Professional Documents
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6 Sigma Project
Project number 1 Wednesday December 18, 2009
TABLE OF CONTENTS
Introduction Quality Management General Layout Observations Process Improvement Follow up Conclusion 2 4 5 19 19 20 21
Ford
Introduction
McDonald's Corporation is the largest fast-food operator in the World and was originally formed in 1955 after Ray Kroc pitched the idea of opening up several restaurants based on the original owned by Dick and Mac McDonald. Today, McDonald's operates more than 32,000 restaurants in over 118 countries at year-end 2008 and have one of the world's most widely known brand names. McDonald's sales hit $57 billion company-wide and over $25 billion in the United States in 2008 (McDonald Annual Report of 2008). McDonalds, the long-time leader in the fast-food wars, faced a crossroads in the early 1990s. Domestically, sales and revenues were flattening as competitors encroached on its domain. In addition to its traditional rivalsBurger King, Wendys, and Taco Bellthe firm encountered new challenges. Sonic and Rallys competed using a back-to-basics approach of quickly serving up burgers, just burgers, for time-pressed consumers. On the higher end, Olive Garden and Chilis had become potent competitors in the quick service field, taking dollars away from McDonalds, which was firmly entrenched in the fast-food arena and hadnt done anything with its dinner menus to accommodate families looking for a more upscale dining experience.
McDonalds Corporation 2111 McDonald's Dr Oak Brook, IL 60523 1-800-244-6227 E-mail: support@mcdonalds.com
MCDONALDS FRANCHISE
I am Lovin it!
Despitethisfuriouscompeti tionin2003,McDonalds servedanaverageof47million customersaday.In2008,the companysaverageincreased to58millioncustomersaday, anincreaseofabout25per centinjustfiveyears.Withthis hugenumberofcustomer servedadayMcDonald'slike anyothercompanyfocuson satisfyingtheircustomerby providinggoodfoodandser vice.McDonald'salsotargets businesscustomersasapartof theircorebusiness.Business customersmaystopduringthe workdayandcancountonfast service,andconsistentlygood food.Therefore,customers
waitingtime(beforegot served)isoneofthemostim portantfactorsthatMcDonalds focusedonlatelyinthisfast paceera. Afieldsamplescollectedfrom twoofthebusiestrestaurantin theregion.Thedatawascol lectedbasedonthetimewhen thecustomerordersthefood untilthetimethecustomerget thefoodonhands.Thewaiting timeinthequeuebeforeorder ingthefoodwasnotconsidered becauseofitswidevariability. Thewaitingtimeofsixtycus tomersweremeasuredbyone operator(toeliminatetheGage variability).
DuringthisSixSigmaproject study,oneprojectmethodology followed.Thismethodologyin spiredbyDemingsPlanDo CheckActCycle.Which,com prisingfivephaseseach,bear theacronymsDMAIC (Wikipedia,2009) DMAIC is used for projects aimed at improving an existing businessprocess.
DMAIC
TheDMAICprojectmethodologyhasfivephases:
Definehighlevelprojectgoalsandthecurrentprocess. Measurekeyaspectsofthecurrentprocessandcollectrelevant data. Analyzethedatatoverifycauseandeffectrelationships.
Determinewhattherelationshipsare,andattempttoensurethatall factorshavebeenconsidered.
Within the individual phases of a DMAIC project, Six Sigma utilizes many established qualitymanagement tools that are also used outside of Six Sigma.
