The Client’s Iowa facility will be testing the new Homogenized Milk Emulsion (HME) Technology as a way to produce a base sauce that will save cost, reduce quantity of ingredients, and improve the nutritional profile for the Frozen Foods product lines – 8 total production lines.

Reason for Project:

• The Client wanted to test the conceptual design of a dual kitchen system.
• They wanted to be able to test having only one kitchen running or both.
• They wanted to determine if one or more CIP systems were needed.
• They wanted to determine staffing needs for conceptual design.

Project Deliverables:

• Development of an accurate computer simulation model of their conceptual dual kitchen HME sauce production facility. The model has variable input parameters that can be changed by the client via Excel input spreadsheet.
• 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:

• Production Rates: Able to show that the homogenizer rate of 850 GPH was not able to keep up with higher product demands.
• Layout Evaluation: Only using one kitchen resulted in having no product available during CIP times.
• Equipment Comparison: Eliminated some of the equipment possibilities such as pump rate and tank size.
• Labor Evaluation: Able to show that a third operator would be needed at higher demands to keep system from waiting on a resource.
• Tool Development: Developed a tool for the Client to use to run many different scenarios/experiments to help them determine equipment and production needs and limitations.

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.