Please enable JavaScript.
Coggle requires JavaScript to display documents.
Kahaki Foods-Reducing Wastage (DEFINE (Collection of waste (Waste Bins,…
Kahaki Foods-Reducing Wastage
DEFINE
Problem Type
Daily waste
4976 pounds
Cost due to wastage
$601,000
Collection of waste
Waste Bins
Machines
Floors
Packaging Materials
Problem Consequences
Loss in Capital
Increase in workload
Sanitation Staff
Inspection Staff
Sanitation
Bad odour
Filth
Disease-prone
Formation of team
Employees
R&D
Finance
Scheduling
Process Improvement Engineer
Production Manager
Blueprint
SIPOC map
Supplier
Input
Process
Output
Customers
MEASURE
Metrics
Daily Waste
Key Performance Indicator
Total waste on bagger
Total waste in nugget line
Existing Waste
Zonal Areas
5 main zones
Subdivided into 14 zones
Greatest opportunities for improvement
Distinguishing zones
Paint
Labelling trashcans
Adding Greek Symbols
Composition of Waste
Batter applicators
% of batter
% of chicken
Fryers
% of tempura nuggets
% of crumb
Freezer entrances
% of tempura nuggets
% of crumb
ANALYSE
Monitor 14 sub zones
Cost for each zone
Waste Composition
Type of lost material
Meetings
Discuss each area
Loss in capital
Determine root cause for waste
Excess flour
Oil spill
Speed of blades
5 Whys
Statistical tests
Variance analysis
Correlation analysis
Sample t-tests
IMPROVE
Calculation of potential savings
24% reduction in daily wastage
Annual Savings of $178,000
Development of solutions
Provide standards for work
Add checks every 30 minutes to ensure bins are emptied
Development of system to capture lost nuggets
Carts to capture waste
Culture Enhancement
Create daily awareness
Daily performance
Company goals
Printouts of historical performances
CONTROL
Control Elements
Daily checklists
Confirm solution elements are used daily
Standard Operating Procedures
Show changes in process
Generate daily printouts
KPI Dashboard
Track daily waste percentage
Update waste tracking system