Improveoroptimizetheprocessbasedupondataanalysisusing
techniqueslikeDesignofexperiments. Control to ensure that any deviations from target are corrected before
they result in de fects. Set up pilot runs to establish process capability, move on to pro duction, set control up
mecha
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Regression analysis Root cause analysis Run charts Stratification Thought process map
Analysis of variance Business Process Mapping Catapult exercise on variability Cause & effects diagram Chi-square test of independence and fits Control Chart Correlation Cost-benefit analysis CTQ tree Quantitative marketing research through use of Enterprise Feedback Failure mode and effects analysis (FMEA) General linear model Histograms Quality Function Deployment (QFD) Pareto chart Process capability
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DMAIC
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
2 2.5 1.5 2 2 4.5 2.5 3 3.5 2.5 3 2 2.5 4 4.5 3 2.5 2.5 2 3
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
3.5 4.5 4.5 3 2 2.5 2 3 2.5 2.5 3 3 2 2.5 2.5 4 3.5 3 3 2.5
41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60
Table1:Sample data used for this study (from two restaurants; location A and B)
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Old vs New
Food Temperature
Lack of Training
Wear
Cause
Unknown Quality
Cleaning Process Time Of Cooking
No Instruction
Employees number
Slow-food Cooking
Taste
Task vs Multi-tasks
Qualified
Not Busy
Pre-cooked Food
Location
Busy
Controled Process
Coffee Quality
Meat Quality
Materials
Figure 1: Cause and Effect Diagram for McDonalds Serving Time Improvement. CauseandEffectDiagramisadiagramthatshowsthecausesofacertainevent.Commonuses oftheC&Ediagramareproductdesignandqualitydefectprevention,toidentifypotentialfac torscausinganoveralleffect.Eachcauseorreasonforimperfectionisasourceofvariation. Causesareusuallygroupedintomajorcategoriestoidentifythesesourcesofvariation. TheC&EDiagramisusedtounderstandtherelationshipbetweenKPIVsandKPOVs.Itcanhelp initiateexperimentalinvestigations.TheKPIVsareinputstovaryandrecord,theKPOVisare sponsetomeasure.Theseexperiments,naturalorDOE,canbeanalyzed.TheC&Ediagram alsoprovidestheinitialinputtotheprocessFMEA.Whenever,aKPOVdriftsoutofspecifica tionthatisan"Effect".Whenthathappens,theC&Ediagramshouldhavelistedwhateverthe "Cause"was,asaKPIVgoingoutofspecification. Also,theC&EmatrixisusedinitiallyintheDefinestagetoprioritizetheissuestofocuson. WhatbusinessesarelookingforaretheParetoissueswhere20%ofeffortwillgive80%ofthe gain.ThisisaStrategicPlanningadaptationoftheC&Ediagramhelpingorganizationsidentify theaspectsoftheirplanthataremostcriticaltoitsoveralleffectiveness.Thiswasusedtocom parecustomerrequirementswithprocesssteps,andidentifyiftheprocessalignedwithcus tomerrequirements. TheoutputsfromtheC&EdiagramarethenfedintoaprocessFEMA(EffectAnalysis)tohelp assesswhatmightgowrongwiththecriticalaspectsoftheplan.
Current and planned Ford hybrid electric vehicles: 2004 Ford Escape Hybrid 2006 Mercury Mariner 2008 Ford Fusion/ Mercury Milan
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FMEAStudy
Process Function (Step) Start Customer enter the restaurant Cashier Available Wait to place Order Place Order long waiting time long waiting time longer than expected longer than expected take long time require one employee to do it. take long time require one employee to do it. Customer not able to serve him self Took longer time Not hot and tasteless Took longer time Bad service Bad service Custer leave Bad service Take loner time to prepare Take loner time to prepare Frustrated customers Frustrated customers Less people will drink Coffee Frustrated customers 4 4 5 4 Bad service Bad service Bad service Bad service Not enough employees to do this order in time. Not enough employees to do this order in time. Do not know how. long waiting time long waiting time long waiting time 4 4 4 4 Inspection Inspection Inspection Inspection Inspection 4 4 4 4 64 64 100 64 Potential Failure Modes (process defects) Potential Failure Effects (KPOVs) Potential Causes of Failure (KPIVs) Current Process Controls OCC RPN SEV DET
120
Employee prepare special item Self service drink Meal is ready Customer wait Customer served End (Customer leave)
80
3 6 4 4
2 5 4 2
3 4 3 2
18 120 48 16
According to the FMEA table the strongest point of the process are 1) the Meal is ready (took more than 5 minutes waiting), 2) the order contain special items (special drink; ice cream, McCafee, Mocha, Expresso, etc), 3) waiting time to place the order and finally the employee taking too much time preparing special order (items). Special items require extra work and should be made fresh and most of the time you have one employee take care of one order at the time. The weakest point of the process are the customer self service drink and when the customer served in less than 4 minutes. According the table 2 the strongest points of the process Figure 2 and Figure 3 show McDonalds Service Process chart and Service Blueprint respectively.
