A Feasibility Study of Replacing Manual Dishwashing with a Mechanical Dishwasher at Taco Bell Prepared for: John *****, Owner Taco Bell #4788 and Paul Kellermann, Professor English 202C By: Andrew ***** August 9, 2005 This report examines the feasibility of installing and operating a mechanical dishwasher in place of manual labor at Taco Bell. Sanitation, economics, and social impact are the main criteria in question regarding this change. Information for this report was obtained from personal experience, managerial staff at Taco Bell, the Pennsylvania Health Code, and vendors of mechanical appliances.
Andrew ***** i 8/9/2005 EXECUTIVE SUMMARY The problem of inconsistent and possibly cost inefficient methods of cleaning and sanitizing dishes at Taco Bell is the focus of this report. Specifically the feasibility o replacing the current practice of hand washing dishes with a mechanical dishwashing unit was researched as a solution to this problem. I researched several different dishwashers and the Hobart HOBSR24H-5 was selected. This model was chosen on a basis of satisfying the sanitation guidelines provided in the Pennsylvania Code of Health. It was also desirable to keep the price of the dishwasher to a minimum while maintaining an advantage over manual labor in areas of speed and water consumption. It was found that the unit would cost around $4000 to purchase and install at Taco Bell. The unit cost was found on an internet website listed for $3269.95 and the estimate for installation was $700 including parts and labor. The installation fee was provided by a Centre County Hobart representative named Howard Porta. The savings due to reduced labor amounted to $8600 per year. Savings based on water consumption were equivalent to $60 per year. The combined savings would cover the costs associated with the dishwasher in less than six months. The recommended course of action is provided at the end of this report. I suggest that a mechanical dishwasher be purchased in order to provide a high level of sanitation to customers as well as minimizing the cost of labor for Taco Bell.
Andrew ***** ii 8/9/2005 Table of Contents Page Number Executive Summary List of Visuals i iii Introduction Problem 1 Research 1 Report Structure 1 Feasibility Criteria for Mechanical Dishwasher Sanitation 2 Economics 2 Social Impact 2 Selection of Dishwashing Unit 2-3 Economic Evaluation of Mechanical Dishwasher 4-5 Conclusions Sanitation 5 Economics 5 Social Impact 5 Recommendations 6 References 7 Appendix
Andrew ***** iii 8/9/2005 List of Visuals Page Number Table 1: Dishwasher selection matrix 3 Figure 1: Hobart dishwasher model HOBSR24H-5 3 Figure 2: Mechanical dishwasher costs vs. savings 5
Andrew ***** 1 8/9/2005 Introduction Problem The ideal working environment in a commercial restaurant is one that can operate efficiently while maintaining a high level of sterility during the entire food preparation process. The current practices at Taco Bell do not satisfy this ideal with regards to dishwashing. There are various types of dishes and utensils used to prepare food that must be cleaned and sanitized throughout the day at Taco Bell. They range from pots that contain ingredients along the assembly line to knives and spatulas. Manually washing dishes leads to inconsistent results regarding sterility. Some employees wash dishes better than others, and while all dishes are soaked in a sanitizing solution, cleanliness is not as well regulated as it could be. Hand washing dishes requires a great deal of time and money. If this process could be streamlined it would help reduce the cost of labor and utilities. Failure to act on this issue could lead to several consequences. Health risks include bacteria and cross contamination from foods contained in the dishes. Either of the previous situations could lead to customer illness, which is unacceptable at any eating establishment. Economically, money is being used to pay workers and supply water to the three sinks involved in the hand washing process. These funds, though currently necessary may not be needed if other options are considered. Research To find a solution for this problem I decided to research the feasibility of installing a mechanical dishwasher to replace the practice of hand washing dishes at Taco Bell. I examined the Pennsylvania Health Code pertaining to dish washing methods in restaurants. I located information on several industrial dishwashers and compared speed, water consumption, dimensions, and cost. Once I selected a specific machine I focused on the feasibility and practicality of installing and using the dishwasher in relation to the current method of washing and sanitizing dishes by hand. I examined the two methods of washing dishes on a basis of sanitation, the ability to consistently meet the standards of the Pennsylvania Health Code, and economic efficiency. I performed an analysis of the amount of money involved in hand washing dishes. This served as a basis for funds that could be put towards the installation, purchase, and use of a mechanical dishwasher at the same restaurant. When comparing the two methods, speed and the amount of labor required for each method was also taken into consideration. The feasibility of introducing a mechanical dishwasher into the workplace required compliance with several criteria that included cost, size, sanitation, and social effects. Report Structure The report will contain sections on the following: General feasibility criteria for mechanical dishwasher Selection of dishwashing unit Economic evaluation of installing and using a mechanical dishwasher Summary of conclusions Specific recommendations
