Domain IV, Topic B

  1. Food production control procedures
  2. Quality control—assuring day-in, day-out consistency in each product offered for consumption.
  3. Quantity control—producing the exact amount needed—no more, no less.
  4. Portion control—the achievement of uniform serving sizes, which is important not only for control of cost but also for customer satisfaction.
  5. Purchase of food according to detailed & accurate specifications to assure that the food purchased will yield the expected number of servings.
  6. Development & use of standardized recipes
  7. Knowing the size & yield of all pans, dishers, & ladles & stating the specific production & service equipment for each standardized recipe.
  8. Scoop Sizes

Dipper # / Approx. Measure / Suggested use
6 / 10 Tbsp (3/4 c) / Entrée salads
8 / 8 Tbsp (1/2 c) / Entrees
10 / 6 Tbsp (3/8 c) / Desserts, meat patties
12 / 5 Tbsp (1/3 c) / Vegetables, muffins, desserts, salads
16 / 4 Tbsp (1/4 c) / Muffins, desserts, croquettes
20 / 31/5 Tbsp / Muffins, cupcakes, sauces, sandwich fillings
24 / 2 2/3 / Cream puffs
30 / 2 1/5 / Lg drop cookies
40 / 1 ½ / Drop cookies
60 / 1 Tbsp / Small drop cookies, garnishes
100 / 2 tsp / Tea cookies
  1. Ingredient Control—two major aspects:
  2. Ingredient assembly—designed for measuring ingredients to be transmitted to the various work centers
  3. Use of standardized recipes—the process of tailoring a recipe to suit a particular purpose in a specific foodservice operation

--when adjusted to an accurate forecast quantity, these recipes provide assurance that standards of quality will be consistently maintained

--Advantages for using:

  • 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
  • Save money by controlling overproduction
  • 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

v. Forecasting production—the art & science of estimating events in the future & provides the database for decision making & planning.

Types of models
  1. Time Series Model—
  2. Involves the assumption that actual occurrences follow an identifiable pattern over time.
  3. Most suitable for short-term forecasts in foodservice operations
  4. Types:
  5. Moving average forecasting model (used only on items that are of the same kind)
  6. Exponential smoothing forecasting model (time series model that is set up on a computer)
  7. Causal Model—
  8. Based on assumption that an identifiable relationship exists between the item being forecast & other factors
  9. Expensive & suitable for medium and long term forecasts
  1. Types:
  2. Regression analysis forecasting models (require a history of data for the dependent & independent variables to permit plotting over time)
  1. Subjective Model—
  2. Used when relevant data are scarce or patterns & relationships b/t data do not tend to persist over time
  3. Must rely on opinions & other info, generally qualitative, that might relate to the item being forecast.
  4. Types:
  5. Delphi technique (involves a panel of experts who individually complete questionnaires; results are summarized & then revised until a simple majority agreement is reached)

Tools of production control

1. Gantt progress chart

2. Program Evaluation & Review Technique (PERT)—system that uses a network to depict the sequence of activities in a particular project.

3. Critical Path Method (CPM)

  1. Production systems

Type / Description / Advantages / Examples
Conventional / Preparation is done on premises where served / -Tailored to individual preferences
-Provides menu flexibility
-Low distribution costs / Centralized—one serving area using temp ctrl
Decentralized—2 serving areas for bulk food delivery
Automated cart—build in monorail; expensive due to duplicate services
Commissary / Food production & service area are in separate facilities / Uniform quality of products for all units
Centralized-no duplicate equip or personnel / Satellite—centralizes production
Ready-Prepared
Cook-Chill
Cook-Freeze / Uses blast freezer & rethermalization for preparation & service / Production schedule more liberal
Lower labor costs
Menu items on call / Microwaves
Convection oven- bulk heating
Intergral heat system
Immersion-boiling H2O to heat food pouches
Assembly Serve / Food is purchased already prepared
Food is then thawed & heated on premises / Curtails labor time
Less equipment
  1. Production scheduling—the time sequence of events required by the production subsystem to produce a meal
  2. Planning stage—forecasts are converted into the quantity of each menu item to be prepared & the distribution of food products to supervisors in each work.
  3. Production schedule
  4. major ctrl in production subsystem; activates the menu & provides a test of forecasting accuracy
  5. highly individualized in various foodservices
  6. Info that must be included: unit, production date, meal, customer count, weather, & special events

