Production Plan Sample

7/27/2019 Production Plan Sample

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III. Production and Operations plan

A. Product Design and/or Business modelKey Networks

-GoldsboroCommercial, Inc.(packaging)-Chocolate Lover,

Inc. (chocolates)-PeotracoIndustries (flour)

-DW PlasticCorporation (straw)-Aquapure (water)-BRS Apartments(warehouse)

-Food Bizz (stall)-SM BusinessCenter (location)

Key Partners

-Emilisa Salih(General Manager)-Shepherd Busto(OperationsManager)

-Kimberly Ragasa(Marketing

Manager)-Charlene Sorilla

(Finance and HRManager)

Key Activities

-Supply the rawmaterialsneeded.-space for the

furtherprocessing ofraw materials

(not included install process)-construction ofthe stall-stall location

Key Resources

- containers and

foils-straws-chocolate bars-flour-water

-warehouse-stall

-location

Value Propositions

-Grab N Go snack- all-in-one-Low cost-snack food

-new to the snackmarket, since it

provides 3-in-1 snack

meal.-innovative packaging-new to the customers

but medium barriersto entry because of

uncertainty ofintellectual property(packaging basedfrom another country)-Quality product

making usingtechnologies-Specially made forstudents.-Cold Drink but hot

and freshly madechurros, quick punch

straw.

CustomerRelationship

-friendlyemployees thatcan

accommodatecustomers atany age.

-Maintainingcleanliness inworkplace-brandestablishment

Distribution

Channels

-Intramuros

stall-Franchises (ifany)-Schools(to be able to

get in touchwith our target

market)

CustomerSegments

-for studentsstudying inManila esp. near

Intramuros andU-belt area-for people who

impulsivelyfeeling somechocolatecravings- for children

Cost Structure-location cost ( PHP 15,000 to PHP 26,000 php)

-raw materials (per wholesale) and equipmenttotal costs range from 30,000-50,000 php.

Revenue Statements-10,000 php allocated for marketing costs (posters

and print ads)-50,000 php for salaries

-50,000 php for business reserve.


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B. General Input-Process-Output FrameworkSuppliers/Manufacturers

1. Jadd ZedricPackaging &

General

Merchandise

2. Food Depot &Cold Store

3. Chocolate Lovers4. Goldsboro

Commercial, Inc.

Inputs/ Enablers

1.Labor- Sales people- Cashier

2.Raw materials- All-purpose

flour and

vegetable oil

- Chocolatesyrup

- Purified waterand ice plastic

container

- Plastic lid- Plastic divided

3.Furniture andfixtures and others

- Chairs- Table

4.Packaging- Stickers

5.Equipment- Deep fryer- Mini

refrigerator

6.Permits- Mayors

permit

- SEC certificate- DTI business

name

certificate

- Baranggayclearance

- Taxidentification

number

- BIR certificate- DOLE

registration

7.Contract- Lease- Manufacturer

8.Suppliers- Cans- Paper bags- Boxes

9. Location- Interior design

10. Utilities- Electricity- Water

Process Flow Outputs

1.Churros withJuice

Wastes

1.Packaging

Productitself

Ingredients

Customers

1.Studentsstudying inManila

especially near

Intramuros and

U-belt area2.People who

impulsively

feeling some

chocolatecravings

3.Children

Identification of vital

business factors

Idea generation

Derivation of product

concept

Identifying location

Accomplishing allbusiness certifications

and permits

Acquisition of

equipment and furniture

and fixtures

Hiring worker/s

Business launching

Acquisition of

inventory

Daily operation

Inventory checking

Profitability checking

Business performance

evaluation

Customer feedback

Market analysis

Employee performance

evaluation


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Cooking Process

1. Making a dough:a. Combine water, salt, vegetable oil, butter, and sugar in a pan over medium heatb. Bring the mixture to a boil and add the all-purpose flour and gently mix until the

dough form like a ball.

c. Remove the mixture from the heat.d. When the mixture is cold add egg and mix until sticky.

2. Frying:a. Scoop the dough into the piping bag.b. Push the dough direct to the frying pan for deep fry.c. When the dough turns gold it means that it is already cooked.

3. Juice:a. Mix water, juice and ice (if necessary).b. Mix well until the powder dissolved.

4. Dip:a. Bring the chocolate into a medium heat.

C. Aggregate planning and master SchedulingMaster Production Schedule

Weekly BI 1 2 3 4 5 6 7

Forecast 1224 1224 1224 1224 1224 1224 1224

Projected Available 1260 36 72 108 144 180 220 256

MPS 1260 1260 1260 1260 1260 1260

Above details shows the calculation when we need to have replenishment orders of raw

materials. The forecast came from the projected sales demand converted to weekly. The

Projected available came from the capacity of how many snackpacks they can produce weekly

D. Supplies Management (process plan, Material requirements, forecasts)Process for Churros

Making dough:

1. Combine water, salt, vegetable oil, butter, and sugar in a pan over mediumheat


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2. Bring the mixture to a boil and add the all-purpose flour and gently mix untilthe dough form like a ball.