Start
Cashier available?
No
Yes
Place order
Yes
Payment
No
Yes
Meal is ready?
Yes
Customer served
End
No
Customer wait
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100 60 40 20
? dy er rd O er rd er ? le
Process function
t t er er ai an th rd rd w a ab ur O o O a re lO al er e st s ce ce Av cia th li la om re la e r p P st in e ea ie sp k to th M Cu e sh in it r r r a Ca te pa lD W en re ia p ec er e Sp ye om o st pl Cu m E RPN 120 120 100 80 64 64 64 48 34 Percent 17.3 17.3 14.4 11.5 9.2 9.2 9.2 6.9 4.9 Cum % 17.3 34.6 49.0 60.5 69.7 79.0 88.2 95.1 100.0
Percent
80
RPN
After examining the output from the Pareto Chart the following recommendation has been made: We have to focus on resolving the issue of number of order per customer (family order) and the existing of special items. The special items must be prepared fresh and cant be prepared in advance. Therefore, McDonalds employee must prepare each order separate and as consequence the serving time increases from an average waiting time of 3 minutes to more than 5 minutes.
We have to identify where human error can cause mistakes or slowness to occur, especially in processes that rely on the workers attention, skill or experience. We have to establish a standard to inspect the special drink preparation, storage, and employee speed and quality of order in order to reduce the risk of have customer waiting too long for their Expresso or Mocha to be ready. A continuous process improvement and self inspection could eliminate a lot of risk in the process too.
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TheidealMcDonaldscustomerswaitingtimeisbetween2.5minutesto4minuteswherethe freshnessofthefoodwontbesacrificedforthefastservice. Followupitems: Keepthefreshnessofthefoodinmind. Addmoregrillersifnecessary Successiveinspectionisdoneatthenextstepoftheprocessbythenextworker. Selfinspectionmeansworkerschecktheirownworkimmediatelyafterdoingit. Sourceinspectionchecks,beforetheprocesssteptakesplace,thatconditionsacorrect. Oftenitsautomaticandkeepstheprocessfromproceedinguntilconditionsareright. CrosstrainingforMcDonaldsemployees. Forlargerorder(familyorder)musthavetwoemployeestoreducethewaitingtime. Musttreatlargerorderasindividualorderinordertoreducethewaitingtime Payattentiontoorderthathavespecialdrinklike(Icecream,McCafe,Mocha,Expresso, andsoon.)because,thiskindofdrinkrequireexpertisetopreparethemandtime.
DescriptiveStatistics:RestaurantA
Total Variable Restaurant A Count 60 N CumN 60 Percent 100 Mean 2.8417 SE Mean 0.0932 TrMean 2.8056
60
Sum of Variable Restaurant A StDev Variance 0.5211 CoefVar 25.40 Sum 170.5000 Squares 515.2500 N for Variable Restaurant A Median 2.5000 Q3 3.0000 Maximum 4.5000 IQR 0.5000 Mode 2.5 Mode 19 Skewness 0.76 Kurtosis 0.12 Minimum Q1 2.5000
0.7219
1.5000
Variable Restaurant A
MSSD 0.3792
15 F requency
10
1.6
4.0
P ercent
3 Location A
Figure 2: Probability Plot of McDonalds Location A Examining Figure 1 and 2 plots the data of restaurant in location A is not normally distributed which mean that the McDonalds waiting time does not follow the normal distribution. The descriptive statistics of restaurant in location A indicates that the average time to serve a customer is 2.8417 minutes and the standard deviation 0.7219. The minimum and the maximum time to serve a customer was 1.5 and 4.5 respectively. The median of this sample is 2.5 minutes.
