Report on the Dexter-Russell, Edlund Company cutlery & sharpener test @ the Northeast Utilities Eurest facility, Berlin,CT
Submitted by Richard Glass, General Manager

Purpose of the test - To contrast the relative fiscal and actual efficiences between contracted knife supply and sharpening services and an in-house cutlery ownership and maintenance program.

Test Dates - 01.August-01.Nov.01

Subsequent to refinement of the Wasserstrom/Compass Catalogue cutlery product offering with Matt Howard, Richard Petty, Fred Berren, Lanny Chase and myself, it was determined that a controlled alpha test was called for to determine the relative efficiencies and impacts on a Eurest facility of contracting a knife service vs. purchasing and maintaining our own knives. As with the findings of the Irving, TX Eurest Microsoft facility (see e-mail from Dorothy Dolata to Wayne Pace, 09.May01, re Eurest Manager Cheryl Booth's findings), our facility's tests results were conclusive in numerous areas. You will see from the subsequent data that, while not only being fiscally sound, the other impacts - ripple effects - of an in-house program go well beyond the obvious/conventional cost savings.

Jeff Cabanaw, VP Sales for Edlund Co., manufacturers of knife racks and sharpening machines, and Lanny Chase, National Account Manager for Dexter-Russell, manufacturers of professional cutlery and tools, met with myself and some of our staff to initiate the test on 01.Aug.01. Jeff provided knife boxes and an Edlund 401 sharpening machine. Lanny supplied us with the following: a pizza wheel, dough cutter, hamburg turner, pie server, pie knife, 3x8 turner, 3x8 perforated turner, slotted turner, 2 baker's spatulas, 4 spreaders, 6 scalloped spreaders, 1 pot fork, 1 heavy duty fork, 1 diamond steel, 4 paring knives, 4 scalloped paring knives, 3 wide boning knives, 3 flexible boning knives, 3 8"chefs' knives, 4 10" chef's knives, 1 cimiter, 2 duo-edged slicers, 2 bread knives, 2 offset bread knives. These were some of the basic needs determined by our Eurest meeting @ Raytheon in July, a copy of which was e-mailed to Wayne Pace, et al.

Our critical categories of focus were:

  • Efficiency
  • Sanitation
  • Loss Prevention
  • Safety
  • Fiscal Impact
  • Proper tool for the prescribed task
  • Team response/satisfaction
  • Overall Performance

    With introductions and instructions on the use of all the test items given by Jeff & Lanny, we began the test. (For the sake of this exercise, I discontinued our sharpening service.)

    On 01.Nov.01, interviews were conducted with several members of the kitchen staff. Notes from two of those, from our Executive Chef and Sous Chef, along with my general observations, follow next.

    Head Chef Steve

  • Having our own knives made me aware of how much lost time and disruption the knife service used to generate each week. While we retained the service, knife day each week was disruptive - that is, several staffers had to stop what they were doing, locate all of the rental knives, await the accounting, await the replacements and chat with our provider. I had never thought too much about or even noticed this aspect until it didn't happen anymore - the actual time lost can be quantified conservatively as 45 minutes x 3 staff x 52 weeks x $x.00/hour x x-lack of production = impact. In time alone, this equates to 117 man hours per year.
  • Our new knives worked better, period.
  • The staff is noticieably more aware of their knives now, equating to better matching the right tool for the right job.
  • Professional, quality tools impact attitudes.
  • The knives were no longer being tossed about into drawers, sinks, etc. - they had taken possession.
  • The sanitation was markedly improved - we were never certain of the service knives' cleanliness upon delivery.
  • With the introduction of the diamond sharpener, the upgraded quality of the knives' steel (vs the servie's cheapies), we didn't need to use the sharpening machine but for once/month or so.
  • The Dexter granton/duo-edged slicer is a major improvement.
  • The offset bread knives are another signigficant improvement.
  • We might consider each chef and cook being issued their own basic array of knives for which they would be accountable - it might prove cheaper for the company in the long run and better for the kitchen.
  • Everyone should be issued a scalloped paring knife.
  • We experienced zero lost days due to injuries or incidents related to the cutlery, as the knives were maintained and the staff knew the condition of the set.
  • The Sofgrip hndles are easier, more comfortable to work with and safer.

