1. JAMES YUNG DSES-6620 Simulation Modeling and Analysis Project Description: 1. ABSTRACT This report discusses and examines the results from a ProModel software simulation model of a Chinese Restaurance kitchen during the busy evening hours of Sunday night. The report and model will analyze the kitchen throughput, in term of number of meals produce, from two different workflow setup, and give suggestion for choosing the better one based on results of the simulation model. 2. OBJECTIVES The objective of this modeling exercise is to be able to simulate the operation of the Restaurance kitchen during the busy hours. The model simulation will allow examination of order received and flow process through the kitchen to draw improvement to increase the throughput of meals and to minimize the waiting time of orders from received to made for deliver. 3. SCOPE The model is limited to modeling the continuous work flow of each chef and does not take into account of the followings:  Worker break-time (rarely taken during busy hours)  Cost (fix pay per day work for every worker)  Wrong order cooked (no rework) The limitations are legitimated based on a Chinese restaurance business model. This simulation study objective only requires determining the throughput during busy hours (5pm to 8pm) when maximum demand is required from the kitchen. In a typical weekend, the orders can be divided into three different groups: Single queue with 3 different servers Three different queues to 3 different servers

2. Collect Data in 5 weeks period

3. 4 hrs = 2400 min 2400 / 72.6 = 3.3 orders per min P(AP) = 55% P(MN) = 30% P(SP) = 15% Draw Input Conditions based on 5 weeks data collected from 5 pm to 8 pm:

4. Arrivals N ( 3.3,.3) 1 hour warm-up time 4 hrs run with 10 replications 5 min extra required to cook non-specialty meals Chef_AAP: N(5,1) SP: N(20,3) MN: N(15,2) Chef_SPAP: N(10,3) SP: N(15,1) MN: N(15,3) Chef_MNAP: N(10,2) SP: N(20,2) MN: N(10,1) Input condition:

5. Output: REPLICATION ANALYSIS (Sample size 10) Statistic Avg Low 95% CI High 95% CI ------------------------ ---- ---------- ----------- AP - Total Changes 42.5 39.4793 45.5207 FIFO_AP - Total Changes 36 31.476 40.524 Main - Total Changes 19.2 17.3593 21.0407 FIFO_MN - Total Changes 18.7 16.0225 21.3775 QTY - Total Changes 71.8 70.4179 73.1821 FIFO_QTY - Total Changes 64.4 61.2875 67.5125 SP - Total Changes 10.1 8.23928 11.9607 FIFO_SP - Total Changes 9.7 7.79102 11.609 Corrected number of meals cooked are the Total change value of AP, SP, MN and QTY.

6. REPLICATION ANALYSIS (Sample size 10) Statistic Avg Min Max ------------------- ---- --- --- AP - 35.6 26 50 MN - 18.3 11 22 QTY - 63.6 58 71 SP - 9.7 8 11 FIFO_Kitchen Throughput from 5 pm – 8pm Chefs are busy all the time

7. Distribute_Kitchen Throughput from 5 pm – 8pm A_CHEF - % Util 84.91 M_CHEF - % Util 77.77 S_CHEF - % Util 67.04 REPLICATION ANALYSIS (Sample size 10) Statistic Avg Min Max -------------------- ---- --- --- AP - 40.8 31 47 Main - 19.7 16 23 QTY - 72.1 69 74 SP - 11.6 9 15

