets drink, unwraps sub to apply

salt, pepper, oil, or oregano if desired• Student exits dining hall building

Operations : 5 Delays : 3

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Glaring Issues With Takeout

• Several Delays– Creates bottlenecks and crowds

• Crowds create hectic work environment for workers• Inefficient use of worker time (I.E. worker swiping IDs)• Variability in sub quality

– Too much/little meat, cheese, etc

• Poor Location of salt, pepper, oil/vinegar, etc

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Proposed Improvements

• New method of entering take out line and swiping for meal

• Layout Improvements• Relocation of some items• Elimination of non-value added worker tasks

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Overview of Changes

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Current Method of Entry and RUID Meal Swipe

1. Student hands RUID card to employee2. Employee swipes card3. Employee gives student bag, cup and napkins.

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Current Method of Swiping (MOST Evaluation)

For Student• Reach, give, wait, grab• A1+G1+P1+(70TMU

Wait) = 100 TMU Total

For Card Swiper• Current method

includes: 2 Reaches, 3 grabs, and a swipe for each cycle

• A1+G1+G1+P1+M1+X1

+A1 = 70 TMU

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New Entry Method

This new method will free up labor hours, maintain order in the takeout area, and allow for a more organized calling system.

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New Entry Method

• Student waits for “Please Wait” light to turn off

• “Please wait” light is on when there are at least 9 students inside that have not yet received their subs

• Once light is off, student swipes RUID card and receives ticket

• Ticket has unique daily number, and sub number.

• Sub number resets after 99

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Proposed “Waiting” Area

Once the student gets their ticket, they enter this waiting area. The students would wait here until they hear their number called.

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Push Button to signal end of sub time

The button is there to signal that the worker has finished making the sub. This tells us :

Worker is ready for another customer Another customer has left the system Time it took to make the sub

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How the system works

• Student enters line• Student swipes and gets ticket (assuming it is not

full)• Student waits for number to be called• Student goes to assigned sub station• When sub is finished, sub-maker hits button• This allows for another student to go to that sub

station• This also allows for another student to get ticket

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Proposed Method

• The Proposed method removes the card swiper, and leaves the student to the self swiping entry method which includes: Reach, Swipe, and Return

• A1+X1+A1 = 30 TMU

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Benefits of a “Network”

• Everything will be hooked up to a centralized network

• This reduces the need for labor hours put towards: swiping students in, collecting data, and calling for the next customer.

• All the data can be analyzed on a computer.

• Some examples of useful data are: how long it takes to finish making a sub, how many students come for a sub, and the rate at which students come in for subs.

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New location for cups and sub toppings

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Cups and Toppings

• Putting the Oil, Vinegar, Salt, and Pepper at the end of the sub line will

optimize the process

• Students can tell the worker not to wrap the sub if they wish to put a topping on it

• Having the cups at the end of the line will eliminate the need for a worker to hand out cups

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Arrivals in a given interval

5:00

5:15

5:30

5:45

6:00

6:15

6:30

6:45

7:00

7:15

7:30

7:45

8:00

8:15

8:30

8:45

9:00

9:15

9:30

9:45

10:0

0

10:1

50

10

20

30

40

50

60

Number of Arrivals

Number of Students

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Data of arrivals (in 15 minute intervals)

TimeNumber of Students

Students in that interval

TimeNumber of Students

Students in that interval

5:00 0 0 7:45 317 265:15 25 25 8:00 347 305:30 46 21 8:15 391 445:45 78 32 8:30 418 276:00 100 22 8:45 439 216:15 143 43 9:00 476 376:30 184 41 9:15 518 426:45 213 29 9:30 557 397:00 244 31 9:45 602 457:15 266 22 10:00 641 397:30 291 25 10:15 697 56

• Average of 33 different students in a given 15 minute interval

• With 3 stations that represents 11 students per station

• The average total time to make a sub is 1.36 minutes or 81.81 seconds

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Current Vs. Proposed Entry Method and RUID Swipe

• Simplifies calling the preceding students to get in line for their sub

• Eliminates task of worker swiping cards manually

• Changes Layout of the assembly line

• Combines swiping the card, tallying number of students served, and allowing students in the door.

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Comparison

• Current Method: 100TMU = 3.6 Seconds/Cycle

• Proposed Method: 30 TMU = 1.08 Seconds/cycle

• And one less worker required

• Roughly 2.5 seconds saved per cycle

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Comparison Continued

• We had observed approximately 700 subs made in 1.5 hours

• Current Method: – (700 subs) (3.6 seconds per sub) = 2,520 Seconds for 700 sub

swipes

• Proposed Method: – (700 subs) (1.08 seconds per sub) = 756 Seconds for 700 sub

swipes

• This new method saves about 1,764 seconds or 29.4 minutes over 700 swipes

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Pre-Portioning of Meat/Cheese on Wax Paper

• 4 pieces of meat and/or cheese takes 7.73 seconds

• Each sub will contain 12 pieces of meat and/or cheese (3 wax papers)

• On average meat/cheese will take 23.19 seconds to assemble

• With 2 people preparing the meats, they can make enough meat for 77.6 subs in a 15 minute interval

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Making a Sub: 1 or 2 man job?

• 2 workers - 1 sub every 52.60 seconds

• 17.11 subs - 15 minutes

• 2 stations - 34.22 subs in a 15 minutes

• 1 workers - 1 sub every 65.72 seconds

• 13.7 subs - 15 minutes

• 3 stations - 41.1 subs in a 15 minutes

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Reduction of time due to pre-portioned meat

• 30.72(avg) seconds to place meat on the sub

• Pre-portioned meat, 14.45(avg) seconds to place meat

• Reduces the time to make a sub by 16.27 seconds

• Time reduced from 65.72 to 49.45 seconds

• Now, with this reduced time, the 3 workers making subs can make 54.6 subs in a 15 minute interval.

• Interestingly, this is fast enough to meet the demand at the peak hour.

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Current vs. Proposed

Current• 2 Stations• 2 Workers per station• 34.22 subs in a 15

minute interval

Proposed• 3 Stations• 1 Worker per station• 54.6 subs in a 15

minute interval

• 159.5% increase from present method

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What we learned!

• Gaining permission to perform a study on union workers is harder then expected

• How to implement relevant course work into daily life activities such as the MOST Evaluation Method and Work Sampling Techniques to obtain a higher efficiency throughout a process

• Group communication and cooperation

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Thank you!Dr. LuxhojLivingston Dinning Hall Staff