# Gate 11E — Kitchen Pilot 001

**Status: READY TO RUN**

Purpose: replace modeled seconds with observed seconds using **20 real premium combos**.

This is not a recipe-development day and not a sales event. It is an engineering pilot.

## Pilot output

### Sale tokens
- **20 test sale tokens**
- each token represents one customer order in the pilot

### Non-sale units
- **1 QC patty/burger allowance**
- **1 remake/recovery patty allowance**

Physical patties prepared:
- 22 × 140 g = **3.08 kg raw premium blend**

Only 20 are test-sale units. The two extras are never treated as orders #21–22.

## Reference combo
For Kitchen Pilot 001, deliberately keep the menu minimal:

- one premium beef burger
- one bun
- one standard sauce
- one pickle/green configuration
- standard cheese only if cheese is already part of the chosen reference burger
- 150 g finished tallow fries
- one house soda

No build-your-own customization.

The purpose is to validate the operating system, not menu breadth.

## Required ingredients

### Beef
- 22 × 140 g premium patties
- total raw blend: **3.08 kg**

### Buns
- 22 buns minimum
  - 20 test combos
  - 1 QC
  - 1 spare/remake

### Fries
Target sold output:
- 20 × 150 g = **3.0 kg finished fries**

Buy/prep enough potato product to comfortably exceed this after process loss.
Record:
- raw/pre-cook weight
- finished served weight
- waste
- leftover usable product

Do not infer potato yield from the target. Measure it.

### Soda
- minimum 22 serving equivalents
- record actual ml/serving
- record syrup and water usage if postmix/house syrup is used

### Condiments / packaging
Prepare enough for 22 units but count actual use.

## Minimal equipment

Required:
- flat-top / plancha or equivalent test surface
- fryer suitable for the selected fat
- thermometer(s)
- digital scale
- timer/stopwatch
- cold storage
- raw-meat tools
- cooked-only tools
- fry baskets/tools
- assembly surface
- ticket/order display method
- 20 numbered order cards
- 2 reserve/QC cards
- waste container
- data sheets / phone/tablet for timestamps

Useful but not mandatory:
- thermal probe logger
- second camera for later motion review
- separate soda dispenser
- heat lamp/pass shelf if testing short hold

## Layout rule

Before cooking:
1. mark RAW zone
2. mark HOT/COOKED transfer zone
3. mark FINISH zone
4. mark HANDOFF zone
5. place all frequently used items within one-step reach

No raw-contact utensil may enter the finish zone.

## Pilot roles

### Operator A — HOT
- patties
- cheese if standard hot-side step
- fries
- cooked transfer
- hot-side temperature checks

### Operator B — FINISH
- bun
- sauce/toppings
- patty receive
- fries portion
- soda
- ticket reconciliation
- handoff

### Observer / recorder
Strongly preferred.
The observer does not rescue the workflow unless a safety problem occurs.

If only two people are available:
- record with fixed video
- log only essential timestamps live
- annotate detail from video afterwards

## Order release schedule

The pilot has three phases.

### Phase 1 — Warm-up
5 orders at **20/hour**
- one new order every 3 minutes

Release:
- #01 at 00:00
- #02 at 03:00
- #03 at 06:00
- #04 at 09:00
- #05 at 12:00

Purpose:
- verify station flow
- catch obvious layout problems
- avoid learning the system for the first time during rush

### Phase 2 — Forced rush
10 orders at **50/hour**
- one new order every 72 seconds

Release:
- #06 at 15:00
- #07 at 16:12
- #08 at 17:24
- #09 at 18:36
- #10 at 19:48
- #11 at 21:00
- #12 at 22:12
- #13 at 23:24
- #14 at 24:36
- #15 at 25:48

Purpose:
- stress the exact reference peak
- test whether HOT and FINISH can keep flow without long holding

### Phase 3 — Recovery
5 orders at **25/hour**
- one every 2 minutes 24 seconds

Release:
- #16 at 28:00
- #17 at 30:24
- #18 at 32:48
- #19 at 35:12
- #20 at 37:36

Purpose:
- see whether the system recovers after rush
- detect accumulated grease, fryer recovery problems, stock-positioning problems or operator fatigue

## Ticket flow

Reference simulation:
1. customer order token is released
2. ticket becomes visible to kitchen
3. sale-token count decrements
4. kitchen begins work
5. ready timestamp recorded
6. ticket number called
7. handoff timestamp recorded

Public counter for the test:
**20 → 0**

Reserve/QC units do not affect the public counter.

