Chapter 6

1. Chapter 6 Food Production

2. Functional Subsystem: Food Production • Food production is the preparation of menu items in the needed quantity & with the desired quality. • Quantity – Distinguishes foodservices production from home or family food preparation. • Quality – Aesthetic, nutritional, & microbiological safety aspects of a food product. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

3. Production Subsystem Objectives • Primary: Transform human, material, facility, & operational resources into outputs. • Secondary: • Product/service characteristics • Process characteristics • Product/service quality • Efficiency: • Effective employee relations & cost control of labor • Cost control of materials • Cost control of facility use • Customer service: • Produce quantities to meet expected demand • Meet delivery date for products or services ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

4. Production Decisions • Includes forecasting, planning, & production scheduling. • Synthesis of quantity, quality, & cost objectives. • Product characteristics • Production process characteristics • Establishment of standards of quality ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

5. Production Forecasting • Primary result of forecasting should be customer satisfaction. • Production Demand • Overproduction – Production of more food than is needed for service. • Underproduction – Production of less food than is needed for service ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

6. Production Forecasting • Quantity Demand • Estimate number of customers or the number of servings. • Essential to use suitable forecasting model. • Examples: • Historical records • Intuition • Complex models requiring large amounts of data ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

7. Production Forecasting • Historical Records • Effective production records should include: • Date & day of the week • Meal or hour of service • Notation of special event, holiday, & weather conditions • Food items prepared • Quantity of each item prepared • Quantity of each item served • Provide fundamental base for forecasting quantities when the same meal or menu item is repeated. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

8. Forecasting Models • Criteria for a Model: • Cost – expenses of both development & operation. • Required accuracy –accuracy of its predictions of future occurrences. • Relevancy of past data–relationship of past & future data. • Forecasting lead time – length of time into future the forecasts are made. • Underlying pattern of behavior – actual occurrences follow some known pattern. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

9. Types of Models • Most common model categories: • Time series • Casual • Subjective • Trends & seasonality in the data must be considered. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

10. Time Series Model • Assumption that actual occurrences follow an identifiable pattern over time. • Suitable for short-term forecasts. • Frequent time series models: • Moving average forecasting model • Exponential smoothing forecasting model ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

11. Moving Average Forecasting Model • First point: average of number of portions sold for the last five or more times the menu item was offered. • Second point: average of dropping the first number & adding the most recent number of portions sold to the bottom of the list. • Continue process for all data. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

12. Moving Average Forecasting Model ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

13. Exponential Smoothing Forecasting Model • All past data are considered in smoothing process. • More recent data are given more weight. • Requires only a few pieces of data to update a forecast. • Easily programmed & is inexpensive to use. • Rate at which the model responds to change can be adjusted mathematically. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

14. Casual Model • Assumption that an identifiable relationship exists between the item being forecast & other factors. • High costs for development & use. • Popular for medium- & long-term forecasts. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

15. Regression Analysis Forecasting Models • Most commonly adapted. • Includes: • Dependent variables – items being forecast. • Independent variables – factors determining the value of the dependent variables. • Requires a history of data to permit plotting over time. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

16. Subjective Model • Used when relevant data is scarce or patterns & relationships between data do not tend to persist over time. • Delphi technique • Market research • Panel consensus • Visionary forecast • Historical analogy ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

17. Production Scheduling • Time sequencing of events required to produce a meal. • Planning stage: • Forecasts are converted into the quantity of each menu item to be prepared. • Distribution of food production to supervisors in each work center. • Action stage: • Supervisors prepare a production schedule. • Items are assigned to specific employees. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

18. Production Schedule • Should include: • Employee assignments • Preparation time schedule • Menu item • Over- & underproduction • Quantity to prepare: forecast amount for each menu item. • Substitutions • Actual yield: portion count produced by the recipe. • Additional assignments • Special instructions & comments • Pre-preparation ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

19. Production Meetings • Should be held daily with employees in the production unit. • Employees encouraged to discuss the effectiveness of the schedule. • Free discussion of work loads. • Conclude with discussion of the production schedule for the following three meals. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

20. Ingredient Control • Begins with purchasing, receiving, & storage of foods. • Continues through forecasting & production. • Ingredient assembly – area designed for measuring ingredients. • Standardized recipes – provides assurance that standards of quality will be consistently maintained. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

21. Advantages of Centralized Ingredient Assembly • Contributes to the cost reduction & quality improvement. • Redirection of cooks’ skills away from collecting, assembling, & measuring ingredients to production, garnishing, & portion control. • More efficient use of labor. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

22. Centralized Ingredient Control • Control of unused portions is facilitated because storage is located centrally rather than in various work units. • Ability to combine tasks for two or more recipes using similar ingredients. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

23. Function of the Ingredient Room • Primary function is to coordinate assembly, pre-preparation, measuring, & weighing of the ingredients. • Availability of appropriate equipment will help determine the activities to be performed. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

24. Ingredient Room Organization • Should be located between the storage & production areas. • Necessary equipment includes: • Refrigeration • Water supply • Trucks or carts for assembly & delivery • Worktable or counter • Scales ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

