Alliyah’s Bakeshop
Presented to the College of Technology
CEBU TECHNOLOGICAL UNIVERSITY
Daanbantayan Campus- San Remigio Extension
Tambongon, San Remigio, Cebu
In Partial Fulfillment
Of the Requirements for the Subject
Work Study and Measurement
Bachelor of Science of Industrial Engineering
By: BSIE-2
Navallo,Francis Nicole
Tabio,Daniela Nicol
April 05, 2023
TABLE OF CONTENTS
TITLE PAGE
TABLE OF CONTENTS ----------------------------------------i
I. METHOD STUDY --------------------------------------
A. Background of the Study --------------------------------------1
B. Work to be Studied ------------------------------------- 2
C. Present Method ------------------------------------- 4
II. WORK DESIGN --------------------------------------6
PROBLEM SOLVING TOOL 1 --------------------------------------
A. 5 Why’s Analysis ---------------------------------------8
B. Fishbone Analysis ---------------------------------------10
C. Pareto Analysis Chart --------------------------------------11
PROBLEM SOLVING TOOL 2 ---------------------------------------
A. Gantt Chart --------------------------------------- 12
B. Flow Process Chart ---------------------------------------13
C. Job/Worksite Chart ---------------------------------------14
MUDA’S (present) ---------------------------------------18
MUDA’S (solution) --------------------------------------- 19
6’ S (present) --------------------------------------- 20
6’ S (proposed) --------------------------------------- 21
MUTHER’S GRID (present) ---------------------------------------22
MUTHER’S GRID (proposed) ---------------------------------------23
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WORK STUDY AND MEASUREMENT
Method Study, Work Design and Standard
Group No.: _________________ Date: February 13,2023
Location: Tambongon, San Remigio,Cebu
Group Members: Francis Nicole Navallo
Daniela Nicol Tabio
I. Method Study
A. INTRODUCTION
Figure 1. Aaliyah’s Bakeshop
The establishment we selected is Alliyah Bakeshop. Alliyah's bakeshop is located in
Tambongon, San Remigio, Cebu. It is a sole proprietorship type of business since it is
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only owned by Mrs. Lilibeth Gullem. The bakeshop opens from 5:00 in the morning
until 8:00 in the evening. The name of the bakeshop is from the first granddaughter of Mrs.
Lilibeth Gullem.
Alliyah's bakeshop has two branches which the other one is called Pañera. The
Pañera is located beside Apple Bytes while Alliyah's bakeshop is located beside 1Lits
bakeshop. Alliyah's bakeshop has two cashiers and three bakers. Two of their bakers were
named Paul Lequin and Jhonrel Bucado. This bakeshop was built in 2011 but Mrs. Lilibeth
Gullem bought the bakeshop and officially owned it on the month of September 2022.
B. Baker's work process in the bakeshop and its environment
Figure 1.2 Sample Product of Alliyah’s Bakeshop
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The baker is responsible for making all the bread, pastries, muffins, and other baked
goods that are sold in the bakery. The baker must use a variety of different ingredients to
create the perfect product. Some of these ingredients include wheat flour, water, yeast
dough, vegetable oil, and eggs. After mixing all these ingredients, it will now be under the
kneading process.
The baker also uses various tools to help them meet their goals. These tools include
rolling pins, dough hooks or blades for kneading dough, knives for cutting bread loaves
from large pieces of dough or cookie sheets, oven mitts for removing hot pans from ovens
safely without burning your hands or arms on the hot metal surfaces inside ovens (they can
even use them as gloves), and special spatulas that help with spreading butter on the bread
before placing them in an oven or grill pan for baking.
Bakers need to be very careful when handling these tools because they can easily
cut themselves if not used properly which can lead to serious injuries including cuts or
burns which could potentially cause serious damage to internal organs such as heart valves
arteries veins etc. It is also important that they wear protective clothing such as an apron,
spare tea towel, and bakery-safe footwear.