3. Remove the mixture from the heat.4. When the mixture is cold add egg and mix until sticky.

Frying:

1. Scoop the dough into the piping bag.2. Push the dough direct to the frying pan for deep fry.3. When the dough turns gold it means that it is already cooked.

Product Life Span

Raw eggs in shell 3 to 5 weeks (Refrigerated)

Breads, baked (no preservatives) 2 to 3 weeks (Refrigerated)

Flour, white or whole wheat 6 to 8 months (Refrigerated)

Butter 2 to 3 months (Refrigerated)

Heavy Cream 1 week (Refrigerated)

Time process to Make Snackpacks

Single Snackpack 10 SnackpacksPreparation for the ingredients 6 minutes 6 minutes

Cooking for the dough 18 minutes including coolingprocess

18 minutes

Frying 8 minutes 20 minutes

Juice 4 minutes 4 minutes

Packaging 10 minutes 30 minutes

In 1 hour and 18 minutes an employee can produce 10 snackpacks

Converted to minutes

1 hour and 18 minutes = 78 minutes

9 hours = 540 minutes

Operating period divided by process time of churros

Process time of churros = 78 minutes


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Operations period = 540 minutes

540 / 78 = 7

7 x 10 snackpacks = 70 snackpacks

In 9 working hours an employee can produce 70 snackpacks. Therefore, in mass production 3

employees can make 210 snackpacks a day in 9 working hours.

Activity Predecessor Description EstimatedTime

(Minutes)

ES EF LS LF

A - Picking up of raw materials

and delivery to stall ( Pasig)

154 0 154 0 154

B - Picking up of raw materialsand delivery to stall (Divisoria)

68 0 68 86 154

C - Picking up of raw materialsand delivery to stall ( Quiapo)

40 0 40 114 154

D A B C Preparation 6 154 160 154 160

E D G Cooking dough 18 160 178 160 178

F E Frying 20 178 198 178 198

G A B C Juice 4 154 158 156 160

H G D Packaging 30 198 228 198 228

Completion Time 340 minutes

Slack (ES-LS): G= 2 B= 86 C= 114

A D E F H 228 CP (Critical Path)

A G E F H 226

B D E F H 142B G E F H 140

C D E F H 114

C G E F H 112


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Details above show that there are 3 slacks. The activities in G, B, and C can be delayed

according to their slack time, for G its 2 minutes, B its 86 minutes, and C its 114 minutes. To

avoid delays, make sure that the activities in the critical path are being managed well. These

activities are picking up of raw materials and delivery to stall (Pasig), preparation, cooking

dough; frying and packaging.Make sure raw materials are always available. There shall be at

least three (3) suppliers.

Snackpack

Ordering cost (K) = Php1200 per order

Carrying cost (Kc) = Php 0.14 per unit (680/4896)Demand (D) = 4896 units

B

68 G

4

C

40

A154

D

6

E

18 F

20H

30

End

Start


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()()

EOQ = 9161 units

.53

()

641.40

Demand Forecast

Projected Sales= 293,453.27

Unit Cost = P 60

Converted to Daily Sales

P 293,453.27/24/P 60 = 204 units

E. Facility requirements and location analysis and layoutLocation Analysis

Venue Address Proximity Cost Otherconsiderations

Walled

stores,Intramuros

Walled stores,

Muralla St.,Intramuros, Manila

Pasig City- Intramuros= 11.4

kilometers(1 hour and 4 minutes)Quipo, Manila- Intramuros= 2.2kilometers (17 minutes) Divisoria,

manila- Intramuros, Manila= 5.9kilometers (43 minutes)

PHP

15,000 toPHP26,000

bidding process

SM CityManila

Natividad Almeda-Lopez, corner A.Villegas and San

SM City Manila Pasig city- SM cityManila=15.5 kilometres(1 hour and2 minutes) Quiapo, Manila- SM

PHP30,000 toPHP

there were noinfo provided


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Marcelino Streets,

Ermita, Manila,Metro Manila,Philippines

City Manila= 1.6 kilometres (18

minutes) Divisoria, Manila- SMCity Manila= 5.9 kilometres (41minutes) 3. Regina 334

45,000

Casa

Regina334

Casa Regina 334,

Intramuros, Manila

Pasig City- Intramuros= 11.4

kilometers(1 hour and 4 minutes)Quipo, Manila- Intramuros= 2.2kilometers (17 minutes) Divisoria,

manila- Intramuros, Manila= 5.9kilometers (43 minutes)

PHP

12,000

2 months

deposit and 1month advance

F. Process plan and Standard ProceduresSanitation Standard Operating Procedure (SSOP)

PURPOSE: To standardize working procedures in order to ensure food safety.

Note: This procedure applies to employees who handle, prepare, or serve food. All procedures

must be followed at all times.