Andrew ***** 2 8/9/2005 Feasibility Criteria for Mechanical Dishwasher The criteria that were taken into account to determine the feasibility of installing a mechanical dishwasher at Taco Bell included sanitization, economics, and social impact. The following sections will go over the requirements in greater detail. Sanitation Section 78.62 of the Pennsylvania Code of Health states that dishes must be subjected to either a chemical or heat sanitization treatment. The current practice at Taco Bell involves a chemical sanitizer that is chlorine based. The code requires a chlorine concentration greater or equal to 50 parts per million, at a temperature no less than 75F. The code also lists the equivalent requirements for a mechanical dishwasher. A mechanical dishwasher should either comply with chemical guidelines, or it should follow the sanitary heat requirements. The Pennsylvania Code of Health states that a thirty second exposure to clean hot water of at least 170 F is adequate for sanitation purposes. (Chapter 78) Economics A crucial way to justify the installation of a new piece of equipment is to show that it is a more economical way to accomplish a task. In order to maximize the economic benefit of a mechanical dishwasher costs should be heavily weighed during decisionmaking processes. This set a goal to minimize the costs related to the installation and purchase of the dishwashing unit. Social Impact Any time manual labor may be replaced by a machine, it is always important to weigh in the social impact that decision carries. An ethical question needs to be raised of whether or not it is harmful to replace humans with a machine. Considerations should be made on a case-by-case basis to determine whether the replacement will generate a financial burden for employees. Selection of Dishwashing Unit Several main factors were involved when selecting the best dishwasher for Taco Bell. Sanitation, cost, dimensions, speed, and water consumption were the criteria used to compare dishwashing units. I selected five specific dishwashers to compare and contrast. The information is displayed in Table 1. Sanitation and cost were the most important parameters. All of the dishwashers under consideration had the ability to boost the temperature of incoming hot water to levels above 170 F. This meant that all of the units were equal with regards to sanitization. The price range of the dishwashers spanned several thousand dollars. It was desirable to keep the cost of the machine itself to a minimum.
Andrew ***** 3 8/9/2005 Table 1: Comparison of Several Mechanical Dishwashers Model Number Cost Height Width Depth Cycle Time Gallons/Rack (racks/hr) HOBAM15-254 $6,989.95 75.75 24.5 26 58 1.9 FI-120W $5,650.00 56.5 26.5 29 60 2.0 HOBLXIH-4 $4,759.95 34.25 23.9375 26.75 30 1.2 JACJPX-300H $4,099.98 33.25 24.25 22.625 24 1.1 HOBSR24H-5 $3,269.95 34 24 24 19 1.4 Dishwashers are listed in descending order according to price. Adapted from: (Ace Mart, Dishwasher, Fagor) Another important consideration was space. The space available for a dishwasher would be approximately 40 wide x 38 deep. This space is currently occupied by a table that is used to prepare food. All of the units being considered would fit in this space; however the two taller units would be unable to provide replacement counter space due to their excessive height. The quick cycle times and low volume of water consumed during a load are impressive for each unit. Though some are faster or more efficient than others, they all have advantages over hand washing. Hand washing takes place in three separate 13- gallon sinks, one for washing, rinsing, and sanitizing. Approximately ten comparably sized loads (20 x 20 racks) of dishes would be washed and sanitized with about 25-30 gallons of water. All things considered the best choice for this application appeared to be the HOBSR24H-5. It was the most inexpensive model by $830 to the machine closest in value. It fit the required dimensions, and had comparable water consumption to several other units. The cycle time was the slowest among the dishwashers being considered but it was still much faster than what a human would be capable of. A picture of the Hobart SR24H-5 is shown below in Figure 1. Figure 1: Hobart HOBSR24H-5
