Process Engineering
EPS-I Process Engineering
1
Overview



Process Engineering
Process Mapping
HW 5 – 7 and Taco Bell Example
EPS-I Process Engineering
2
Engineering and Process Engineering

Engineering often involves building a model
of an entity



Stresses on a bridge (Civil Engineering)
Flow of electricity in a circuit (Electrical
Engineering)
Process Engineering involves building a
model of a process (usually multi-step,
parallel or series operations)
(Industrial/Management Engineering)
EPS-I Process Engineering
3
A Process


A good definition of a process describes it as a
series of connected steps or actions to achieve an
outcome.
A process has the following characteristics:





a starting point and an end point. This is the scope
a purpose or aim for the outcome
rules governing the standard or quality of inputs throughout
the process
it is usually linked to other processes
it can be simple and short, or complex and long
From: NHS, UK
EPS-I Process Engineering
4
Examples of different processes



From ordering a taco to receiving it.
From first developing symptoms of a gastric
ulcer to being discharged as fit
From the doctor saying that you need a chest
x-ray to knowing the results
EPS-I Process Engineering
5
Process Map



A flow diagram to help create a better
understanding of the processes.
Can model each process.
Can eliminate or improve each process.
EPS-I Process Engineering
6
Process Mapping



Use to graphically show the processes
involved
Allows for examination of processes
(elimination or improvement)
Used in manufacturing, logistics, and medical
areas
EPS-I Process Engineering
7
HW5-7: Fast Food Systems

Aims





Work as a team
Examine an application of process engineering to
see how an example restaurant operates
Give presentation on your results
Select fast food restaurant.
Visit and examine their operation.
EPS-I Process Engineering
8
HW5-7: Fast Food Systems

How does the restaurant handle product
variety?



Examine menu of restaurant (ignore minor items)
Identify the food inputs for the main menu items
(again, ignore minor items)
How does the restaurant handle speed of
delivery?



Produce a process map using IDEF3
How is customer wait time reduced?
How does it handle bulges in demand?
EPS-I Process Engineering
9
Fast Food Providers

Customer requirements






Low cost
Fast
Variety
Consistency
Safe, clean, convenient, pleasant surroundings
HW5-7 will mainly examine how a fast food
restaurant meets these requirements
EPS-I Process Engineering
10
Two Main Approaches to Making Items
for Customers

Make in advance of customer order (“Push”)


Make to Customer Order (“Pull”)



Examples: car dealers lot, McDonalds standard
items.
Make after customer has ordered.
Examples: Taco Bell, Dell computers
What are advantages/disadvantages of each
for fast food restaurants?
EPS-I Process Engineering
11
Taco Bell
(think outside the bun)



Products include: burritos, tacos, gorditas,
chalupas, nachos and quesadillas
Some background: Taco Bell have re-engineered
their operations to a k-minus (kitchenless) operation,
meaning that most food preparation operations were
taken from the stores to centralized facilities.
This has resulted in significant cost savings,
reduced space requirements and increased quality
control. They also eliminated middle-management
layers and implemented the TACO (Total
Automation of Company Operations) program to
give an integrated information system.
EPS-I Process Engineering
12
These changes have had a huge impact on the
company -- Taco Bell went from a failing regional
Mexican -American fast food chain with $500 million
in sales in 1982, to a $3 billion national company 10
years later
The K-Minus program, or kitchenless- restaurant,
established a system where the large majority of
food preparation occurs at central commissaries
rather than in the restaurant, pushing 15 hours of
work a day out of the restaurant, improving quality
control and employee morale, reducing employee
accidents and injuries, and resulting in substantial
savings on utilities.
From: http://future500.org/case_02.php
EPS-I Process Engineering
13
Main Menu Items


Value

Spicy Chicken Soft Taco

Spicy Chicken Burrito

Grande Soft Taco

Double Decker Taco

1/2 lb Bean Burrito Especial

1/2 lb Beef Combo Burrito

1/2 lb Beef and Potato Burrito
Tacos

Original Taco

Taco Supreme

Soft Taco

Ranchero Chicken Soft Taco

Soft Taco Supreme

Grilled Steak Soft Taco

Double Decker Taco

Double Decker Taco Supreme®



Burritos

Bean Burrito

7-Layer Burrito

Chili Cheese Burrito

Burrito Supreme®

Fiesta Burrito

Grilled Stuft Burrito
Gordita

Gordita Supreme®

Gordita Baja®

Gordita Nacho Cheese
Chalupa

Chalupa Supreme

Chalupa Baja

Chalupa Nacho Cheese
EPS-I Process Engineering
14
Main Ingredients

Wraps





Soft tortilla
Hard taco shell
Flatbread (Gordita)
Chalupa
Meats



Chicken
Beef
Steak

Other










Beans
Lettuce
Onions
Cheese
Red sauce
Potatoes
Sour cream
Tomatoes
Rice
Guacamole
EPS-I Process Engineering
15
Taco Bell

How does the restaurant handle product
variety?
EPS-I Process Engineering
16
Simplified Taco Bell Process Map
Ingredients
Prepared 1
Number shows worker ID
Customer
Orders
Order
Entered 2
Order
Assembled 3,4
Customer
Waits
EPS-I Process Engineering
Order
Delivered
17
Taco Bell

How does the restaurant handle speed of
delivery?



How is customer wait time reduced?
Where does it use Pull and/or Push approaches?
How does it handle bulges in demand?
EPS-I Process Engineering
18
Taco Bell

How does Taco-Bell meet other customer
requirements?

Low cost


Consistency


Training, uniform measures
Safe, clean, convenient, pleasant surroundings


Ingredients, central preparation of food, small site, low
wage labor
Well?
How can operations be improved?
EPS-I Process Engineering
19