MGMT6055: Food Factory Case Study - DMAIC Process Improvement

This project management case study focuses on applying the DMAIC (Define, Measure, Analyze, Improve, Control) methodology to improve the production process of glazed donuts, as depicted in the "Food Factory" television show. The project begins with a project charter outlining the goals of enhancing customer satisfaction, reducing waste, and decreasing the production cycle time. It identifies critical-to-quality (CTQ) elements, such as the proper cooking of donuts. The "As Is" process is mapped using a SIPOC diagram and process map. The analysis phase identifies inefficiencies, such as the delivery of uncooked donuts, potentially stemming from quality control issues. The improvement phase proposes solutions, including enhanced cook training and quality standards. The control phase emphasizes the importance of training, policy documents, and regular monitoring to sustain improvements. The project aims to implement these changes to ensure donuts are consistently cooked properly, improving the overall quality and customer experience. The methodology is applied to improve the quality of donuts and reduce the number of complaints received from customers.

Running head: PROJECT MANAGEMENT
Case Study-Food factory
Name of the Student
Name of the University
Author’s Note

1
PROJECT MANAGEMENT
Table of Contents
Task 1:........................................................................................................................................2
1.1 Project charter..................................................................................................................2
1.2 Project CTQ.....................................................................................................................3
1.3 Toll gate...........................................................................................................................3
1.4 Map “As Is” process.........................................................................................................4
1.5 Measure............................................................................................................................5
1.6 Analyze............................................................................................................................5
1.7 Improve............................................................................................................................6
1.8 Control..............................................................................................................................6
Bibliography...............................................................................................................................8

2
PROJECT MANAGEMENT
Task 1:
1.1 Project charter
The paper mainly reflects on the organization “Food factory” that is one of the
popular television show that helps in describing how different products are generally made. It
is found that Glazed donuts are one of the most popular sweet treats around and the entire
procedure of making it is reflected in the TV show of Food factory. However, it is analyzed
that the donuts that are popular among the world does not have hole in the middle and after
the implementation of ring donut it is found that the donuts are not always cooked properly
and this is the reason, complainants against donuts are received. In order to improve the
quality of the food, it is found that DMAIC methodology will generally be used (Food
Factory, 2019). Thus the main purpose of the project is to improve the food named “donuts”
with the help of DMAIC methodology. It is assumed that the project will be successfully
executed within the time of 1 month. It is assumed that the entire project will be completed
within the expected time and budget by following the scope of the project so that the
objectives of the project can be achieved successfully. The team members who are involved
within the project are generally elaborated below:
 Project manager
 Project planner
 Financial manager
 HR manager
 Quality analyst
 Cook
 Workers

3
PROJECT MANAGEMENT
1.2 Project CTQ
The objectives or goals that are generally achieved with the help of the process
improvement plan are generally elaborated below:
Improving customer satisfaction: It is found that improvement in the process of
creating donuts will be helpful in satisfying the customers as they does need to eat uncooked
food items. With the improvement in quality, the customers generally get attracted towards
the food item (Badewi, 2016).
Reducing waste: If the food items was uncooked then the chances of food wastage is
quite high and in order to reduce wastage of food, it is necessary to improve the procedure of
cooking donuts.
Decreasing time cycle: If donuts get cooked properly then the individuals who are
associated with the procedure o making donuts does not need to waste their time on its
preparation (Hornstein, 2015).
1.3 Toll gate
By using the DMAIC methodology, improvement procedure is started in order to
improve the cooking off donuts however, it is found that if the alternative method that is
analyzed to become successful for the project is not appropriate then it is analyzed that the
improvement procedure get terminated (Kassardjian et al., 2015). In addition to this, it is
found that budget can be another reason due to which the process improvement plan that is
generally undertaken can get terminated in the middle of the procedure but the chances are
quite low.

4
PROJECT MANAGEMENT
1.4 Map “As Is” process
SIPOC diagram
Suppliers Inputs Process Output Customer
Material needed
for making
donuts
Gas supply
Utensils
Gloves
Water supply
Proper
preparation of
donuts with
new procedure
Owner of
food item
Process Map
Figure 1: Process Map
(Source: Created by Author)
Testing for
issue
Adopting
new
procedure
Donuts are
prepared with
new technique
Complete
preparation
Testing
Objectives
achieved

