manong pepe karinderia
TRANSCRIPT
Quality AssuranceStore Audit Report
February 22 – March 10, 2010
by:Maida S. GamboaR&D/QA Department
March 18, 2010
Objectives Maintenance of Gold Standard Quality
Products across all stores Evaluation of the holding and storage
equipment and temperatures Evaluation of product conditions during
storage and holding Assurance of FIFO implementation Assessment of the Good Manufacturing
Practices of the stores
Scope Product Quality Audit Product Storage and Holding Quality Audit Good Manufacturing Practices Inspection
Product Quality Audit
Product Quality Audit General Presentation
Product Presentation Serving Portion Serving Temperature (for rice, soup and soup based
products) Organoleptic Properties
Color/Appearance Aroma Taste/Flavor Texture/Mouthfeel Consistency
Rating Category Scaling
1 – Poor 2 – Fair 3 – Good 4 – Very Good 5 – Excellent
Rice 13% of the stores met gold standardsDeviations Major MinorBelow standard serving temperature (70°C)
79%
Dark and Dry 40%Stale 7%Underportioned 25%
Rice Findings
Possible Causes Prolonged opening of the rice warmer Steaming beyond standard time Holding beyond standard time Incorrect rice: water ratio Refilling of steamed rice into used rice keepers Loosely packing of rice into rice scoopers
Soup 27% of the stores met gold standards
Deviations Major MinorBelow standard serving temperature (70°C)
64%
Without pechay leaves
50%
Soup Findings
Possible Causes Prolonged opening of the soup kettle Broken soup warmer knob Failure to follow the standard serving portion Unavailability of vegetables
Core Products Beef Caldereta Laing Sweet Garlic Chicken Fried Lumpia
Beef Caldereta 50% of the stores met gold standardsDeviations Major MinorUnderportioned (3pieces)
7%
Thick sauce 7%Prominent oil separation
13%
Tough meat chunks (connective tissues)
7%
Tough potato 7%
Beef Caldereta Findings
Possible Causes Inadequate portioning Undercooked meat chunks
Particularly those containing connective tissues Undercooked potatoes Failure to comply with standard holding procedures
Mixing of products every 15 minutes Troubleshooting
Laing 7% of the stores met gold standardsDeviations Major Minor Olive – brown color
73%
Dry 27%
Laing Findings
Possible Causes Cooking beyond standard time Holding beyond standard time
Sweet Garlic Chicken 36% of the stores met gold standardsDeviations Major MinorTough, dry and dark meat
36%
Undersized 27%
Dried up honey garlic sauce
18%
Thin sauce consistency
9%
Sweet Garlic Chicken Findings
Possible Causes Over thawing Frying beyond standard time Extensive holding Storage of honey garlic sauce in frozen condition
Fried LumpiaDeviations Major MinorSoft and oily wrapper
100%
Pale 7%
Burnt filling due to wrapper holes
13%
Soft filling (carrot strips)
13%
Fried Lumpia Findings
Possible Causes Holding beyond standard time Holding at ambient conditions after frying (not
immediately transferred into fried warmers) Horizontal arrangement of the product during holding Too thin lumpia wrapper; prone to chilling injury Thawing Loosely sealed lumpia wrapper Overcooked filling
Merienda Spaghetti Palabok Miki Bihon
Spaghetti 68% of the stores met gold standardsDeviations Major MinorWatery; bland 25%
Underportioned noodles
7%
Spaghetti Findings
Possible Causes Noodles were not thoroughly drained Noodles were under weighed: 100g
Palabok 93 % of the stores met gold standards
Deviations Major MinorWatery 7%
Palabok Findings
Possible Causes Noodles were not thoroughly drained
Miki Bihon 38% of the stores met gold standardsDeviations Major MinorSoft vegetable toppings
22%
Bland bihon concentrate and garlic flavors
22%
Dry and salty noodles
22%
Miki Bihon Findings
Possible Causes Overcooked vegetables Incorrect proportion of ingredients Excessive evaporation of bihon concentrate Overholding
Kontra Init Halo Halo Mais con Yelo Saba con Yelo Sago’t Gulaman
Halo Halo 100% of the stores met gold standards
Mais con Yelo 100% of the stores met gold standards
Saba con Yelo 37% of the stores met gold standards Deviation Major MinorSaba had uneven dark patches of brown
63%
Dark saba 7%
Saba con Yelo Findings
Possible Causes Saba was not mixed while held with the syrup Steamed syrup and saba were held beyond standard
time
Sago’t Gulaman 100% of the stores met gold standards
Dessert Buco Pandan
Buco PandanDeviations Major MinorNot within the standard serving temperature
100%
Cream sauce had thin consistency
100%
Buco Pandan Findings
Possible Causes Inefficiency of the salad tray to hold brine (ice + salt)
for 4 hours
Breakfast Fried Egg Hotdog Longganisa Tocino
Fried Egg 87% of the stores met gold standards
Deviations Major MinorOvercooked yolk 7%
Too brown edges
13%
Fried Egg Findings
Possible Causes Cooking beyond standard time Cooking beyond standard temperature
Hotdog 87% of the stores met gold standardsDeviations Major MinorHad an off-flavor 7%