25. Ingredient Room Staffing • Employees must be: • Literate • Able to do simple arithmetic • Familiar with storage facilities • Responsible for receiving, storage, & ingredient assembly. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

26. Ingredient Room Staffing • Ingredient assembly personnel considerations: • Size of operation • Frequency & time of deliveries • Size of ingredient room & location of other storage areas • Type, number, & complexity of menu items • Number of workstation to be supplied • Schedule for delivery of ingredients to production & serving areas • Extent of pre-preparation performed in ingredient assembly area ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

27. Future of Ingredient Rooms • Centralized or food factories are being used for procurement & production. • Prepared menu items are distributed to several remote areas for final preparation. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

28. Recipe • Formula by which weighed & measured ingredients are combined in a specific procedure to meet predetermined standards. • Written communication tool that passes information from the foodservice manager to the ingredient room & production employees. • Quality & quantity control tool. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

29. Recipes • Recipes include: • Name of food item • Total yield • Portion size & number of portions • Cooking time & temperature • List of ingredients in order of use • Amount of each ingredient by weight, measure or count • Procedures • Panning or portioning information • Food safety (HACCP) guidelines. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

30. Format • All recipes in an operation should be in the same format. • Common large quantity formats: • Block format • Complete block format • Modified block format ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

31. Block Format • Ingredients listed on left side of recipes. • Procedures directly opposite ingredients on right side. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

32. Complete Block Format • Horizontal lines separate each group of ingredients with procedures. • Vertical lines separate the ingredient, amount, & procedure columns. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

33. Modified Block Format • Most common • Horizontal lines separate the required ingredients for each procedure. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

34. Format • Additional information often added at bottom or on back: • Approximate nutritive values per portion • Variations on the recipe • Special serving instructions • Storage requirements before & after service ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

35. Format • Recipes should be in large print easily readable from 18-20 inches. • Recipe name should be in bold letters. • Major categories (breads, meat, salad, etc.) may be color coded to make identification easier. • KEEP BACKUP OF RECIPES!!! ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

36. Standardization • Ideal to have recipes that consistently deliver the same quantity & quality product when followed precisely. • Recipe standardization – process of tailoring a recipe to suit a particular purpose in a specific foodservice operation. • Requires repeated testing. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

37. Justification • Advantages for using standardized recipes: • Promote uniform quality of menu items. • Promote uniform quantity of menu items. • Encourage uniformity of menu items. • Increase productivity of cooks. • Increase managerial productivity. • Save money by controlling overproduction. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

38. Justification • Advantages (cont.): • Save money by controlling inventory levels. • Simplify menu item costing. • Simplify training of cooks. • Introduce a feeling of job satisfaction. • Reduce anxiety of customers with special dietary needs. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

39. Three Phases of Recipe Standardization • Standardized recipes: • Developed for use by a foodservice operation. • Found to produce consistent results & yield each time prepared. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

40. Three Phases of Recipe Standardization ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

41. Recipe Verification • Review components of the recipe • Recipe title • Recipe category • Ingredients • Weight/measure for each ingredient • Preparation instructions • Cooking temperature & time • Portion size • Recipe yield • Equipment to be used ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

42. Recipe Verification • Make the recipe • Verify the recipe yield • Record changes to the recipe ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

43. Product Evaluation • Informal Evaluation: • Visual appearance • Flavor • Ability to obtain ingredients • Cost per serving • Labor time • Availability of equipment • Employee skill ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

44. Product Evaluation • Formal Evaluation • Select group of staff members & customers as a taste panel. • Choose or develop an evaluation instrument. • Prepare sample recipe. • Set up sampling area. • Sampling & evaluation of products. • Summarize results. • Determine future plans for the recipe. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

45. Quantity Adjustment • Methods include: • Factor method • Percentage method • Direct reading measurement tables • Computer software also available ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

46. Factor Method • Change ingredient amounts to whole numbers & decimals. • Divide desired yield by the recipe yield to determine the conversion factor. • Multiply all recipe ingredients by the conversion factor. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

47. Factor Method • Reconvert decimal unit back into pounds & ounces or quarts & cups. • Round off amounts to quantities simple to weigh or measure. • Check math for possible errors. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

48. Percentage Method • Convert all ingredients from measure or pounds & ounces to tenths of a pound. • Total the weight of ingredients in a recipe after each ingredient has been converted to weight in the edible portion. • Calculate the percentage of each ingredient in the recipe in relation the total weight. • Check the ratio of ingredients. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

49. Percentage Method • Establish the weight needed to provide the desired number of servings. • Add handling loss to the weight needed. • Multiply each ingredient percentage number by the total weight to give the exact amount of each ingredient needed. • Convert to pounds & ounces or to measures. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458

50. Direct Reading Measurement Tables • Quick to use & require no mathematical calculations. • Used to adjust weight & volume of ingredients in recipes that are divisible by 25. ©2004 Pearson Education, Inc. Upper Saddle River, New Jersey 07458