Andrew ***** 4 8/9/2005 Economic Evaluation of a Mechanical Dishwasher Time and Labor Michelle Benitez, a manager at Taco Bell stated that on average about 7 hours a day are dedicated to cleaning dishes. This workload is not carried by one person but is shared among the workers on each shift. An approximate figure for the hourly rate of pay is $6.75, this was evaluated from knowledge that most workers are paid between $6.40 and $7.00 an hour. According to these values it costs Taco Bell $47.25 per day to have workers wash dishes by hand. This amount is equivalent to $17,246.25 per year in dishwashing labor expenses. Utilizing a mechanical dishwasher would greatly reduce the amount of time that humans need to dedicate to this task. If the amount of labor required was reduced by fifty percent the savings would be approximately $8,620 per year. The only need for labor would be to soak dishes in water, load the machine, and start the cycle. Water The State College Borough Water Authority website stated that it charges $3.65 for every 1000 gallons of water consumed (Water 1). I estimated that the three thirteen gallon sinks used to wash and sanitize dishes by hand require about 100 gallons of water per day. This amount of water would be used to wash and sanitize about 40 equivalent loads for a mechanical dishwasher utilizing a 20 x 20 rack. The HOBSR24H-5 uses 1.4 gallons of water per load, and on a daily basis would require about half as much water as hand washing. The total estimated amount of money spent on water per year for manual washing totals $133 and the machine would cost $75 per year. This is another place for economic savings that would accumulate over time. Cost of Mechanical Dishwasher The listed price for the HOBSR24H-5 was $3269.95 at acemart.com, and I received a quote for the installation of approximately $700. The quote for installation was based on an average of five previous installations of the same model dishwasher. Prices for zoning costs and parts were also factored in to the estimate. This would amount to just under $4000 in total. The previous savings related to using a mechanical dishwasher would sum to about $8700 per year. A graph was generated to find the amount of time it would take to recover the costs of the dishwasher and installation. In Figure 2 it can be seen that it would take less than six months for the savings to overcome the initial expenses of the dishwasher.
Andrew ***** 5 8/9/2005 Money (dollars) 10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 Figure 2: Economic Evaluation of Dishwasher Savings ($) Expense ($) 0 2 4 6 8 10 12 14 Time (months) Conclusions Sanitation The mechanical dishwasher HOBSR24H-5 can deliver water at temperatures over 170 F to sanitize dishes. This complies with the Pennsylvania Code of Health and ensures that sanitation will meet or exceed the necessary levels of sanitation. The mechanical dishwasher will produce results that as a whole will be more consistent and reliable than what humans can accomplish by hand. Economics There are obvious economic benefits that will occur if a mechanical dishwasher is installed. It will reduce the required hours of labor and therefore reduce the overall expense for hourly wages every day. The estimated savings total $8700 dollars per year considering labor cost cuts and a reduction in water usage. These savings would cover the initial capital investment of $4000 in less than six months. Social Impact In this specific case the social impact would be minimal. This change would take place on a local level and would only impact the State College area. Currently a majority of the employees at this location are high school or college-aged workers. Most of the employees are part-time and do not depend on their hours washing dishes in order to live. This would be an acceptable situation to replace human labor with a mechanical device.
Andrew ***** 6 8/9/2005 Recommendations Purchase the Hobart HOBSR24H-5 from acemart.com Call Howard Porta, a Hobart installation representative, to get a proper installation estimate drawn up for Taco Bell; Telephone: (814) 946-5437 Have Hobart professionally install the dishwasher Train employees in functions and operations of dishwashing unit Reduce number of hours for workers Enjoy $8700 of savings each year in the future
Andrew ***** 7 8/9/2005 REFERENCES Ace Mart: Dishwashers. Ace Mart. 29 July 2005. <http://www.acemart.com/merchant.mv?screen=ctgy&store_code=am&cate gory_code=d13-3&ref=main&cm_re=category2.0>. HOBAM15-254. 2005. Ace Mart. 29 July 2005. <http://www.acemart.com/specsheets/hobam15-254.pdf> HOBLXIH-4. 2005. Ace Mart. 29 July 2005. <http://www.acemart.com/specsheets/hoblxih-4.pdf> HOBSR24H-5. 2005. Ace Mart. 29 July 2005. <http://www.acemart.com/specsheets/hobsr24h-5.pdf> Chapter 78: Food Establishments. Pennsylvania Code. 1996. RestaurantEdge.com. <http://www.restaurantedge.com/uploads/pennsylvaniaxcode.htm>. Dishwasher, Undercounter, Heat Sanitizing: JACJPX300H. Big Tray Inc. 29 July 2005. <http://bigtray.com/productdetails.asp?catid=11690&sku=jacjpx300h> Fagor Commercial Door Style Dishwashers: FI-120W. 2005. Galasource. 2 August 2005. <http://www.galasource.com/proddetail.cfm/20192>. Water Authority Rates. State College Borough Water Authority. 2 August 2005. <http://www.scbwa.org/rates.htm>.