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C. Workflow Process
Figure 1.3Workflow process of Alliyah’s Bakeshop
Breadmaking is a process that has been around for centuries. The most common method
of making bread is by mixing flour with water and letting it rise. This method has been
used for hundreds of years, but there are some changes that can be made to make the
process easier.
The first change I would make is to use a stand mixer instead of hand mixing. With a
stand mixer, you can mix the dough faster and with less mess than when using your hands.
The second change I would make is to use less water in the dough by about half
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compared to what you would use in other methods such as hand mixing. You will still need
enough water so that it does not dry out too much when rising, but too much water will
cause problems later when baking or storing this loaf.
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II. Work Design
A.
Processing and
Preparation Mixing and
Ripening
and Mixing Kneading
dough
Middle Molding and
Final Shaping
Fermentation First Shaping
Final
Bread Baking Cooling
Fermentation
Figure 2.Recommended Workflow Process
The bread production of the bakeshop is a workplace that does not have enough
space for workers to move around, which often leads to injuries. The workplace should be
redesigned so that workers have enough space to move around freely. The workers should
also be given more tools and equipment to help them make better-quality of bread. Other
than that, in terms of their ingredients, it should have proper labels to avoid
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getting confused such as salt & sugar(white) and flour & baking powder which can lead to
sloppy work.
One way that we can change the way that we produce bread is by using newer
machines instead of older ones. This will allow for a faster production process as well as a
more consistent product. Another way that we can change our production process is by
having more workers involved in each step of the production process so that each step takes
less time than it does currently.
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PROBLEM SOLVING TOOLS
5 Why’s Analysis
PROBLEM Bread Deformation
WHY? Too slack of dough
WHY? Failing to weigh of dough
WHY? Carelessness
WHY? Lack of Focus
WHY? Distracted of
kneading
assorted
bread
SOLUTION Make proper list of ingredients
and steps of bread.
Figure 3. 5 Why’s Analysis
Refer to the figure above, it is an example of the five why's analysis. Five whys is a
question-asking technique for identifying the root cause of a problem. It involves asking
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the question "why" as many times as necessary. As you can see, the main problem above
is the bread deformation and it is followed by the five why's.
The first one is too slack of dough, has a tendency to loose ,and is unable to hold its
shape. It is because of poor mixing or dough development through bulk fermentation. Next
is failing to weigh of dough, it is because of the carelessness of the worker. He/she lack the
focus to do his/her job properly because of distraction. Kneading assorted bread every day
can be complicated sometimes. Different ingredients to mix and different steps to follow
can bewilder you. That is why the solution to this problem is to have a proper list of
ingredients and steps written on a board located in front you so that it will be easy for you
in the kneading section
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Fishbone Diagram
Figure 3.1 Fishbone Diagram
Based on what I have read, fishbone diagram is a cause-and -effect discovery tool
that helps figure out the reasons for defects,variation or failures within a process. In the
figure above, you can see an example of fishbone diagram. The effect is placed at the head
of the fishbone while the causes are at the bone. For example, all of the causes that are
under on each six M's will result to an over proofed dough. The six M's that being showed
above are manpower,materials, method, mother nature, machine and measurement. Each
M's has sub-causes and root causes which we can compare to a branch of trees.
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Pareto Chart
Figure 3.2 Pareto Chart
The pareto chart is a graphical representation of the distribution of a data set. In this
case, the pareto chart shows that the cause of bread leftovers is the competitor beside their
bakery. This can be inferred by observing that there are more causes for leftovers than for
bakeshop production, and that there is no significant difference between bread and bread
leftovers.
