supervisor on mar1

8/14/2019 Supervisor on Mar1

1/32


2/32

R & D Department


3/32

Family mart would like FFA improve taste of GW553

INTRODUCTION

FFA decide to improve taste GW553 for- More delicious ,Soy sauce flavor ,Spice taste

RD TAB & FFA Co-Operation test on Lab - Test

TAB & FFA Co-Operation Cp - Test

R & D Department


4/32

Detail of Lab-Test

- 2 R/M size ( 15-19g ,18 -22g), 2 Typerecipe ,

- Up soy sauce in MR- Add Soy sauce powder MN in BA- Remove salt , sugar in BA

- Family mart can accept this lab sample

- Confirm quality by Cp- Test 1 st

- 2 R/M size : 15-19g ,20-24g

- Change recipe in MR- Change white pepper to Gaban White

pepper- Fry condition : From 165 C , 3.00 min- To 180 C ,2.00 min ,2.20 min

Lab Test1 st : 1/10/50

Lab Test2 nd :30/11/50

- 2 R/M size ( 15-19g ,18 -22g)- Change recipe in MR- Add Koji Aji in MR for delicious taste

Result of test

- All most are OK but weak soy sauce flavor- Taste not on target

- All most are OK but have to improve taste

- R/M 20 -24 is little big size of finishedproduct

Lab Test3 nd :8/1/51

R & D Department


5/32

CP Test 1 st On5/02/51

Result of cp-test : - Family mart cant accept cp-test sample weak soy sauce flavor- FFA request Lab-Test again

- For confirm quality of lab-test 3 nd 8/01/51 - Confirm dropping test by New skewer Teppou skewer

Teppou skewer

Broken skewer

R & D Department


6/32

Lab Test 5 th on 27/02/51

- Family mart can accept this labsample

- Confirm quality by Cp Test 2 nd

Result of test

CP Test 2 On 5/02/51

- For confirm quality of lab-test 27/02/51

- Confirm dropping test by current skewer

- Increase Soy sauce extra in MR

- Increase Soy sauce powder in BA

- FFA & Family mart can accept this cp test

- Result of dropping test is OK

R & D Department


7/32

Conclusion of GW553 Rev. : GW568- GW553 (Karaage kushi) To GW568 (Karaage

kushi)- R/M size : Bl K 18 -22 g- Used Gaban white pepper (From Malaysia)- Current skewer ( Same GW553)

Schedule of GW568

- FFA & Family mart conclusion on Feb.- Prepare R/M , Ingredient & Package with in Mar.- Mass Production about on 1 April- Delivery to Japan on April

R & D Department


8/32

R & D Department


9/32

Market detail Fried Roasted

Home maid 40 11Cooked in store 30 54

Frozen (retail) 10

Chilled (retail) 4

Total 84 69

4

* Billion baht

2007 forecast chicken market (retail product)

R & D Department


10/32

Fried Chicken MarketFried Chicken Market

We have 30% in fried chicken market bymainly RWK1- W & ROK1. It means market leader .

Roasted Chicken MarketRoasted Chicken Market

We have no share in roasted chicken market.So we have to try to gain by SYC & New charcoalproduct (2008 autumn).

R & D Department


11/32

Why they stopped using frozen food?Why they stopped using frozen food?

1. Not delicious 48 50

2. Anxiety for meat 17 30

3. Too small 30 18

4. Too expensive 35 19

5. Time for cooking 3 3

2005 2007 (%)

R & D Department


12/32

Why they stopped using frozen food?Why they stopped using frozen food?

In 2007, the ratio of anxiety for meat increase twice as morethan 2005.So we can win in the market if we clearly informconsumers about the safety of Betagros chicken meat.

From 2008, FFA will say much louder about the safety of Thai chicken, promotion in store and message on our package.

1. Good taste

2. Safety raw material

3. TraceabilityR & D Department


13/32

Preference of new product idea (n=80)Preference of new product idea (n=80)

Sumibi chicken 4P(yakitori sauce)

Vege in Tsukune4P (sumibiyaki)

Sumibi chicken 4P(oroshi sauce)

1. Absolutely buy 3 4 4

2. Want to buy 66 68 24

3. Cant decide 28 26 55

69 72 28

Tsukune need some another machines and to take moretime than sumibi chicken. So we decide to make Sumibi chicken

(yakitori sauce) for 2008 autumn.

R & D Department


14/32

Image of the new productImage of the new product

1. Texture of chicken (soft & juicy)

2. Using safe chicken

3. Charcoal flavor

4. Taste of yakitori sauce

5. Other ingredients like vegetables( Healthy food product)

Same asSYC

We will try them on new product.

R & D Department


15/32

Image of packageImage of package

Subdividable 4 hole tray + pillow film

R & D Department


16/32

RBS Cp test1 st on 25/02/51

Detail of

Cp Test & Result of Cp -test

Result of sensory test

Confirmation point in next cp -test

R & D Department


17/32

RM

PROCESS

BL-K 23 27 g

(New size)

SELECTION

TUMBLING(75 MIN CONTINUE )

- : 14.6%

- 9.62%

DRAIN

R & D Department


18/32


19/32

PROCESS

IR 1, IR 2 OFF : X -Actual cp test use IR2 for solveskin attach CV.