    Sous Chef Paul

  • I used the Edlund sharpener once - the quality of the kinives, coupled with proper honing and sharpening with the diamond steel, meant that I didn't need the machine as often.
  • I instructed my cooks on the diamond steel, resulting in measurably better performance and efficiencies by them.
  • The prep cooks were especially pleased with the enhanced quality of knives vs. the service's - their job became faster & easier.
  • The prescibed sanitation regimine was more closely adhered to - there was an enhanced sense of ownership and pride with the new, non-commodity tools.
  • The safety aspect was enhanced due to sharper knives, the Sofgrip handles and the heightened awareness of whereabouts, condition and cleansing - no longer are the cooks tossing the knives into the sinks - they are cleaning them - they are responding to our investment in quality tools for them.
  • The yield on the prepped and carved food is demonstrably higher, due to efficiencies and increased sharpness. Less wasted product, better looking, easier to serve.
  • The Edlund knife racks are safer than the old magnabars - and easy to clean.
  • When I did use the Edlund sharpening machine, it took very little to bring my edges back - it worked simply and quite well.
  • Some of the staff will take a little longer to fully accept the standards and most effective techniques, yet they have all improved as a result of the new system.

    Some of my observations:

  • There was no loss due to cut, strain, or knive-related injury during the test period.
  • The sharper knives afforded more efficiencies of production and time - higher product output, less waste.
  • The combination of the diamond sharpener, knife racks and sharpening machine has not only addressed the maintenance and honing requirements, but they have also enhanced awareness, sanitation, safety, productivity and pride.
  • The overall product mix is complete and covers our kitchen's needs.
  • The direct costs of owning the knives and sharpener are offset in a short period of time (see comparison).
  • The attitude and productivity have been makedly enhanced, as the right tools are now available for specific needs.
  • The team is more aware of their tools, their condition, whereabouts, sanitation and purpose.
  • The staff has learned how to maintain their own edges, formerly a basic skill, now a re-trained empowerment - sharper= faster=less time=less waste=more efficient=more profitable.
  • The challenge is the basic education of the kitchen team in the ways of cutlery use, safety, sanitation, maintenance, & application.
  • We are more than ever ready to commence the Compass Classroom.

    Sharpening vs. Owning #'s

    We rented on a wekly basis
    6 Chefs' Knives
    3 Boning Knives
    4 Slicers

    The weekly direct fee was $19.75

    Annualized, it represented a direct expense of $1,027.00

    The same knives purchased at a rate of list less 35% work out to:
    3 Boning @ $11.38 ea = $34.40
    3 8" Chefs' @ $19.18 ea = $57.54
    3 10" Chefs' @ $21.52 = $64.56
    4 Slicers @ $23.37 = $93.48

    Purchase Total = $249.92
    Edlund Sharpener = $240.00

    Total Acquisition costs = $489.92

    The knives were Sofgrip
    The slicers were much better
    The sharpener was a one-time cost

    The lines of investment vs rental cross @ < 6 months. If we were to purchase two sets of these knives, the direct r.o.i. would be realized within 8 months With three sets, the direct r.o.i. is less than a year, AND we don't have the expense of the sharpening machine in year two to ammortize. Fiscally conclusive on direct investment's return.

    The soft cost savings, aka The Ripple Effects, of such a program are tangible. Loss prevention savings Lost time and production during swap-out days Controlling our own sanitation environment Product yield efficiences - less waste Ease of production enhancements - more efficient workers Enhanced pride in the workplace

    This test was conclusive. As Cheryl Booth discovered in Irving, TX, we are a better unit as a result of controlling our own cutlery program in-house - for a number of reasons.

    Thank you for reading.
    Respectfully submitted by,

    Rich Glass