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Gantt Chart
Alliyah's Bakeshop Project Start: Wed, 2/8/2023
Today: Mon, 4/3/2023
Display Week: 1 Feb 6, 2023 Feb 13, 2023 Feb 20, 2023 Feb 27, 2023 Mar 6, 2023 Mar 13, 2023 Mar 20, 2023 Mar 27, 2023
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 1 2
ASSIGNED
TASK PROGRESS START END M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S M T W T F S S
TO
Method Study, Work
100% 2/8/23 2/12/23
Design and Standard
Work Design 80% 2/13/23 2/19/23
Problem Solving Tools 1
5 Why analysis 90% 3/2/23 3/12/23
Fish Bone Diagram 80% 3/2/23 3/12/23
Pareto Chart 80% 3/2/23 3/12/23
Gantt Chart 50% 3/13/23 3/19/23
Flow Process Chart 70% 3/13/23 3/19/23
Job/Worksite Analysis 80% 3/20/23 3/26/23
7 MUDAS 90% 3/26/23 3/28/23
6'S 70% 3/29/23 3/30/23
Muther's Grid 90% 3/31/23 4/2/23
Figure 4 Gantt Chart
The figure shown above is an example of gantt chart. Gantt chart is a project
management tool that illustrates work completed over a period of time in relation to the
time planned for the work. In our schedule above, we started our papers on February 8 and
ended up on April 3,2023. It was clearly stated above the number of days we have been
working on a specific task and the percentage of our progress. And also the dated of our
weekly task. In conclusion, it took us almost two months of completing the task.
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Process Flow Chart
Location: Tambongon, San Remigio, Cebu Summary
Activity: Process of making bread Event Present Proposed Savings
Date: Operation 5
Operator: Mr. & Mrs. Gullem Analysts: Navallo, F. N. Transport 1
Tabio, D. N. Delay 1
Circle appropriate Method and Type: Inspection 1
Storage 1
Method: Present Proposed
Time(min) 145
Distance(ft) 5
Type: Worker Material Machine
Cost
Symbol
Description Distance (ft) Time(min)
Gathered ingredients 10
Kneading 15
Processing and proofing of dough 30
Molding and first shaping 20
Middle Fermentation 10
Final Shaping 15
Final Fermentation 10
Move to cooking area 5 5
Bread baking 15
Cooling 15
Figure 4.1 Process Flow Chart
Process flow chart diagram visualizes the steps of a process and the decisions that must
be made in order for the process to function. It is shown in the table above, at the bottom
right corner, a series of steps in the production of bread. From the gathering of ingredients,
kneading, processing and proofing of dough,molding, and first shaping, middle
fermentation, final shaping, final fermentation, move to cooking area, bread baking and
cooling. Beside of that are the corresponding distance and time of each steps. After that,
are the symbols. Each symbols have corresponding meaning. Circle stands for operation,
arrow for transport, horizontal half oval stands for delay, square for inspection and inverted
triangle is for storage. Each steps will be determined on what symbol they are belong. From
there on, each column will be added and the total will be put in the summary above the
symbols which will be under on proposed column. Time and distance will be added as well.
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Job/Worksite Analysis
Job/Worksite: Analyst: Date: 9/17/12
Description: Baker in Bread Production
Worker Factors
Name: Paul Lequin Age: 29 Gender: M Height: 5’6 Weight:
116 lbs
Motivation:High JobSatisfaction:High
Education Level: Highschool Level Fitness Level: High
Personal Protective Equipment: Apron,gloves and toque chef
Task Factors Refer To:
What happens? How do parts flow in/out? Picking up Flow Process Charts
from conveyor to two press machine and then back to
conveyor.
What kinds of motions are involved? Extension and Video Analysis,
flexion of arms, turning. Principles of Motion
Economy
Are there any jigs/fixtures? Automation? Yes, press
machine and conveyor are automated.
Are any tools being used? No there are not. Tool Evaluation
Checklist
Is the workplace laid out well? Any long reaches? It is Workstation
laid out well, have to turn, and have to walk within a 5’ Evaluation Checklist
x 5’ area.
Are there awkward finger/wrist motions? How CTD Risk Index
frequent? There are none.