5
PROJECT MANAGEMENT
1.5 Measure
The steps that are reflected in the table generally focuses on the step that is utilized in
process map in order to properly analyze, review as well as evaluate the entire procedure.
Step Step Description How to Measure
1. Checking quality before
delivering to the customer
Average time is spent on checking
2. Identified that donuts are
not cooked
Sending the food to the preparation zone
3. If the donuts are cooked Average time in analysis
4. Delivered to the customer Average time taken inn delivering the order
1.6 Analyze
The process were problem may occur are generally listed as well as elaborated in the table
that is given below:
Step of the Process Where
Inefficiencies Might Occur
Brief Description of the Nature/Type of
Inefficiencies
1 Identifying the quality of food If the food quality are not checked then it might
occur that uncooked donuts are delivered to the
customers which detoriate brand quality of the food.
2 Donuts that are rejected as they
are uncooked
The donuts that are rejected that are uncooked can be
wasted as none of the further procedure can be
helpful (Hakimi, Zahraee & Mohd Rohani, 2018).
3 Further procedure on uncooked
food
If the donuts that are uncooked undergoes through
further process then the quality of the food gets
detoriate.

6
PROJECT MANAGEMENT
4 Food delivered to the customer If the food that are delivered to thee customers are
not of good quality then quality related issue occur.
5 Decision making of the manager If the manager cannot be able to decide then under
quality food may be delivered to the customers.
1.7 Improve
Process Alternatives of improvement
1. Donuts that are rejected
as they are uncooked
1. Analyzing proper ways to cook them
2. Testing whether the quality standards of the
food are met or not
3. Then the food will be delivered to the
customers.
1.8 Control
It is found that in order to implement the change within the project it is quite necessary to
undertake the following procedures that are generally listed below:
Training: It is quite necessary to provide training to the cooks so that they can be able to
know the other alternatives procedures that are helpful in cooking and will be helpful inn resolving
the problems in a very much less time (Lu et al., 2016). In addition to this, it is found that training
would also helpful in maintaining the quality of food.
Policy documents: It is quite necessary to create proper policy documents that generally
focuses on proper standards of quality so that the delivered food must be proper quality in order to
avoid quality related issues and challenges.
Monitoring procedure: It is found that regular inspection of food will be helpful in
maintaining proper quality of food ad will be further helpful in resolving issues and challenges that
are mainly associated with quality of the food (Hornstein, 2015). In addition to this, regular

7
PROJECT MANAGEMENT
monitoring also helps in mitigating short term risks as well as challenge and thus considered to be
one of the important control procedure.

8
PROJECT MANAGEMENT
Bibliography
Badewi, A. (2016). The impact of project management (PM) and benefits management (BM)
practices on project success: Towards developing a project benefits governance
framework. International Journal of Project Management, 34(4), 761-778.
Ding, K., Jiang, P., Sun, P., & Wang, C. (2017). RFID-enabled physical object tracking in process
flow based on an enhanced graphical deduction modeling method. IEEE Transactions on
Systems, Man, and Cybernetics: Systems, 47(11), 3006-3018.
Food Factory: Season 2, Episode 2 - Salty & Sweet. (2019). Retrieved from
https://www.youtube.com/watch?v=xItrZTHTrJQ
Hakimi, S., Zahraee, S. M., & Mohd Rohani, J. (2018). Application of Six Sigma DMAIC
methodology in plain yogurt production process. International Journal of Lean Six
Sigma, 9(4), 562-578.
Hornstein, H. A. (2015). The integration of project management and organizational change
management is now a necessity. International Journal of Project Management, 33(2), 291-
298.
Kassardjian, C. D., Williamson, M. L., Van Buskirk, D. J., Ernste, F. C., & Hunderfund, A. N. L.
(2015). Residency training: quality improvement projects in neurology residency and
fellowship: applying DMAIC methodology. Neurology, 85(2), e7-e10.
Lu, R., Chao, C. C., & Cheng, Y. (2017, September). To improve the measure fail rate on SEM
through six sigma DMAIC methodology—Chien-Hui Lu. In 2017 Joint International
Symposium on e-Manufacturing and Design Collaboration (eMDC) & Semiconductor
Manufacturing (ISSM)(pp. 1-4). IEEE.

9
PROJECT MANAGEMENT
Todorović, M. L., Petrović, D. Č., Mihić, M. M., Obradović, V. L., & Bushuyev, S. D. (2015).
Project success analysis framework: A knowledge-based approach in project
management. International Journal of Project Management, 33(4), 772-783.
Zhang, Z. H., & Awasthi, A. (2016). A DMAIC-based methodology for improving urban traffic
quality with application for city of Montreal. International Journal of Six Sigma and
Competitive Advantage, 10(1), 24-49.