## Patty batch test

Start with the current reference hypothesis:

- **5 patties per rolling batch**
- new batch approximately every 6 minutes during the rush

Do not force this cadence if the physical cook curve proves it wrong.

For every batch record:
- load time
- flip time
- cheese time if used
- transfer time
- surface temperature before/after load if measurable
- first and last patty ready times
- any hold duration

## Fries batch test

Start with:
- **~1.25 kg finished-output target per batch**
- approximately one batch every 10 minutes at 50-combo/hour equivalent

For every batch record:
- pre-cook/raw input weight
- load time
- oil/tallow temperature before load
- temperature recovery
- lift time
- drain time
- finished weight
- waste
- crispness score at 0 / 5 / 10 min if possible

## QC tasting

Before order #01:
- taste sauce
- taste first fries
- taste at least one representative cooked patty sample
- verify salt/seasoning
- verify bun condition

If a full QC burger is made, code it:
**QC-01**

It is not test sale #01.

## Mandatory measurements per order

For each of the 20 sale tokens record:
- order release time
- hot start
- patty ready
- finish start
- fries ready
- soda ready
- combo ready
- handoff
- any remake/error
- any hold time
- finish active seconds if observable
- customer-ready latency

## Sensory scorecard

For selected burgers, score 1–5:
- crust
- juiciness
- seasoning
- patty temperature
- bun integrity
- sauce balance
- fries crispness
- fries salt
- overall burger
- overall combo

At minimum taste:
- one warm-up burger
- one early-rush burger
- one late-rush burger
- one recovery burger

This is specifically to detect quality drift during peak.

## Waste ledger

Every discarded or diverted item gets one code:

- `QC`
- `REMAKE`
- `DROP`
- `OVERCOOK`
- `UNDERCOOK`
- `ASSEMBLY_ERROR`
- `FRIES_WASTE`
- `SODA_WASTE`
- `OTHER`

Record both count and weight where practical.

## PASS / FAIL thresholds

### Safety — HARD FAIL
Immediate FAIL if:
- raw/cooked cross-contact occurs and is not contained;
- validated cook endpoint is missed;
- cold/hot handling falls outside the chosen documented process;
- operator cannot maintain safe workflow under rush.

### Throughput — PASS
For the 10-order rush:
- all 10 orders must be absorbed without uncontrolled queue growth;
- projected station capacity must be >=50 combos/hour;
- 90th-percentile customer-ready latency target: **<=8 min**

### Finish/front — PASS
- median active finish time: **<=60 s/combo**
- 90th percentile: **<=75 s/combo**

### HOT — PASS
- no systematic crust degradation during rush
- no repeated surface-recovery failure
- no need for long pre-cooking just to survive the queue

### Fries — PASS
- peak production sustains required output
- no repeated starvation of assembly
- quality remains acceptable through rush

### Quality — PASS
No more than one full point average decline (1–5 scale) between:
- warm-up quality sample
and
- late-rush quality sample

Any repeated 2+ point deterioration triggers redesign.

### Waste — provisional target
- zero preventable remakes preferred
- <=1 recovery/remake unit in 20 orders
- total edible waste recorded, not hidden

### Human factors — PASS
Each operator scores after pilot:
- fatigue 1–5
- stress 1–5
- station clarity 1–5

A technically fast workflow that requires sustained 5/5 stress is not a PASS.

## Output after pilot

Kitchen Pilot 001 produces:
1. observed median/p90 order latency
2. observed finish active time
3. observed HOT active time
4. actual patty batch cycle
5. actual fries yield and batch cycle
6. actual reserve usage
7. actual edible waste
8. actual operator stress/fatigue
9. sensory drift across service
10. revised Day 001 model

## Decision rule

Do not optimize everything at once.

After the pilot, identify the single largest constraint:
- HOT
- fries
- finish
- ordering
- layout
- ingredient prep
- cleaning
- quality hold
- human fatigue

Then change **one major variable** before Kitchen Pilot 002.

That keeps the experiment interpretable.