Pre-Operational Sanitations

1. Clean and sanitize equipment, tables, and other product contact surfaces throughout the dayas needed to prevent contamination of food products.

2. Clean processing area floors at the start and end of each production day.The correct cleaning steps for food contact surfaces are as follows:

Wipe away any food scraps and rinse with water. Wash with hot water and detergent to remove any grease. Rinse off any loose dirt or detergent foam with clean water. Sanitize using food grade sanitizers. If instructions require rinsing of the sanitizers, do so3. If necessary, clean the Refrigerator once a week.4. Maintain refrigerators temperature at 4C (40F)


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5. Sanitize equipment with an approved sanitizer that is mixed and used according to themanufacturers directions, and, if required, rinse with potable water.

6. All cleaning and sanitizing chemicals shall be properly labeled and stored separately fromfood and processing areas.

Note: that it is recommended to clean floors first and then clean equipment from top to bottom

7. Change outer garments, properly wash and sanitize hands with hand sanitizer/alcohol, put onclean gloves.

8. Outer garments, such as aprons, hairnet and gloves, are required. Wear the appropriategarments. Keep your outer garments clean and change them at least daily (e.g. gloves) and, if

necessary, more often

9. Follow the SOP for food storage.Operational Sanitations

1. No person with illness, or open/infected wounds is allowed to handle foods or food-contactsurfaces.3

2. All employees must begin their shift wearing clean garments. Raw product processingemployees must wear hair covers and change or clean/sanitize (or replace) outer garments when

they become soiled. Ready-To-Eat (RTE) product processing employees must wear hair covers

and single-use disposable gloves, and maintain the cleanliness of all outer garments.

3. Employees must wash hands: Before starting work

During food preparation

When moving from one food preparation area to another

Before putting on or changing gloves


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After using the toilet

After sneezing, coughing, or using a handkerchief or tissue

After touching hair, face, or body

After smoking, eating, drinking, or chewing gum or tobacco

After handling raw meats, poultry, or fish

After any clean up activity such as sweeping, mopping, or wiping counters

After touching dirty dishes, equipment, or utensils

After handling trash

After handling money

After any time the hands may become contaminated

HAND WASHING INSTRUCTIONS:

Follow proper hand washing procedures as indicated below:

Wet hands and forearms with warm, running water at least 100 F and apply soap.

Scrub lathered hands and forearms, under fingernails, and between fingers for at least 10-15

seconds. Rinse thoroughly under warm running water for 5-10 seconds.

Dry hands and forearms thoroughly with single-use paper towels.

Dry hands for at least 30 seconds if using a warm air hand dryer.

Turn off water using paper towels.

Use paper towel to open door when exiting the restroom.

Use hand sanitizers only after hands have been properly washed and dried.

4. Employees may not use cigarette in production area.5. Employees may not wear jewelry or cosmetic items that could contaminate product.6. Waste is removed when bins are full.


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7. Waste containers are covered, kept clean and emptied after each work period.Post Operational Sanitations

1. Clean processing area floors at the start and end of each production day.The correct cleaning steps for food contact surfaces are as follows:

Wipe away any food scraps and rinse with water. Wash with hot water and detergent to remove any grease. Rinse off any loose dirt or detergent foam with clean water. Sanitize using food grade sanitizers. If instructions require rinsing of the sanitizers, do so2. All cleaning and sanitizing chemicals shall be properly labeled and stored separately fromfood and processing areas.


3. If necessary, clean the Refrigerator once a week.4. Maintain refrigerators temperature at 4C (40F)5. Waste is removed when bins are full.6. Waste containers are covered, kept clean and emptied.7. Follow the SOP for food storage.MONITORING SANITATION:

Use a check list to see if the employees are following the sanitation standard operatingprocedure and write down results to resolve or prevent problems. See Figure 2.G

CORRECTIVE ACTION:

When an item on the check list is missed or poorly done, make sure it is corrected in thecorrective action log. See Figure 3.G


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Be sure to re-check and then write down that it was corrected. Retrain any employee found not following the procedures in this SOP.VERIFICATION AND RECORD KEEPING:

The manager will complete the Food Safety Checklist to indicate that monitoring is being

conducted as specified. The Food Safety Checklist is to be kept on file for a minimum of 1 year.

See Figure 2.G

Standard Measurements

Ingredients Weight Unit usedAll-purpose

Flour

1 kg 1 cup

Sugar 1kg cup

Butter cup

Vegetable

oil

1 liter liter

Egg 2 pcs 2 pcs

Salt 500g tsp

Dark

Chocolate

1 kg 2/3 kg

Heavy

Cream

1030g cup

Tang litro

pack

25g 25g

Water 5 gallon 18.95 liter

SOP (Standard Operating Procedure) 1.1 Procurement/ Picking up/ Receiving Deliveries

PURPOSE: To make certain that all raw materials procured are best of quality and aligned to

customer requirements: To ensure that all food is received fresh and safe when it enters the stall

operation, to facilitate traceability, and to transfer food to proper storage as quickly as possible.

