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Chipotle: Lean Manufacturing
Applying lean manufacturing to the food industry
Even though the food industry faces certain unique challenges regarding manufacturing (such as maintaining appropriate sanitary measures), there are many similarities between it and other industries
Particularly in the fast food industry, where foods are 'assembled' at point-of-purchase with standardized materials the concepts of lean manufacturing can be applied
Risk of applying lean in food industry, lean culture
Traditionally, it has been assumed that the food industry did not lend itself to lean manufacturing principles
"Typically these business types sell their product from large distribution or product mixing centers, and are not make-to-order businesses" (Heymans 1).
Fast food companies "manufacture to a forecast, and usually the forecast lead time to production is long, resulting in large differences between the forecast that drives production levels, and actual demand" (Heymans 1).
However, "companies in this industry have the same cost, quality and delivery pressures as any other type of business" which can be helped via lean manufacturing (Heymans 1).
Genba walk
The genba walk is, quite literally a 'walk' by management around the company to see which processes can be improved and where waste is being generated.
The genba walk at a fast food company should encompass the production of the food as well as the service
The supply chain can likewise be subjected to the 'genba walk' for quality purposes.
Muda
'Muda' in lean manufacturing terms is defined as waste.
According to Heymans, muda can be generated by the following problems: overproduction; excess inventory; transportation; excessive motion of people; over-processing, rework; and waiting (Heymans 2)
"Poor quality is often the result of too much variation in the process:" standardization regarding quality is critical (Heymans 2)
Examples of muda at a fast food company like Chipotle might include assembling excess amounts of ready-to-order products (like salads); having too much of certain kinds of foods people do not want; excess raw, perishable materials transported to various stores; too much movement of people assembling food and taking orders; inefficient assembly
References
Heymans, B. Lean manufacturing in the food industry. Retrieved from:
http://www.flowmakers.com/articles/Articlefoodindustryandkaizen.pdf
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