One of our clients, a manufacturer of agricultural and construction equipment, had an existing combine component paint system which was not able to keep up with their projected sales. As a result, they had decided to redesign their paint system to enhance its capacity with a target of a +30% capacity increase.

Reason for Project:

• Before investing in new paint system equipment ($3MM), the client wanted to model the system in order to quantify the impact of planned design changes. In addition, the client wanted to use the simulation model as a basis for the conveyor control system logic and to consider alternative load/unload station configurations.

Project Deliverables:

• Created a computer simulation model (ProModel) of the conceptual paint system including the load/unload stations, power-and-free conveyor systems, prep and paint booths, cure ovens and cool-down operations.
• Assisted in the system redesign efforts using the simulation model as a collaborative tool.
• Worked with the controls engineers to document the planned software changes.

Project Results/Benefits:

• Capacity Increase: Significantly increased the paint system capacity through the redesign efforts (30% improvement).
• Investment Reduction: The model was used to redesign the e-coat dip process (crane sequence) so that an additional, planned $500,000 crane would not be required.
• Control Systems Design: The project uncovered some existing controls system logic issues and was used as a basis for the new controls system logic for the power-and-free conveyors.

Bob Evans was evaluating the design of a new compressed restaurant layout concept.

Reason for Project:

• Bob Evans wanted to evaluate the design of the new concept using their base simulation model already developed.

Project Deliverables:

• Completion of an analysis of the new layout concept to understand opportunities for improvement in the kitchen system design.
• Recommendations for improving the kitchen systems based upon the initial analyses.

Project Results/Benefits:

• Validated Planned Design: Validated the expected performance associated with the compressed layout design.
• Capacity Improvement: Identified simple modifications to the kitchen that would increase the peak-period capacity by 20% (no additional staff).
• Capacity Improvement: Quantified the expected benefits of changes in the order controls system, simple equipment and staffing for an overall capacity increase potential of 41%.

Mimi’s Café had a need to use simulation modeling as a tool for enhancing and evaluating the existing design and decision-making process.  Bob Evans, the parent company of Mimi’s Café, is a publicly traded restaurant that retails food products organization with operations across the country. Historically, kitchen operations improvement efforts have been developed through the use of kitchen “mock-ups” at an existing restaurant which is labor intensive and slow to implement.

Reason for Project:

• Mimi’s wanted a simulation platform of base restaurant operations that could be used to investigate the use of simulation in evaluating different layouts, recipe/processes and menu mix scenarios.

 Project Deliverables:

• Development of an accurate computer simulation model of their back-of-house kitchen operations (two major layout variations).
• Completion of a base analysis to understand opportunities for improvement in the kitchen system design.
• Recommendations for improving the kitchen systems based upon the initial analyses.

 Project Results/Benefits:

• Ticket Time Reductions: The model demonstrated how food order delays could be reduced by up to 10 minutes during peak periods through the redesign of the order handling system.
• Layout Evaluation: The model identified the “best” kitchen layout configuration option (quantified benefits).
• Equipment Comparison: The model identified the impact of upgraded kitchen equipment on the ticket times, ticket backups and food quality.
• Labor Evaluation: The model quantified the potential benefits associated with adding a “floater” cook during peak periods of the day/week.

Bob Evans is a publicly traded restaurant and retail food products organization with operations across the country. Historically, kitchen operations improvement efforts have been developed through the use of kitchen “mock-ups” at an existing restaurant which is labor intensive, disruptive and slow to implement.

Project Deliverables:

• Development of an accurate computer simulation model of their back-of-house kitchen operations (three major layout variations).
• Completion of a base analysis to understand opportunities for improvement in the kitchen system design.
• Recommendations for improving the kitchen systems based upon the initial analyses.

 Project Results/Benefits:

• Ticket Time Reductions: Identified an 18% average improvement in fulfilling orders through modifications to how orders are released into the kitchen.
• Layout Evaluation: Evaluated the three layout variations and determined the “best” layout option (quantified benefits).
• Equipment Comparison: Identified alternative griddle sizes that would increase the peak-period kitchen capacity in certain regions of the country.
• Labor Evaluation: Quantified the potential benefits associated with alternative staffing level and assignments.