Note: This procedure applies to employees who handle, prepare, or serve food.


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Figure 1.F

Approved Listed Suppliers

Items Supplier(s) / Sources Lead time Quantity req.

Straw, Paper cup & Plastic seal Goldsboro Commercial, Inc. /Dasma packaging & Plastic

products

2 50

Chocolates Chocolate Lovers 1 1 kilo

All-purpose flour & vegetable oil Food depot & Cold Store 1 1 sack

Salt, egg, butter, sugar Market / Puregold 1

Figure 2.F

Procurement Process Flow

Step 1Purchasing

Hazards:

High-risk food contaminated with pathogenic micro-organisms and/or toxins. Contamination by physical materials. Contamination by chemicals. Food of poor physical or microbiological quality through damage, contamination, use of

inappropriate ingredients or the processes of decomposition.

Growth of pathogens/toxin production during delivery process.Controls:

Food must be purchased only from approved listed suppliers (See figure 1.F)

Requirement

Analysis

Writing

SpecificationProcurement


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Step 2Picking up/ Receiving deliveries

Hazards:

High risk food contaminated with pathogenic micro-organisms and/or toxins. Food of poor physical or microbiological quality through damage, contamination or

decomposition.

Wrong specification food delivered. Growth of pathogens/toxin production during period from receipt to storage.

Controls:

All food deliveries must be accepted and checked-in by a member of staff. All pre-packed foods must be appropriately labeled. Food deliveries must be properly and promptly put away.

Traceability INSTRUCTIONS:

1. Organize refrigeration space, and store rooms before picking up deliveries.

2. Gather product specification lists and purchase orders, temperature logs, calibrated

thermometers, pens, flashlights, and clean carts before unloading deliveries.

3. Keep area clean and well lighted

4. Mark products with the date of arrival or the use-by date accordingly upon receipt.

5. Compare delivery invoice with products ordered and products delivered for both delivery

quantities and product code.

6. Update records in inventory checklists.

7. Transfer foods to their appropriate locations as quickly as possible.


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THE MANAGER WILL:

1. Train employees on using the procedures in this SOP.

2. Schedule deliveries when to pick up raw materials.

3. Post the delivery schedule, including the names of suppliers, days and times of deliveries.

MONITORING:

Use a checklist to see if employees are following the standard operating procedure and writedown results to resolve or prevent problems (See figure 2.G Critical Item 1.6)

CORRECTIVE ACTION:

When an item on the check list is missed or poorly done, make sure it is corrected in thecorrective action log. (See Figure 3.G)

Update Inventory Checklist (See Figure 1.G) Retrain any employee found not following the procedures in this SOP. Re-set specifications Re-assess suppliers Return non-specification, etc. food to supplier. Reject the following:

a. Cans that have signs of deterioration, such as swollen sides or ends, flawed seals orseams, dents, or rust

b.Punctured packagesc. Foods with outdated expiration dates

VERIFICATION AND RECORD KEEPING:

The employee assigned will update records in inventory checklist. The manager will verify that

employees are receiving products using the proper procedure by visually monitoring receiving


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practices. All Checklists involved are kept on file for a minimum of 1 year. (See figure 2.G

Critical Item 1.1, 1.6)

1. Inventory ManagementThe purpose of inventory is to have a record of all products an operation has in storage and in the

kitchen. Ideally, snackpacks operation will have only the needed amounts of food and nonfood

items it needs to meet customer demand. Having too little inventory means customers don't get

what they want. Having too much inventory means food spoils and storage costs go up.

The two most common methods for snackpacks are the physical inventory method and the

perpetual inventory method. In the physical inventory method, the entire stock is physically

reviewed on a regular basis. The operation determines the reorder point for each inventory item.

The perpetual inventory method is the recording of items when received and again when issued.

The recommended frequency of physical inventory is daily since there is only a small volume of

operations. We have prepared Inventory Checklist in order to control and keep track of items for

the production of snackpack. (See figure 1.G) In order to prevent food deterioration older stocks

must be use first.

Note: It is a best practice to have two people involved in taking inventory; one to count and one

to record. To maintain integrity, at least one of the people should not be involved with day-to-

day storekeeping responsibilities such as receiving or issuing.

The recommended method for food storage is FIFO (First In First Out) Method. This is a safe

food storage system of rotating food so that the oldest items are used first. This ensures that food

will not go bad and leave wasting space and storing items that are no longer any good and

wasting money by throwing out things that could have been used.

Re-Order Point= Demand x Lead time


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Demand (daily) = 204

Lead time = 1 day

Converted weekly

204 (demand daily) x 6 (operating days) = 1224

Demand x Lead Time

1224 x 1 = 1224

Re-Order Point= 1224

When the items in inventory reach its level of Re-Order Point, its time to replenish those items.

