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    What Is An Example of A Lean Pull Process

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    The document describes how McDonald's transitioned to a Lean Pull process for cooking burgers. Originally, McDonald's would cook extra burgers and store them in heating bins, leading to waste. Now, burgers are cooked individually for each order in steaming bins next to the assembly area in a "just-in-time" process. This reduces waste and ensures burgers are fresh for each customer. The document asks for other examples of Lean Pull processes.

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    What Is An Example of A Lean Pull Process

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    Pat
    18 views7 pages
    The document describes how McDonald's transitioned to a Lean Pull process for cooking burgers. Originally, McDonald's would cook extra burgers and store them in heating bins, leading to waste. Now, burgers are cooked individually for each order in steaming bins next to the assembly area in a "just-in-time" process. This reduces waste and ensures burgers are fresh for each customer. The document asks for other examples of Lean Pull processes.

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    What is an Example of a Lean Pull Process

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    The document describes how McDonald's transitioned to a Lean Pull process for cooking burgers. Originally, McDonald's would cook extra burgers and store them in heating bins, leading to waste. Now, burgers are cooked individually for each order in steaming bins next to the assembly area in a "just-in-time" process. This reduces waste and ensures burgers are fresh for each customer. The document asks for other examples of Lean Pull processes.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    18 views7 pages

    What Is An Example of A Lean Pull Process

    Uploaded by

    Pat
    The document describes how McDonald's transitioned to a Lean Pull process for cooking burgers. Originally, McDonald's would cook extra burgers and store them in heating bins, leading to waste. Now, burgers are cooked individually for each order in steaming bins next to the assembly area in a "just-in-time" process. This reduces waste and ensures burgers are fresh for each customer. The document asks for other examples of Lean Pull processes.

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    U a

    What is an example of a Lean Pull Process?


    SSDSI Blog

    Related SSDSI Articles

    Let’s start with a story about establishing the Lean Pull improvement process with a McDonalds
    case study…

    When I was 18, my family and I had just returned from an accompanied tour with my father (a U.S.
    Marine) in London, England. We were in Jacksonville, NC, for about two weeks when he received
    orders to ship off to the Middle East to be a part of “Desert Storm.”

    I was preparing to go to college in Greenville, NC which was about three hours from Jacksonville.
    When we got the news that my father was to be deployed again, I changed my plans and decided to
    go to the local community college so I would be able to watch after my mom and two sisters.

    Once I was registered for school, my first order of business was to find a job.
    Privacy - Terms
    The only employment I found that would work around my school schedule was McDonald’s. I was
    hired as a night shift cook. I have always had the mind to be frugal with money. Like teaching, you
    don’t enlist in the Marine Corps to get rich. I say this because I immediately saw waste at
    McDonalds, even though at the time I did not know the concepts of Lean nor Six Sigma.

    For those of you who remember in the early 90’s, McDonald’s used to cook their burgers and place
    them in a heating bin. We would place a marker behind a batch of burgers to let everyone know
    when those would expire (thus becoming waste).

    A Six Sigma McDonalds case study

    Management either used “gut feeling” or forecasting to predict demand. Most would over-predict
    during peak hours (especially when the rumor of a bus full of hungry athletes was coming) and
    under-predict during non-peak times.

    In either case, they were taking a risk. I saw the result of that risk in the waste bin every day. This
    was the case during my 1.5-year employment at McDonalds.

    Jump ahead 15 years. I was waiting in a McDonald’s line during the peak of lunch and I saw that the
    bins were empty except for special orders.

    I thought that maybe I had come in on the tail end of a big rush and they were trying to catch up. I
    decided to sit in the lounge where I could watch their process.

    I discovered steaming bins (like small closets with trays) where the cooked meat was being stored
    next to the place of sandwich assembly. Every order was assembled immediately after the order
    was made. I was impressed with the improvement, and I thought to myself; this is a perfect example
    of establishing the Lean Pull Improvement Process!

    The old process included creating an inventory of burgers and storing them under a heating lamp.
    The constraint in the whole process that kept it from being “just in time” was cooking the meat.

    In this new system, that constraint is removed.


    I also remember that when you received your hamburger from the bin in the old process, the
    ketchup and mustard would soak into the bun, making it lose some of its “fullness.”

    In the new Pull Process, the bins for the cooked meat are referred to as the “Supermarket.” When
    the orders are placed, the meat is pulled from the Supermarket into the assembly area. The
    hamburger is assembled just in time to fulfill the order.

    Do you have any examples of a Lean Pull Process that you can share like the McDonalds case
    study?

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    2 Comments
    Carmen on October 7, 2019 at 6:58 am
    I work in McDonald’s. Also green belt lean six sigma. The drinks, desserts, are pulled.
    A little batching on basic ingredients like grilled meat and fried chicken. A lot of
    kanbans and visual management to pull dry stock and fresh or frozen food stock. A
    fascinating world!!

    Reply

    Kevin Clay on October 7, 2019 at 2:38 pm


    Carmen, thanks for your reply. It is a fascinating world!

    Reply

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