4.Distribution

a. Form of food delivered

b. Equipment

Types of Meal Distribution / Benefits / Constraints

Hot Thermal Retention

Heated base / Support equip & system operation are uncomplicated
No req for a special plate: any std-size chine.
No special delivery cart is req / Provisions for maintenace of cold items such as milk, salads, gelatin, ice cream are not made.
Hot food cannot be held for a long period of time.
Additional service ware pieces need to be inventoried, stored, transported, & washed.
Induction heat bases: difficult to determine if heating process initiated.
Insulated components / Only the dinner plate & food are heated; there are no special bases to heat. Simple in operation. No burn hazard to the attendant or customer. No special delivery cart is req. / Additional service ware pieces need to be inventoried, stored, transported, & washed.
Attractive insulated components are often taken home by pts as useful memento of their hospital experience.
Heat support cart / Foods remain heated until tray is removed for service to the pt. / The potential for maintenance/repair problems is high.
Carts can be heavy & diff to maneuver.
No provisions are made for maintenance of cold food items at proper temp.

Hot & Cold Thermal Retention

Split tray / Centralized supervision & ctrl of the meal assembly process.
No reassembly of tray components is req in the service areas.
Good temp retention of both hot & cold items.
System accommodates late trays within a reasonable period. / Cart is heavy & bulky. A motorized version may be req if any ramps are to be negotiated.
Carts are diff to sanitize.
Initial cost of the cart is high & maintenacnce costs can be high.
Due to the relatively heaby wt Y limited maneuverability, carts & wall surfaces are subject to damage.
Match-a-tray / Same as described for split tray except that decentralized assembly of meal trays is req prior to service. / Same as described for split ray.
Additional labor prior to service is needed to reasseble the complete pt meal.
Insulated trays / Maintains hot & cold zones well w/out external heat or refrigerant sources.
Simplicity of transport is achieved.
Does not req a heavy, enclosed delivery cart. Stacked trays protect & insulate food.
Less lead on the dishwashing facility due to disposables.
No complex components to repair, replace, or maintain. / Purchase of special disposable dishes results in higher operational costs. Food holding time is limited to 45 minutes. Long-rg cost could be substantially higher than other systems due to disposable & lease costs.
Insulated components / Only the dinner plate & food are heated. No bases to heat No burn hazard to the attendant.
Cold food items can be held longer than 30 min.
No special insulated delivery cart is required. / Additional service ware pieces need to be inventoried, stored, transported, & washed.
Attractive insulated components are often taken home by pts. As useful mementos of their hospital experience.

Cold Thermal Retention/Food Reheating

Refrigerated carts w/ conduction heat units / Centralized supervision & control of the meal assembly process.
No reassembly of tray components in service area.
Good refrigerated temp retention / Carts diff to sanitize
Initial cost of carts is high & maintenance cost can be high.
Hot bev. Must be added just prior to service.
All hot food items must fit on plate or bowl to be on conduction base.
Split-cart—refrigerated & convection heat / Same as described for refrigerated carts w/ conductin units.
All food items can be placed on tray in central assembly area. / Cart is heavy & bulky
Initial cost is very high

No Thermal Support

Covered tray / Tray is a simple standard unit
Equipment cost of the system is low. / Requires an immediate & responsive transportation sys
High labor component is required for transportation process.
No thermal support is available for entrée & other food items.
Equipment / Purpose / Procedure
3-compartment sink dishwasher / Clean & sanitize / Wash: 110-120’F
Rinse: warm water
Sanitize: 170’F for 2 min, or use chemical solution for 1 minute @ 75”F
Mechanical dishwasher / Clean & sanitize / Pre-rinse, pre-wash: 110-140’F(removes food)
Wash: 140-160’F
Rinse: 170-180’F (sanitizes)
Air-dry: 45 sec
Deck oven / Stacked to save space in oven
Convection oven / Fans for circulation; even heat distribution; less time; more quantitiy
Rotary oven / Revolving tray for lg volume baking; can be used for meats
Microwave oven / Food cooked very rapidly. “On-demand” pt feeding can be achieved
Large batch compartment steamer / More energy efficient than electric or gas / Measured in 5-8 PSI (Pounds per Square Inch)=225-235’F
High pressure steamer / Speed facilities batch cooking; reduces long holding periods, better quality, uniform cooking, fewer leftovers
No pressure convection steamers / Compact; handle large quantities
Steam-jacketed kettle / VERY Energy efficient; circulates steam through conduction & radiation heat so that food does not touch steam; / Uses water & a drain for operation
Measured in 5-8 PSI
Sizes: 5-20 gallons for vegetables
Up to 40 gal for entrees
>40 gal for high
Infared tubes / Keeps food warm; less loss of moisture over conventional heating
Mixers / Providers planetary action in which arms move in circles while rotating beater
Deep-fat fryers / Uses pressures to decreases cooking time / Use recovery time to see how quickly it returns to proper temp after a batch of food has been cooked
Self-contained refrigerator / Temp regulated through attached compressor