SOP (Standard Operating Procedure) 1.2 Food storage

PURPOSE: To ensure that all food and supplies are in proper placement to avoid damage and

contaminations.

Note: This procedure applies to employees who handle, prepare, or serve food. All procedures

must be followed at all times.

1. No food is to be stored directly on the ground.2. All food stored inside the stall must be at least 150 millimetres above the ground and bewrapped, packaged or kept in enclosed containers.

3. All stored food must be covered or in sealed containers.4. Place high use products near the door for easy access.5. Keep products in original cases, unless pest infestation is a problem, so that informationneeded for traceability remains intact.

6. Place products in storage areas in the order of inventory forms to label shelving and assignproducts to specific locations then print inventory checklists using the same order.


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7. Store chemicals away from food and paper supplies, in a separate locked section of storagearea away from food to protect food and supplies from contamination.

8. Store the heaviest containers near entry on lower shelves, dollies, or racks to reduce thechance of injuries when moving product

9. Place expensive products in locked racks or away from easy access to exits.10. Use FIFO methodProper placement of items in storage:

USED INFREQUENTLY-Decorations, Uniforms

LIGHTWEIGHT ITEMS-Paper trays, Light foods

MEDIUM-WEIGHT ITEMS-Cans, Bottles, Jars

CASES, RACKS, BOXES HEAVIEST ITEMS-Sacks, Barrels, Crates

MONITORING:

Pest Control Service Record (Provided and maintained by contractor). Completion of cleaning schedule Use a checklist to see if employees are following the standard operating procedure and writedown results to resolve or prevent problems (See figure 2.G Critical Item 1.1)

CORRECTIVE ACTION:


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Adjust temperatures or discard food Additional cleaning Discard contaminated food When an item on the check list is missed or poorly done, make sure it is corrected in thecorrective action log. (See Figure 3.G)

SOP (Standard Operating Procedure) 1.3 Tracking Products

PURPOSE: To ensure that all food and supplies can be identified and accounted for from the

moment they are received until they are consumed and disposed of.


Traceability INSTRUCTIONS:

1. Compare delivery invoice against products ordered and products delivered for both deliveryquantities and product code.

2. Record upon receipt of product, when product is removed from storage, or when a productis disposed of.

3. Store products in labeled storage area.4. If a leftover product is used, include the date the product was originally prepared on theproduction record.

THE MANAGER WILL:

1. Train employees on using the procedures in this SOP.

2. Post SOP in storage area.

MONITORING:

The manager will observe products received, removed from storage, and produced.


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Use a checklist to see if employees are following the standard operating procedure and writedown results to resolve or prevent problems (See figure 2.G Critical Item 1.1)

CORRECTIVE ACTION:


Retrain any employee found not following the procedures in this SOP.2. LogisticsThe business will utilize the public transportation vehicles for picking up their raw materials.

The travel time is a maximum of 154 minutes back and forth for all locations. There should be an

allowance of 1 hour before raw materials are to be used. They also observed traffic flow by

considering Saturdays and Sundays as their procurement days. Below details are the

transportation costs for raw materials.

To go to Pasig for the packaging, from Intramuros the workers must first go to Quiapo forPhp 10.00 because there are jeeps from Quiapo that will go to Pasig for Php 22.00.

PHP 10 + PHP 22 = 32 x 2 workers = PHP 64 (for fare)

PHP 64 x 2 (back and forth)= PHP 128

PHP 70 (for food) x 2 workers = PHP 140

PHP 128 (fare) + PHP 140 (food) = PHP 268 (total)

To go to Quiapo for the ingredients, from Intramuros the wokers just need to ride jeep forPhp 10.00.

PHP 10 x 2 workers = PHP 20 (fare) x 2 (back and forth) = PHP 40

PHP 70 x 2 workers = PHP 140 (food)


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To go to Divisoria for the packaging, the workers also can ride a jeep going to Divisoria forPhp 10.00.

PHP 10 x 2 workers = PHP 20 (fare) x 2 (back and forth) = PHP 40

PHP 70 x 2 workers = PHP 140 (food)


3. Quality processesQuality Management System

The manager is responsible for knowing and enforcing all the procedures in the SSOP, WMI,

MEI, SOP, Food Safety and Quality Policy (See figure 1.G, 2.G, 3.G, 4.G)

1. Setting the example

-Provide an example of professionalism and high quality standards for employees.

2. Coaching and skill development.

-Observe activities and food handling procedures in all areas. Measure temperatures and times

and take corrective action if necessary.

3. QA Inspections

-Conduct weekly inspection using the Food Safety checklists. (See figure 2.G)

4. Food safety training program

-Maintain an effective yearly training program with regular training sessions to teach and

reinforce food safety. Ensure all employees undergo thorough training.

5. Maintaining equipment


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-Provide and maintain adequate sanitation, food preparation and storage equipment to allow

employees to do a quality job.