Is there any lifting? Yes, the worker lifts the glass NIOSH Lifting
fixtures. Analysis, UM2D Model
Is the worker fatigued? Physical workload? No, does Heart Rate Analysis,
not appear to be. Work-rest Allowances
Is there any decision making? Mental workload? No,
the worker follows a consistent and repeated routine.
How long is each cycle? What is the standard time? Time Study, MTM-2
Each cycle is about 38 seconds long. Checklist
Work Environment Factors Work Environment Checklist
Is the illumination acceptable? Is there glare? Yes it is IESNA Recommended
acceptable and there does not seem to be any glare. Values
Is the noise level acceptable? Moderate noise levels OSHA Levels
beside when alarm goes off.
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Is there heat stress? Some probably due to melting of WBGT
glass and because the worker is wearing long sleeves,
pants, and gloves.
Is there vibration? It is unlikely that there is any ISO Standards
vibration.
Administrative Factors Remarks:
Are there wage incentives? There does not appear
to be any.
Is there job rotation? Job enlargement? No there
are none.
Is training or work hardening provided? Minimal
training needed
What are the overall management policies? N/A
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Job/Worksite: Analyst: Date: 9/17/12
Description: Kneader in Bread Production
Worker Factors
Name: Jhonrel Bucado Age: 24 Gender: M Height: 5’6 Weight:
121 lbs
Motivation:High JobSatisfaction:High
Education Level: Highschool Level Fitness Level: High
Personal Protective Equipment: Apron,gloves and toque chef
Task Factors Refer To:
What happens? How do parts flow in/out? Picking up Flow Process Charts
from conveyor to two press machine and then back to
conveyor.
What kinds of motions are involved? Extension and Video Analysis,
flexion of arms, turning. Principles of Motion
Economy
Are there any jigs/fixtures? Automation? Yes, press
machine and conveyor are automated.
Are any tools being used? No there are not. Tool Evaluation
Checklist
Is the workplace laid out well? Any long reaches? It is Workstation
laid out well, have to turn, and have to walk within a 5’ Evaluation Checklist
x 5’ area.
Are there awkward finger/wrist motions? How CTD Risk Index
frequent? There are none.
Is there any lifting? Yes, the worker lifts the glass NIOSH Lifting
fixtures. Analysis, UM2D Model
Is the worker fatigued? Physical workload? No, does Heart Rate Analysis,
not appear to be. Work-rest Allowances
Is there any decision making? Mental workload? No,
the worker follows a consistent and repeated routine.
How long is each cycle? What is the standard time? Time Study, MTM-2
Each cycle is about 38 seconds long. Checklist
Work Environment Factors Work Environment Checklist
Is the illumination acceptable? Is there glare? Yes it is IESNA Recommended
acceptable and there does not seem to be any glare. Values
Is the noise level acceptable? Moderate noise levels OSHA Levels
beside when alarm goes off.
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Is there heat stress? Some probably due to melting of WBGT
glass and because the worker is wearing long sleeves,
pants, and gloves.
Is there vibration? It is unlikely that there is any ISO Standards
vibration.
Administrative Factors Remarks:
Are there wage incentives? There does not appear
to be any.
Is there job rotation? Job enlargement? No there
are none.
Is training or work hardening provided? Minimal
training needed
What are the overall management policies? N/A
Figure 4.3 Job/Worksite Analysis Guide
The figure shown above is a job/worksite analysis of the business entity we have been
visited. We interviewed two workers on Alliyah's bakeshop to answer the given questions.
As you can see, it is clearly stated there the response of the workers. To summarize it all,
we figure it out how passionate the workers are in there work and they enjoy ehat they are
doing. In terms of how we interviewed them, they are very accommodating and willing to
give their response in any of our concerns.
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7 MUDAS/TIMWOOD
Overproduction Defective Bread
Figure 5 Mudas in Alliyah’s Bakeshop
The figure above shows the present Mudas that present in Alliyah’s Bakeshop.They
have two waste which are the overproduction and defective bread. We notice that there are
more overproduced products than expected—that is, there are too many breads baked per
day compared to what their customers want or need. We also see that some of the bread is
defective, as evidenced by its color and appearance (it is brownish in color). This could
mean that the bread was made incorrectly or even spoiled before it got put into production.