CR - ROASTER- Charcoal 4 kg/box, takt time 500

- Clearance 20 180 mm, time 500

2 nd STEAM

PUT IN TRAY

- Chicken 4 pcs/tray

- Skin side is upper

R & D Department


20/32

PROCESS

FILLING SAUCE

FREEZING

Chicken 1 pcs/sauce 5 g

(spiral freezer)

Product A/F Frozen

R & D Department


21/32

PROCESS

WEIGHT CHECKER

X RAY DETECTER

CARTONING- 12 bags/box, 2 boxes/case

COLD STORAGE

WRAPPING (By Machine)

METAL DETECTOR

X- Plan test machine on 22 26/03/51

R & D Department


22/32

1. Difficult of put skin bottom when molding that effect to som

3. Have clearance during IR2 CV. & CR CV. Effect to product

4. Color of product some pieces are too dark next cp test mus.

CR conveyor

Product drop

5. Product A/F steam 2nd found huddle meat , not flat that effect to sauce

2. R/M is small size that easy to skin separate during process

R & D Department

Co operatewith supplier


23/32

Appearance : All most nearly OK but cant accept should to improve dark color point

Taste & Flavor : That tend of CR are OK but not enough chacoal flavor

Texture : The edge of product little hard but can accept

OKNG NG

R & D Department


24/32

- Test 2 type of Tray

Type 1 Type2

R & D Department

Choice type 2

- Easy to put on tray

- Look good appearance


25/32

1. Improve taste and appearance

2. Process speed (1 st CP-test 220 pcs/min, target 320 pcs/min)

3. Find easy method take off meat from mold

4. Wt./Pcs.

5. Test making sauce in line ( by Kneader)

6. Test wrapping machine

R & D Department


26/32

1.DECREASE % LOSS OF BOILING BAG GW086

- Auto vacuum setting too difficult especially

sealing and sauce weight.

- Thickness of bag not appropriate for machine

- Size of bag not convenience for working

Cause of reject boiling bag GW086

From Start - Jan

IMPROVEMENT PROJECT

Characteristic of reject

- Shrink seal

- Dirty on seal

- Seal not complete

- Adjust wt. sauce etc.

R & D Department

IMPROVEMENT PROJECT


27/32

IMPROVEMENT PROJECT

% Boiling bag reject / shife

0.00

5.00

10.00

15.00

20.00

25.00

30.00

35.0040.00

45.00

50.00

55.00

1 2 3 4 5 6 7 8 9 10 11 12

No.of production

% reject

Dec. JanFeb

Avg. 28.81%

Avg. 14.67%

Avg. 22.51%

-1.914.306FebNew size

30329.611.7823.118Avg.

10601.671.7826.302Jan

50057.551.7819.934Dec.Old size

Dif (Bath)Cost /

pcs.(Bath)Total%Reject/

MonthMonthBag

Old bag- SIZE ( W * L ) : 140 *190 mm.

- Thickness : ( LLDPE ) 60

New bag- SIZE ( W * L ) : 150 *190 mm.

- Thickness : ( LLDPE ) 70

Conclusion

New boiling bag can decrease% loss of bag

% loss boiling bag New sizeis 14.306 % it still highshould to improve.

Profit of new bag

R & D Department


28/32

Check process that how to reducesetting sauce and control wt. a/f put inbag on std.

- STD. : Wt. A/F put in bag 150g/Bag: Wt. Min. 145.5g/Bag

CP Test

Meat a/f steam 77 g up + Setting sauce

75 g Found problem some bag under wt.

Actual production

Meat a/f steam 77 g up + Setting sauce79 g

Found wt. some bag over wt. too much(150 175 g) Avg. 165 g

2.DECREASE WT. SETTING OF SYC SAUCE

Auto vacuum sauce packing

R & D Department


29/32

Actual process

- To much meat a/f steam delay put in bag

- Delay time of meat b/f put in bag is over 20 min

- Wt. of put in bag 150 175 g ,Avg. 165 g

Effect of this process

- Weight meat a/f steam loss

- Charcoal flavor loss

- Wt. a/f put in bag risk to under wt.

- Quantity of sauce /bag is high

R & D Department


30/32

- Delay time of meat b/f put in bag is less 10

min

- Meat delay b/f put in bag not over 3 box

Control process

- Good smell charcoal flavor

- Wt. a/f put in bag is over (160 170 ) Avg.165.0 g

Result of controlprocess


31/32

Test reduce sauce

10 min150 - 172158.0375 - 9784.9475 g

Immediately154 - 177165.3173 - 9888.61

15 min149 - 171158.8374 - 9584.29

10 min160 - 169164.7477 - 9587.82

79 g

RangeAvg.RangeAvg.

Delay time a/f steam b/f fill sauce

Wt. a/f put in bagWt. a/f steamWt.setting

- Setting 75g/Bag

- Control delay time less 10 min

- Control meat delay b/f put in bag not over 3 box

Conclusion Reduce

settingsauce

R & D Department


32/32

supervisor on mar1

Documents