6. Reporting illness

-Report any indications of foodborne illness to the Health Unit (See figure 4.G Food Safety and

Quality Policy 1.1)

Organization responsibilities and duties

The owner will:

be responsible for implementation, control, monitoring and review of every policy andstandard procedures

ensure that all staff are trained in the food handling techniques and the requirements offood safety

be qualified to implement and review the Food Safety Policy regulations and practices ensure that all records and systems in relation to food safety are maintained and filed.

The manager will:

be responsible for the day-to-day implementation and control of food safety. ensure that all records and systems in relation to food safety are maintained. ensure that staff will follow all personal hygiene rules. ensure that all work areas are kept clean and free from pests. ensure that all staff are trained in the food handling techniques and the requirements of

the food safety policy.


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be qualified to implement and review the food handling techniques and the requirementsof the food safety policy.

All kitchen staff will:

be responsible for food safety in the kitchen, preparation and storage areas. be qualified to implement the food handling techniques and the requirements of the food

safety policy.

complete all records and systems in relation to food safety in the kitchen, preparation,receiving and storage areas as directed.

abide by all personal hygiene rules. report incidents that impact on the quality of food, to the manager. (eg sightings of pests,

malfunctioning or defective appliances, etc)

keep all work areas clean and free from pests. be trained in food handling techniques and the requirements of the food safety policy. report to the manager if they are suffering from any communicable disease.

Quality Control Process 1

Purchasing food products from an approved supplier is the first step in ensuring safe foods to

serve customers. As a purchaser of food products, owner/manager can ask the suppliers to verify

that their sources of supply are approved by the appropriate food regulatory agency.

In order to have Quality Control this will be imposed effectively: Strict Implementation,

Monitoring, and Controlling of the following: (See figure 1 & 2.F, SOP 1.1, 2.G Critical item

1.6, 4.G 1.2)


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Since snackpack will utilize the public transportation vehicles for picking up their raw materials.

There should be an allowance of 1 hour before raw materials are to be used, also as observed

considering traffic flow, Saturdays and Sundays are their procurement days.


Monitoring, and Controlling of the following: (See figure SOP 1.1, 2.G Critical item 1.1, 4.G

1.2)


Since snackpack is a food business, operators must complete and maintain a food safety

management system. To be able to achieve high quality and protect the health/safety of

consumers, it is essential to have effective food control systems.


Monitoring, and Controlling of the following: (See figure MEI, WMI, SOP 1.1, 2.G Critical item

1.1, 4.G 1.2)

Below are the critical processes of snackpack that must have quality controls.

Control Process 1 Control Process 2 Control Process 3

4. Waste management Eco-efficient packaging

The snackpacks packaging would be made out of cardboard since plastics are prohibited

Procurement of

Raw Materials

Pick up delivery

of Raw

Materials

Production

/Operation


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in Manila.

WMI (Waste Management Implementation):

Refuse container with a fitted lid and bin liner for the disposal of waste. It must be storedin a location that does not allow contamination of food or food contact surfaces.

Adequate refuse bins near the stall for the public to dispose of used takeaway foodcontainers and other waste. Adequate arrangements must be made for the storage and

removal of refuse generated inside and outside the food stall.

Waste oil must be stored in a container labeled Waste Oil Only and disposed of at anapproved waste transfer station.

Implement inventory control procedures to avoid over-ordering Usage of recycled paper for Checklist Forms

MONITORING:

Use a checklist to see if employees are following the waste management implementationand write down results to resolve or prevent problems (See figure 2.G Critical Item 1.3)

CORRECTIVE ACTION:


Retrain any employee found not following the WM (Waste Management)Implementation

5. Operations analysis and maintenanceMEI (Maintenance of equipment Implementation):

PURPOSE: To ensure that all equipment are well maintained



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Equipment:

Electrical deep fryer Mini fridge Juice Dispenser Observe equipment for missing part or parts. Call for the repairman in case of equipment

malfunction and document what was done in the Corrective Action Log.

Sanitize equipment with an approved sanitizer that is mixed and used according to themanufacturers directions, and, if required, rinse with potable water.


MONITORING:

Use a checklist to see if employees are following the Maintenance of equipmentimplementation and write down results to resolve or prevent problems (See figure 2.G Critical

Item 1.2)

CORRECTIVE ACTION:


Retrain any employees found not following the Maintenance of equipment implementationand write down results to resolve or prevent problems.


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G. End of period reporting (templates, rationale, expectations, integration to planning)Figure 1.G

Inventory Checklist (daily)

Item Quantity

in stock

Quantity

in

Reorder

Date

Purchased

Date

Expiration

Price Invoice/

Receipt

no.

Received,

Product Log/

Notes

All-

purpose

Flour

Sugar

Butter

Vegetable

oil

cinnamonEgg

Salt

Dark

Chocolate

Heavy

Cream

Tang litro

pack

Water

Container

Straw

An inventory system is a tool that must be maintained for an efficient food service

operation. This inventory checklist provides food service managers with a systematic method for

taking and maintaining a complete inventory record of purchased food and supplies.

