Using lean to improve a pizza restaurant - A case study

Let me share an interesting case study brought up by a student from my previous class this case study was published on Linkedin outlining the use of "Lean" to improve the processes at a pizza restaurant.

Stoelb (2016) wrote the case study in how to use Lean to improve a pizza restaurant. He states that, This experience reaffirmed that any process, no matter what it is or how small, can realize significant benefits from implementing lean.

The author recommended the following improvements based on Lean philosophy and practice which the restaurant implemented:

The ovens were relocated from the center of the work area, to be against the outside wall. This opened up a larger area for people and product flow, and gave more options to organization and storage of materials.

A small team of employees, with the owner, looked at and laid out a revised material storage area, based upon the concepts of reduced traveling.

Some additional shelving was added above the work areas that allowed for more storage area resulting in fewer trips to get replacement ingredients etc.

A visual system was created when ingredients, boxes etc were needed. By using a simple tack board, the items were listed on the board.

The storage of the delivery bags was moved from under the counter to near where the pizzas were taken from the oven, cut, and boxed. This reduces the traffic.

A minimum, throughout-the-shift cleaning schedule was created.

A new ticket control system was developed to ensure that orders were processed and delivered in the order taken.

A training format and classes were developed and used to re-train everyone on procedures and policies.

A time clock was put in place (the deliverer's idea) and when a person left to go on a delivery, the green copy of the order form would be 'stamped" with the time. When they returned, they once again "stamped" the same ticket. The average time per delivery has decreased by 25% in the short time that this system had been in place.

The order taker workstation was improved by adding shelves and keeping the worktable organized and free of "extraneous materials".

Measuring the ingredients more consistently was accomplished by having different size cups that were marked for each size pizza made. This simple technique significantly improved the consistency of the amount of ingredients that were put on each pizza, no matter who was making it.

It is estimated that the improved work organization and layout has reduced congestion, improved flow and reduced redundancy in movement by at minimum of 20%.

The author used this pizza case study to show that Lean method can improve organizations, workplace cleanliness, and improved productivity.