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Variable Restaurant B
MSSD 0.611
Here the data distribution is skewed and have tail in the right it looks like a Gamma distribution.
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Percent
3 4 Location B
Figure 5: Probability Plot of McDonalds Location B Examining Figure 4 and 5 plots the data of restaurant in location B is not normally distributed which mean that the McDonalds waiting time does not follow the normal distribution. The descriptive statistics of restaurant in location B indicates that the average time to serve a customer is 2.855 minutes and the standard deviation 0.899. The minimum and the maximum time to serve a customer are 2 and 6.5 minutes respectively. The median of this sample is 2.5 minutes. The skewness of the data is 1.76. The high skewness is due to the assignable cause forcing the customer to wait The average time more than to serve a customer 5 minutes is 2.855 minutes to receive and the standard the meal. deviation 0.899
_ X=2.842
LSL=2
1 1 7 13 19 25 31 37 Observation 43 49 55
LCL=1.016
Figure 6: Individual Chart of McDonalds Location A The Individual chart for location A indicates that the process is in control all the observations are inside the LCL and the UCL (scattered around the process mean). However based on our research we find out that McDonalds have policy to control the total waiting time for their customer the USL should be less than 5 minutes and LSL should be more than 2 minutes (customer should expect to wait at lest 2 minutes). We chose here UCL=4.5 minutes and LSL=2 minutes in order to show that there are few customers can complain about the process.
I d u Valu n ivid al e
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The Individual chart for location B indicates that the process is in control all the observations are inside the LCL and the UCL (except the point number 29 where the waiting time was 6.5 minutes due to a large family order). All the observation scattered around the process mean. The process showed that few customers their waiting time exceed the USL
Xbar Chart of McDonald's Location A
5 UCL=4.667 USL=4.5 4 S p M am le ean
_ _ X=2.842
LSL=2
1 1 7 13 19 25 31 Sample 37 43 49 55
LCL=1.016
Figure 8: Xbar Chart of McDonalds Location A The xbar chart for location A indicates that the process is in control all the observations are inside the LCL and the UCL (scattered around the process mean).
Xbar Chart of McDonald's Location B
7 6 5 S p M am le ean 4 3 2 1 LCL=0.601 0 1 7 13 19 25 31 Sample 37 43 49 55 _ _ X=2.855 LSL=2 UCL=5.109 USL=4.5
1
The xbar chart for location B indicates that the process is in control all the observations are inside the LCL and the UCL (except the point number 29 where the waiting time was 6.5 minutes due to a large family order).
Xbar-R Chart of Restaurant A, ..., Restaurant B
5 U C L=4.595 Sam ple Mean 4 3 2 1 1 7 13 19 25 31 Sample
1
_ _ X=2.848
LC L=1.102 37 43 49 55
U C L=3.034
_ _ X=2.855
LSL=2
1 1 7 13 19 25 31 Sample 37 43 49 55
LCL=1.181
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Figure 15 shows the data plotted by stage (by location). The process shows that the average time to serve a meal at McDonalds is the same across the two locations. However, the process overall have a little variability because of the uniform policy and procedures across all McDonalds locations. There are few exceptions due to the variability of the customers visiting the restaurant (different customers in each location).