Inventory checklist is used to:

1. Develop meaningful food cost analysis

2. Prepare orders for food and supplies

3. Avoid being overstocked or under stocked.


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5. Are all storage areas neat and tidy with food productsstored off the ground and not in contact with wall

surfaces?

6. Are all foods in storage containers covered andlabeled with name of product, date of receipt?

7. Is all packaging in good condition? 8. Are foods stored in a rotation use-by date basis? 9.Is there sufficient storage space? 10. Are temperatures of the storage areas operating inthe correct range?

11. Is the structure of the storage area in goodcondition i.e. no cracks in walls, impervious floors, nocondensation in refrigeration?

12.Have appropriate corrective actions been taken andrecorded?

13. Are chemicals and cleaning products stored awayfrom food storage areas?

14.Are storage areas free of evidence of pests? 15. Is refrigeration appliance calibrated on a regular

basis? (at least once? every six months)

Critical Item 1.2

(daily)

Compliant

YES

Compliant

NO

Completed/

Actioned

Cleaning

16.The Cleaning Schedule is visible and is beingfollowed

17.Does the cleaning schedule include all relevantinformation e.g.: instructions on chemical preparationand cleaning steps, items to be cleaned, frequency,

chemicals to be used, equipment to use, who isresponsible etc?

18.Are the cleaning schedules completed regularly? 19. Is there adequate equipment and facilities toundertake cleaning effectively?

20. Is the cleaning equipment clean, in good repair andstored appropriately after use?

21. Are sanitizers for work surfaces readily availablefor use during food preparation?

22. Is any verification of cleaning effectiveness


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regularly conducted?

23.Are all cleaning chemicals store separately fromfood areas?

Maintenance of Premises and Equipment

24. Is all the equipment in good repair and facilitatecleaning?

25. There is sufficient and well maintained: Lighting,Ventilation, Drainage

26.All reported equipment defects are being dealt witheffectively

27.Unused or broken equipment is removed from the

premises

28.Fittings such as benches are free from cracks andcrevices, in good condition

29.Food service equipment such as boards/ crockery isfree from cracks and chips

30. All major pieces of equipment such fridges,freezers, hot holding equipment, cold holdingequipment are fitted with working temperature

monitoring gauges

31. All fixed temperature monitoring gauges have beencalibrated at least in the past six months

32. All probe thermometers have been calibratedmonthly and any without a 1C tolerance

33. Is the premises in good repair with clean drains, no

peeling paint, no holes or gaps where pests might enter

etc.

34.Are there building and equipment maintenanceprograms and are they being followed?

35.All probe thermometers have been calibrated everymonth and recorded

Critical Item 1.3

(daily)

Compliant

YES

Compliant

NO

Completed/

Actioned

Pest control

36.There is no evidence of pest or rodent activity 37.Records of pest control visits and the treatmentsadministered are kept

38.There is a pest control contract on-site 39.Pest sightings are reported by staff 40. Have actions been taken and recorded when there


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has been evidence of pest activity?

41. External openings are adequately sealed to prevententry of pests

Waste

42.Waste is removed when bins are full 43.Waste containers are covered, kept clean andemptied after each work period

44.The refuse storage area is separated from the food

preparation areas

Critical Item 1.4

(daily)

Compliant

YES

Compliant

NO

Completed/

Actioned

Personal Hygiene

45. Daily hygiene practices are monitored by themanager/supervisor and all corrective actions completed

46.There are sufficient hand-washing facilities installedin all food handling areas

47.Warm water Soap Paper towelling 48.Food handlers wash their hands as often asnecessary

49.Food handlers use gloves appropriately andcorrectly

50. All jewelry including watches is removed prior tocommencing direct food

Handling

51.There is no evidence of eating or smoking in foodpreparation areas

52. Kitchen personnel wear appropriate protectiveclothing and protective head coverings

53.All staff understand their responsibilities withregards reporting of illness

54.Sick staffs are excluded from working with food 55. Are staffs aware of food safety practices and theirresponsibilities?

56.Are staffs aware they must not be at work whenthey may be suffering from a food borne illness or

condition?

57.Are staffs trained in food hygiene?


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Critical Item 1.5

(weekly)

Compliant

YES

Compliant

NO

Completed/

Actioned

Food Preparation

58. Is preparation scheduled so that foods that do notcontain allergens can be prepared withoutcontaminating them

59.Correct use of equipment/ utensils prevents cross-

contamination

60.Are standard measurements being followed? 61. Is there documentation to show that the cleaning

program is followed?

62. Have appropriate corrective actions been taken and

recorded where problems arose concerning food

preparation?

63.Are work surfaces, utensils and equipment cleanand is there

64.Are chemicals stored in a manner to prevent

contamination?

65. Is the risk of foreign objects (physical items)

controlled to prevent contamination?

