A Food Services cost reduction assessment completed at a Victorian Hospital highlighted potential FTE reduction opportunities through the optimisation of food production processes.
The sandwich production process required up to 3 kitchen staff to produce up to 170 rounds of sandwiches with an average completion time of 8 hours.
ImpRes was provided with 2 weeks to identify the key constraints of the process and to optimise to reduce the completion time and enable FTE reduction.
The current process was mapped during the initial cost reduction review. The process was constrained due to sandwiches being produced in a unit by unit method. The completion time was also impacted by breakfast and lunch production line and dish line tasks requiring the sandwich staff to cease production.
Developed a batch production method (40 rounds in a run), improved the sandwich production area layout, purchased power cutting utensils and fit for purpose sandwich containers.
Delivery staff who had a low workload during the breakfast production line tasks were utilised on the breakfast production line to enable the sandwich process to continue uninterrupted.