Between/Within Capability of McDonald's Location A
LSL
P rocess D ata LS L 2 T arget * USL 4.5 S ample M ean 2.84167 S ample N 60 S tD ev (B etw een) 0.775709 S tD ev (Within) 0 S tD ev (B /W) 0.775709 S tD ev (O v erall) 0.721884
1.6
O bserv ed P erformance P P M < LS L 16666.67 PPM > USL 0.00 P P M T otal 16666.67 E xp. B/W P erformance P P M < LS L 138954.50 PPM > USL 16265.33 P P M T otal 155219.83
2.4
3.2
4.0
E xp. O v erall P erformance P P M < LS L 121821.09 PPM > USL 10802.79 P P M T otal 132623.88
1
O bserv ed P erformance P P M < LS L 0.00 P P M > U S L 33333.33 P P M T otal 33333.33
E xp. B/W P erformance P P M < LS L 143616.87 PPM > USL 20303.80 P P M T otal 163920.67
E xp. O v erall P erformance P P M < LS L 170900.72 PPM > USL 33703.18 P P M T otal 204603.90
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OBSERVATIONS
The menu at McDonald's typically consists of hamburgers, chicken sandwiches, salads, drinks, shakes, and a recent influx of healthier alternatives. McDonald's also is widely known for their breakfast menu, which consists of sandwiches, pancakes, French toast, hash browns, breakfast, Coffee, and a large variety of drinks. During the phase of collecting data an assignable cause observed during the food serving. Most customers in both restaurant who had a waiting time more than the USL=4.5 minutes they had an item that is considered special order (e.g.: McCafe, Mocha, Espresso, Ice cream, or Smoothed milk) or a combined order for more than one person. In addition the highest waiting time observed in location B was 6.5 minutes. The reason for this long waiting was due to the fact that this order was for a family of 5 kids and three adults. Also, we observed that most of
PROCESS IMPROVEMENT
1. Add more burger cooking space (larger stoves). 2. Add more frying containers for the French fries 3. Add more workers to prepare each order; do not wait until more collect 4 to 5 order to deliver them to the waiting customer. 4. Separate the process of food preparation. 5. Add more cashier 6. Have the manager present in the store all the time. 7. Have the cashiers after taking orders help in preparing the special drinks (items). 8. Cross training of the employees (train the cook to be able to do different functions in the process). 9. Train the drive thru employees to be able to help in different functions when it is necessary in the busy time. 10. Design a service for family orders.
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4. Provide reasonable assurance regarding prevention or timely detection of process mal functioning that might harm the company assets. 5. Provide efficient internal controls which assess the effectiveness of the process, including the possibility of human error and the circumvention or overriding of controls. 6. Provide a mechanism to reduce the variability of the process across multiple locations. 7. Establish a measurement criteria to test continuously evaluate the process functionality and effectiveness.
Conclusion
Despite McDonald's is well known for their maximum customer focus. McDonalds faces some difficult challenges. Key to its future success will be maintaining its core strengthsan unwavering focus on quality and consistencywhile carefully experimenting with new options. These innovative initiatives could include a brilliant idea to make the waiting time of their customers an enjoyable time (life experience). In addition, McDonalds should have a separate brand name company responsible for maintaining McDonalds compliance with safety, quality, environment, and customers satisfaction. A brand new branch will improve the company image and will reduce the company risk toward loosing ground for competitors. The company also could look into improving their service toward family orders (large orders).
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References
[1] http://www.mcdonalds.com/ [2] www.analist.nl/reports/mcdonalds-2008.pdf [3] http://en.wikipedia.org/wiki/McDonald%27s [4] www.encyclopedia.com/doc/1G1-71707946.html [5] https://news.fidelity.com/news/news.jhtml? cat=MarketBeat&articleid=200911130921MRKTWTCHWSJ_MRKB_30C04424-C2D4-D422D354-B056E088919D&IMG=N [6] http://mcchronicles.blogspot.com/2008/07/wall-street-manhattan-mcdonalds.html [7] http://blogs.barrons.com/stockstowatchtoday/2009/11/09/mcdonalds-us-sales-stall/
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