66. Is equipment working and well maintained in thisarea?

67. Is equipment installed to facilitate effective cleaning

in this area?

68. Is food waste disposed of efficiently and

appropriately?

69.Are waste bins emptied regularly? 70.When questioned are staff aware of the risks when

handling food?

71.Are staffs wearing appropriate protective clothing 72.Are staffs following good hygiene practices? 73.Are staffs that are not in good health kept away

from direct contact with food?

74.Are there adequate hand washing and drying

facilities for staff?

75.When questioned are staff knowledgeable in

personal hygiene practices?

76. Are staff personal belongings stored in appropriate

manner and not at risk of contaminating food or

equipment during preparation?

.


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Critical Item 1.6 Compliant

YES

Compliant

NO

Completed/

Actioned

Procurement of Raw Materials

77. Source: Whether procured from authorized/certified sources

78. Raw Materials specification: Correct delivery ofordered raw materials (product, quantity)

79. Quality Raw Materials/ Products are free from any

physical impurities (e.g. dirt, dust, stones, wood, signsof infestation, pest or their remains, metal pieces or

any other foreign matter) free from any off odour andfree from any fungal (frothy) growth

80. Quality of packaged food products: Packaging andpack seals are intact. Pack is without holes. Pack

air/vacuum intact. Pack is without leakage, dents,puffing and rusting signs. Raw Materials/products areunder best before/expiry or Use by date

Critical Item 1.7 Compliant

YES

Compliant

NO

Completed/

Actioned

Training

81.All staff have been provided with the Food SafetyTraining Handouts

82. All new staff have been taken through an inductioncovering reporting of illness, correct hand washing /correct use of gloves, and personal hygiene standards

83.All staff have appropriate skills and knowledge infood hygiene

84.Staff training records are up-to-date

The goals of the above Food Safety Checklists is to ensure best practices regarding food

safety standards; identify the risks associated with a specific supplier and/or products and to

mitigate the risks, and ensures consumer protection and strengthens consumer confidence. These

checklists serve as a tool for inspection of quality and monitoring of the SSOP, SOP, WMI, MEI


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Figure 3.G

Corrective Action Log

Describe Problem Describe what you didabout it

Who isresponsible?

When will theproblem be

fixed by?

Completedon (date)

The goals of this corrective action plan are to establish a system that allows and promotes rapid

response to nonconformities from a critical limit; correct and eliminate the cause of the

nonconformity and restore process control; and maintain accurate documentations and records.

Figure 4.G

Food Safety and Quality Policy 1.1

The purpose of this agreement is to inform employees of their responsibility to notify the person

in charge when they experience any of the conditions listed. The person in charge is required to

take appropriate steps to prevent transmission of foodborne pathogens.


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I AGREE TO REPORT TO THE PERSON IN CHARGE:

Any Onset of the Following Symptoms, While either at Work or Outside of Work, Including the

Date of

Onset:

(a) Diarrhea

(b) Vomiting

(c) Jaundice

(d) Sore throat with a fever

(e) Infected cuts or wounds, or lesions containing pus on the hand, wrist, an exposed body part,

or other part and the cuts, wounds, or lesions are not properly covered. Workers may be allowed

to handle produce if impermeable cover or single-use glove is worn over a dry, durable, tight-

fitting bandage.

Note: Workers need to cover mouth/nose when sneezing or coughing, then immediately wash

hands. If discharge from eyes, nose, or mouth, in contact with hands, immediately wash hands.

I understand and will comply with the above Food Safety and Quality Policy.

Date:


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Food Safety and Quality Policy 1.2

HACCP (Hazard Analysis Critical Control Points)

Problems Solutions

Purchasing: serve raw foods free from bacteria cooked foods must be free of dangerous

bacteria

purchase from the safest possible source foods from approved sources will have aninspection marking on them

Harmful ingredients:

foreign objects chemicals

employees must protect food fromcontamination by foreign objects andchemicals

Cross-contamination by: hands equipment

properhand washing procedure proper cleaning and sanitizing

Food production: food left out at room temperature

no food left out longer than 30 minutes work in small batches

Hot food services:

evaporative surface cooling is a problem

cook food to the proper center temperaturefor a sufficient time to reduce the pathogenic

population by almost 100%

Controlling cooling: spores germinate during cooling and fast

reheating

cool foods as quickly as possible

cool a product thicker than 2

ice baths will reduce the temperature faster

Control leftovers or prepared food. reheat to original cooking temperature for atleast 15 seconds

use a stove, oven or microwave to reheatfoods, not hot holding equipment

The goal of HACCP (Hazard Analysis and Critical Control Point) is to provide a plan for the

prevention, control and mitigation of problems and the benefits of preventing illness. HACCP

(Hazard Analysis and Critical Control Point) is a system that controls food safety by determining

and controlling biological, chemical and physical hazards in a food process.

Documents

Production Plan Sample