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Mudas of Alliyah’s Bakeshop (Recommended Solution)
Figure 5.1 Recommended Solution of Alliyah’s Mudas
The most common cause of defective bread is the improperly stored ingredients,
equipment, or utensils can lead to contamination and spoilage. Excessive moisture and
humidity in the air can also lead to mold growth, which will affect the quality of baked
goods. In addition, improper storage conditions can allow for bacterial growth that will
result in a spoiled product.
To prevent this from happening, we recommend to ensure that all ingredients are stored
properly in a cool, dry place with good ventilation. Ensure that there are no leaks or gaps
around doors or windows that allow moisture to seep into your facility. Make sure that all
equipment is cleaned regularly and sanitized according to manufacturer specifications
before use.
We recommend a solution to the overproduction issue of the Alliyah’s bakeshop is to
get it under control with a good monitoring system. The best way to do this is with a bread
production tracking system that keeps track of all the different kinds of breads and bakes,
as well as the quantities produced. By using this method, we can ensure that we are
producing only the types of breads that we need at the time and in quantities needed
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6’S
Sort Set in Order
Shine Safety
Figure 5.1 Six S of Alliyah’s Bakeshop
The figure above shows the four S present in Alliyah’s bakeshop,the sort,set in
order,shine and safety of the workplace. The bakeshop is clean, with no spills or dirt on the
floor.The workplace is organized to ensure that all products are placed appropriately and
are easy to reach,organized in an orderly manner,clean and free from dirt and dust,and there
are no hazards present within the workplace.The baker and kneader also wear apron to give
the baker ease, comfort, and mobility to move around the workplace.
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Proposed 6 S
Figure 5.2 Recommended S of Alliyah’s Bakeshop
We recommend Alliyah’s bakeshop the two S which is the standardize and sustain.
This can be done by having a standardized product line, which would allow for more
consistent quality control and produce higher-quality products. Sustaining means that we
can maintain consistency of quality, which is important for our customers .A standardized
product line would allow for less variation between products, which will mean that we can
offer an even greater variety of different types of breads. This means that customers will
have more choice available to them when they come into the bakery. With fewer options
on offer, we will be able to ensure that our product lines are consistently high-quality while
still offering variety in terms of taste and texture.
Having a standardized product line would also help us keep up with changing
consumer demands. Every year there are new trends in breads that consumers want to try
out, so it is important for us as an organization to stay current with what our customers
want from us (and vice versa). Standardization allows us to do this because we can create
one system for creating these products so all of our employees are working off the same
set of instructions on how best to make these items at our facility.
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Muther’s Grid
Figure 5.3 Present Muther’s Grid and Present Layout
The figure shown above is the present muther's grid and present layout of Alliyah's
bakeshop. As you can see, there is an area which is too crowded while the other side is
spacious. In short, it is not organize very well. Having a crowded workplace can bring the
uncomfortable feeling that can cause distraction to the workers and that can affect to the
production. For us, we need to consider other options to minimize this issue. Perhaps a
little renovation of the area can benefit them.
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Recommended Muther’s Grid and Layout
Figure 5.4 Recomnended Muther’s Grid and Recommended Layout
As you can see above, that is our recommended arrangement of the place. If you look
closer, you will notice that dining area, production area, stock room, cashier and display
area becomes more spacious than the present. We occupied the whole place perfectly.
Bigger dining area will have a pleasant ambiance to the customers who wants to stay. Huge
space for production can greatly affect the workers because they can move freely. Having
a large scope of stock room is much better and a large display area are essential for
increasing the sales of the products because it will look so organize and pleasing to the
eyes. Also, the display strategy also plays a role in keeping the baked items fresh and tasty
for a long time.
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