Wrinkled 7%
Dried up surface 7%
Hotdog Findings
Possible Causes Hotdog and longganisa shared a common food pan in
the Baine marie Overcooked
Longganisa 87% of the stores met gold standardsDeviation Major MinorPale 13%
Longganisa Findings
Possible Causes Undercooked
Tocino 37% of the stores met the gold standardsDeviations Major MinorIrregularly shaped slices
63
Underportioned 63
Thick, tough and dry
63
Tocino Findings
Possible Causes Improper slicing Holding beyond standard time
Product Storage and Holding Quality Audit
Product Storage Quality AuditDeviations Major MinorProper stacking of products not observed
47%
Chiller temperature below the standard (-3.0)
7%
Products stored in the chiller and freezer without cover
80%
Product Storage Quality AuditDeviations Major MinorChilled products stored in frozen conditions
20%
Due to limited storage space
13%
Product Storage Quality AuditDeviations Major MinorProducts stacked beyond the maximum stacking height
40%
Contents of opened packs not transferred into covered containers
53%
FIFO not observed in stacking
7%
Product Holding Quality AuditDeviations Major MinorBroken Baine Marie knobs
13%
Broken soup warmer knob
7%
Product Holding Quality AuditDeviations Major MinorBaine Marie temperature set below 80°C (40, 60, 70 °C)
20%
Products in the Baine Marie not mixed every 15 minutes
40%
Good Manufacturing Practices
Good Manufacturing Practices
Deviations Major MinorDirty kitchen and dining area floor (wet; with stains)
53%
Flies coming in contact with the food and customers
53%
Baine Marie knobs were broken
13%
Good Manufacturing Practices
Deviations Major MinorRoaches were visible in the dining area
13%
Assemblers were serving without face mask on
33%
Assembler and other staffs were serving without gloves on
73%
Good Manufacturing Practices
Deviations Major MinorMODs not wearing hairnet within the hairnet zone
80%
Crates with deliveries were placed on the floor without underliners
7%
Poor water supply 7%
Good Manufacturing PracticesDeviations Major MinorProducts withdrawn from the chiller were placed on top of trash bin
7%
Used knives were used in opening boilable bags (steamed)
13%
Good Manufacturing PracticesDeviations Major MinorWarm in the dining area making unwanted odors very perceptible
7%
Same chopping board was used in slicing meat and vegetables
13%
Good Manufacturing Practices
Deviations Major MinorKitchen leader/assembler with unshaved beard and mustache
20%
Dining area ceiling had spider webs that harbored dusts
7%
Rice keepers were not thoroughly washed and dried prior to refilling
7%
Good Manufacturing PracticesDeviations Major MinorAssembler used the toilet with apron, hairnet and face mask on
7%
Food pans with steamed products were brought to the dining area (downstairs) without cover
7%
Good Manufacturing Practices
Deviations Major MinorAssemblers/KLs wipe the BM area without removing gloves
13%
Other Observations Holding of steamed products in hot water
bath Causes overcooking Further color degradation in laing leaves
Conclusion Most common deviations from serving
Gold Standard Quality Products were due to Serving temperature Holding conditions
Conclusion 50% of the products evaluated had
deviations from ≥50% of the stores Rice Soup Laing Sweet Garlic Chicken Fried Lumpia Miki Bihon Saba con yelo Buco Pandan Tocino
Conclusion 50% of the products evaluated had
deviations from <50% of the stores Caldereta Spaghetti Palabok Halo Halo Sago’t Gulaman Mais con Yelo Fried Egg Hotdog Longganisa
Conclusion Storage and Holding Deviations occurring
in ≥50% of the stores Storing of products in the chiller and freezers
without cover Not transferring the contents of opened packs
into covered containers
Conclusion GMP Deviations occurring in ≥50% of the
stores Major
Presence of flies in the dining, Baine Marie and kitchen areas
Assembling orders without gloves on Dirty kitchen and dinning area floor
Minor MODs without hairnet within the hairnet zone
Recommendations Products
Observe the standard serving portion and temperature especially for rice and soup
Minimize over production to avoid extensive holding of products
Follow the standard holding conditions Holding time Mixing of products in the Baine Marie Troubleshooting measures
Recommendations Storage
Store products in their appropriate storage conditions
Ensure sufficient storage space for chilled products especially for high volume stores
Develop stacking guidelines Orient mother stores on Standard Guidelines on
the use of water bath in steaming and holding Ensure that all the products stored in the freezer
and chillers are covered to avoid cross contamination
Ensure immediate repair of faulty equipment
Recommendations GMP
Review of guidelines on gloves and hairnet use More efficient pest control measures Maintenance of cleanliness within the stores
Thank You!