Good evening my dirty little city. It’s good to be writing again.
It’s time to do something more impossible than solving world hunger, than boiling the ocean. Tonight, I’ll be answering the quintessential problem that baffled even John Nash.
To solve the incredibly long service times in Mc Donald’s.
How many times have you walked into a sardine-packed Golden Arches and went through the hassle of waiting in line for more than ten minutes, only to realize that you’d have to wait five to ten more minutes to eat your Big Mac because the food that you want still has to be deep-fried (syn. cooked/prepared)?
Now, upon getting your order, paying your five hundred pesos to the cashier (who’s also the person serving you the food), and having to wait another five minutes, because the cashier is short-changed, you lift your tray and you weave through the thick lines and precariously dodge the first rows of chairs and tables, which are frustratingly placed too close to the line.
Well now, I can see that you’re nodding your heads in affirmation. Boys and girls, it’s time to apply what we’re learning in school (you have been listening after all, haven’t you?) and put the shit that’s stored in your ‘noggins into practical use.
Let’s apply Six Sigma and 5S to Mc Donald’s
Of Americans and why everything about them falls short of six
Six Sigma (6σ) is a system of practices originally developed my Motorola to systematically improve processes by eliminating defects (wiki).
Defects, on the other hand, are defined as units that are not members of the intended population (wiki). This is statistically defined as having 3.4 defects per 1,000,000 transactions (in layman’s terms, not having more than 3.4 cases of deviations beyond the allowable variance per 1,000,000 products or services). To easier understand the Six Sigma philosophy, here’s a breakdown of the number of defects per million transactions, and where 6σ is placed:
The Sigma Levels |
Sigma | Percent Defective | Defects per Million |
1 | 69% | 691,462 |
2 | 31% | 308,538 |
3 | 6.7% | 66,807 |
4 | 0.62% | 6,210 |
5 | 0.023% | 233 |
6 | 0.00034% | 3.4 |
7 | 0.0000019% | 0.019 |
For our case, we want to improve the number of customers being served satisfactorily in McDonald’s. Of course, in reality, a Six Sigma project should not have the solutions identified yet. For the sake of this post, let’s pretend that we don’t know the solution yet and we’re going through the process together.
DMAIC
One of the key methodology in Six Sigma is DMAIC, which stands for:
Define – which concerns the problem statement, the objective statement, necessary for identifying the problem.
Measure – which is about understanding the process, validating data accuracy, determining process capability, and setting baseline data.
Analyze – which is basically about forming the relationship of Y = f ( X ) + e (of causality), and screening for potential causes.
Improve – which is about determining, validating, and implementing solutions to achieve the objective statement, and
Control – which is about implementing process control methods and monitoring performance to sustain results.
Finally, to operationally define being served satisfactorily is, it is the amount of allowable idle time where a customer starts to fall in line, to transact their order, to receive a set meal (that is prepared consistently x% of the time. This should be another six sigma project), and sitting down to eat the meal. All of these should be done in about 4 minutes. Taking into consideration the maximum allowable variance of ±1 minute, the ideal time should be between 3-5 minutes (prescribed optimum are estimates, for the sake of discussion). Too early, and errors on food preparation, and money changing may arise. Too late, and customer satisfaction is diminished.
The below figure summarizes the macro process model for a Mc Donald’s cashier-cum-crew in taking orders (sorry for the grubby resolution).
The process begins with the cashier clearing the serving area of clutter from the previous transaction, prepares the tray, and takes the order from the customer.
The cashier then double-hats into a crew role and gathers the order list from the serving bay.
Three control points are first being asked in the general process: 1. does the order contain drinks? If yes, the crew proceeds in preparing the drink. 2. does the order contain sundaes? If yes, the crew proceeds in preparing the sundae, and 3. does the order contain food that needs to be cooked? If yes, the crew instructs the mess crew to prepare the orders and prepares them accordingly.
After putting everything together onto the tray, the fourth control point questions if the entire order list is accounted for.
The cashier issues the receipt, and the final control point asks if he is short changed or not. Everything easy so far?
Now, another quality improvement methodology that would come to play is 5S.
Of Japanese and why everything about them falls short of five
5S is a philosophy that originated in Japan, and is about the way of organizing and managing in the workplace. The key impacts of 5S is upon workplace morale and efficiency. By ensuring everything has a place and everything is in its place then time is not wasted looking for things and it can be immediately obvious when something is missing (wiki).
The real power of this methodology is in deciding what should be kept and where and how it should be stored.
This dialogue builds good clear understanding amongst a workforce of how work should be done and instills an ownership of the process when done efficiently. It is often, therefore, executed in partnership with standard work, which are operations for which these things are used (wiki).
The name derives from its five principal philosophies in Japanese characters, which all begins with “s”.
SSSSS
The 5S’s are:
Seiri – tidiness, organization
Seiton – orderliness
Seiso – systematized cleanliness
Seiketsu – standards
Shitsuke – sustaining discipline.
Identification and objective statement
As a company, the time duration for serving foods are not meeting the scheduling requirements. Overall, this is causing customer dissatisfaction, layout problems, and manpower deployment issues, as well as resource issues, that are costing the company as much as x in lost revenues and x for unnecessary expenditures per year.
We want to reduce the service time from an average of x to 4 minutes, with an upper limit of 5 minutes. this will meet the current maximum goal of x greater than x percent of the time. The new goal will be achieved by x month and year. it will support our serving efficiency goal (of that darn one time deal of being able to serve a customer in three minutes or less, provided that you take your order late at night and no one else is at the burger joint) and achieve an annual savings of x per month and significant implied projected earnings of x per month.
[End of part one]
Part two will talk about identifying areas of improvement. Again, these are all assumptions as there are no statistical information to establish baseline data.
Part two will also take a look at the macro process and reveal hidden processes that take up time (i.e. the rate at which fries are being deep fried are so slow that customers ordering would have to wait as new batches would have to be prepared to accommodate them).
Finally, part three will talk about applying the philosophy of 5S, in conjunction with Six Sigma. For example, the space between the first row of tables and chairs needs to be moved further from the cashier. More cashiers need to be open for service as too few ones are being used, hence the bottleneck effect, and manpower placement has to be thought of, i.e. those people who roam between lines and ask about your order, tallying them in teeny pads. Guess what, they’re not significantly improving the time of you being served. They might as well be put into better use as cashiers or crew people. The horizontal distance between cashiers should be extended as people carrying trays with their orders in it waste valuable time in dodging the lines (not to mention those pesky people who snug themselves across lines to pick up straws).