PART $4$: LEAN OPERATIONS

Part $4$ is the continuation of Part $3.$ Part $3$ is mainly about how the restaurant operates given

the current settings. Part $4$ goes further to identify wastes and eliminate them, which is the

notion of lean operations. To enrich your work, you would need to review and apply the

concepts of lean operations in Module $06$ and methods of process improvements in Module $04.$

In your report of this part, you need to present the following:

$($a$)$ Explicitly state the wastes that you see in the U$-$profile in Part $3.$ State if the process is

balanced or not. Briefly discuss the effects of the wastes on production, revenue, and profit.

$($b$)$ A brief proposal on how to eliminate the wastes that you find. $($Hint: labor reconfiguration$)$

$($c$)$ A new Extended Table to show how your proposal in $($b$)$ can work. Essentially, you would do

some experiments $($trials and errors$)$ with the new Extended Table in Excel where:

The total number of employees stays unchanged throughout your experiment.

Assume that you already cross$-$trained the workers and, hence, you can easily move them

around the resources.

The number of workers at one resource can be understood as the percentages of time they

work at that resource or station $($for example: two workers work full time or $100\%$ and the third

worker spends only $35\%$ of his$/$her time at that station$).$ Thus, the number of workers can be

presented as a decimal number $($for example: $2\mathrm{.}350$ workers$).$

You can move the workers around the resources with increments as fine as $0\mathrm{.}001$ workers.

With a new labor setup, you should achieve all utilizationPart $3$ Confused on how to calculate the new processing times to balance the IU profile. Please help

$\backslash$table$[[$Labor and technology settings,R$1,$R$2,$R$3,\backslash$sqrt$($R$4),\backslash$bar $($R$5),\backslash$bar $($R$6)],[$Number of workers,$5,5,4,2,2,2],[$Processing time for A $($minutes$/$unit$/$worker$),,,,22,0,11],[$Processing time for B $($minutes$/$unit$/$worker$),1\mathrm{.}5,2\mathrm{.}5,1\mathrm{.}5,0\mathrm{.}5,0,1],[$Processing time for C $($minutes$/$unit$/$worker$),2\mathrm{.}5,1,0,0,3,1],[$Resource capacities in minutes of work, per hour and per day $(10$ hours$)],[$Capacity $($minutes$/$hour$),300,300,240,120,120,120],[$Capacity $($minutes$/$day$)(10$ hours$/$day$),3000,3000,2400,1200,1200,1200],[$Demands in product units, workloads in minutes, and original implied utilizations$],[$Demand for A $($units$/$day$),540,,540,540,,540],[$Demand for B $($units$/$day$),621,621,621,621,0,621],[$Demand for C $($units$/$day$),459,,,0,,],[$Workload on A $($minutes$/$day$),810,1620,1350,1080,0,540],[$Workload on B $($minutes$/$day$),931\mathrm{.}5,1552\mathrm{.}5,931\mathrm{.}5,310\mathrm{.}5,0,621,-1],[$Workload on C $($minutes$/$day$),1147\mathrm{.}5,459,0,0,1377,459],[$Total workload $($minutes$/$day$),2889,3631\mathrm{.}5,2281\mathrm{.}5,1390\mathrm{.}5,1377,1620],[\backslash$table$[[$Implied utilization $(\%,2$ decimals$)]],96\mathrm{.}30\%,\backslash$table$[[121\mathrm{.}05\%]],95\mathrm{.}06\%,\backslash$table$[[115\mathrm{.}88\%]],114\mathrm{.}75\%,135\mathrm{.}00\%],[$DAR $=1/$ IU$,74\mathrm{.}07\%,,,,,],[$Flow rate of A $($units$/$day$),400,400,400,400,0,400],[$Flow rate of B $($units$/$day$),460,460,460,460,0,460],[$Flow rate of C $($units$/$day$),340,340,0,0,340,340],[$Effective workload on A $($minutes$/$day$),600,1200,1000,800,0,400],[$Effective workload on B $($minutes$/$day$),690,1150,690,230,0,460],[$Effective workload on C $($minutes$/$day$),850,340,0,0,1020,340],[$Total effective workload $($minutes$/$day$),2140,2690,1690,1030,1020,1200],[$Effective IU $(\%,2$ decimals$),71\mathrm{.}33\%,89\mathrm{.}67\%,70\mathrm{.}42\%,85\mathrm{.}83\%,85\mathrm{.}00\%,100\mathrm{.}00\%],[$Utilization $(\%,2$ decimals$),71\mathrm{.}33\%,89\mathrm{.}67\%,70\mathrm{.}42\%,85\mathrm{.}83\%,85\mathrm{.}00\%,100\mathrm{.}00\%]]$

$4$ is the continuation of Part $3.$ Part $3$ is mainly about how the restaurant operates given

the current settings. Part $4$ goes further to identify wastes and eliminate them, which is the

notion of lean operations. To enrich your work, you would need to review and apply the

concepts of lean operations in Module $06$ and methods of process improvements in Module $04.$

In your report of this part, you need to present the following:

$($a$)$ Explicitly state the wastes that you see in the U$-$profile in Part $3.$ State if the process is

balanced or not. Briefly discuss the effects of the wastes on production, revenue, and profit.

$($b$)$ A brief proposal on how to eliminate the wastes that you find. $($Hint: labor reconfiguration$)$

$($c$)$ A new Extended Table to show how your proposal in $($b$)$ can work. Essentially, you would do

some experiments $($trials and errors$)$ with the new Extended Table in Excel where:

$$ The total number of employees stays unchanged throughout your experiment.

$$ Assume that you already cross$-$trained the workers and, hence, you can easily move them

around the resources.

$$ The number of workers at one resource can be understood as the percentages of time they

work at that resource or station $($for example: two workers work full time or $100\%$ and the third

worker spends only $35\%$ of his$/$her time at that station$).$ Thus, the number of workers can be

presented as a decimal number $($for example: $2\mathrm{.}350$ workers$).$

$$ You can move the workers around the resources with increments as fine as $0\mathrm{.}001$ workers.

$$ With a new labor setup, you should achieve all utilizations close to $100\%,$ e$.$g$.$ more than $99\%.$