8. ENTITY ACTIVITY (Time stall in the kitchen) FIFO_Kitchen Average Average Average Average Average Current Minutes Minutes Minutes Minutes Minutes Entity Total Quantity In In Move Wait For In Name Exits In System System Logic Res, etc. Operation Blocked ------ ------- --------- --------- -------- --------- --------- -------- Meal 0 1.4 - - - - - (Average) Meal 0 0.516398 - - - - - (Std. Dev.) Meal A 35.6 8 34.998543 0.166000 17.995812 13.197412 3.639319 (Average) Meal A 7.07421 3.43188 7.884183 0.000000 7.371682 0.513169 0.314182 (Std. Dev.) Meal S 9.7 2.3 40.613202 0.166000 13.214442 23.884894 3.347866 (Average) Meal S 1.1595 1.63639 7.859942 0.000000 6.901122 0.881158 1.024611 (Std. Dev.) Meal M 18.3 3.7 39.687849 0.166000 17.314115 18.312140 3.895594 (Average) Meal M 3.62246 2.75076 7.278683 0.000000 6.943116 0.587160 0.520118 (Std. Dev.) DIS_Kitchen Meal 0 3 - - - - - (Average) Meal 0 0.471405 - - - - - (Std. Dev.) Meal A 40.8 2.1 21.781616 0.295000 3.031991 15.099593 3.355032 (Average) Meal A 4.93964 0.875595 3.455094 0.000000 2.603878 0.226648 0.928918 (Std. Dev.) Meal S 11.6 1.3 35.650320 0.384000 3.143700 25.121059 7.001561 (Average) Meal S 2.319 1.05935 6.388774 0.000000 3.768347 0.339092 2.996392 (Std. Dev.) Meal M 19.7 1.5 29.671632 0.424000 3.863329 19.908107 5.476196 (Average) Meal M 3.0203 1.17851 7.237355 0.000000 4.443849 0.320514 2.770553 (Std. Dev.)

9. 1.Chefs utilization output data shows the Dis_kitchen require less work from each chef. 2.Number of meals throughput are also higher in DIS_KITCHEN than FIFO_KITCHEN. 3.Entity Activity table shows average time meal wait for process is greater in the case of FIFO_Kitchen setup.

10. DIS_KITCHEN Chefs Average Minute Per Entry REPLICATION ANALYSIS (Sample size 10) Statistic Avg Min Max ---------------------------------- --------- --------- --------- A_CHEF - Average Minutes Per Entry 4.961354 4.707368 5.345344 M_CHEF - Average Minutes Per Entry 9.488253 9.098706 10.059947 S_CHEF - Average Minutes Per Entry 13.849531 12.730250 15.368300 Validation and Verification 1.Total change value of AP, SP, MN and QTY are the corrected number of dishes cooked 2.C.I. Calculate based on Min Max values after warm-up which is not true representation of the actual system throughput from 5 pm to 8 pm.

11. Average Variable Total Minutes Minimum Maximum Current Average Name Changes Per Change Value Value Value Value -------- -------- ---------- -------- -------- -------- -------- FIFO QTY 64.4 3.699230 11.1 75.5 75.5 43.8272 (Average) FIFO QTY 4.35125 0.221134 1.28668 3.92287 3.92287 2.47939 (Std. Dev.) FIFO AP 36 6.650917 5.7 41.7 41.7 23.9937 (Average) FIFO AP 6.32456 1.217403 2.31181 5.2504 5.2504 3.12299 (Std. Dev.) FIFO SP 9.7 25.163349 1.7 11.4 11.4 6.5543 (Average) FIFO SP 2.66875 9.988899 1.41814 3.33999 3.33999 2.92238 (Std. Dev.) FIFO MN 18.7 12.805729 3.7 22.4 22.4 13.2793 (Average) FIFO MN 3.74314 2.295091 1.82878 4.27395 4.27395 3.0619 (Std. Dev.) FIFO Ml 73.2 3.255722 17.1 90.3 90.3 53.9124 (Average) FIFO Ml 0.788811 0.037930 0.316228 0.823273 0.823273 0.435939 (Std. Dev.) QTY 71.8 3.304031 11.6 83.4 83.4 47.336 (Average) QTY 1.93218 0.086214 0.966092 1.50555 1.50555 0.971072 (Std. Dev.) AP 42.5 5.614435 6.8 49.3 49.3 27.7098 (Average) AP 4.22295 0.543032 1.8738 4.83161 4.83161 3.03304 (Std. Dev.) SP 10.1 22.657472 1.4 11.5 11.5 6.46964 (Average) SP 2.60128 4.950216 1.07497 3.02765 3.02765 1.97236 (Std. Dev.) Main 19.2 12.302016 3.4 22.6 22.6 13.1566 (Average) Main 2.57337 1.834326 1.26491 3.1693 3.1693 2.06287 (Std. Dev.) ML 72.5 3.284489 17.4 89.9 89.9 53.7278 (Average) ML 1.08012 0.039790 0.516398 1.19722 1.19722 0.667982 (Std. Dev.)

13. Questions ???????????????????