Chapter 6
Food Production
Production Scheduling
Time sequencing of events required to
produce a meal.
Planning stage:
Forecasts are converted into the quantity of
each menu item to be prepared.
Distribution of food production to supervisors
in each work center.
Action stage:
Supervisors prepare a production schedule.
Items are assigned to specific employees
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Production Scheduling
Production Planning and scheduling
require knowledge of the steps through
which a product must go and the time
required for each, as well as the steps that
can be completed early without affecting
the quality of food.
Foodservice Organizations, 5th edition
Spears & Gregoire
Most menu items go through part or all
of the following steps:
Storage: dry, refrigerated, freezer
Thaw time
Assembly: weighing or measuring
ingredients
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Pre-preparation: vegetable cleaning,
peeling, cutting, chopping, preparing
pans
Preparation: mixing, combining
ingredients, panning
Cooking: baking, frying, broiling,
steaming,simmering
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Finishing: setting up salads,
portioning desserts, slicing meats,
packaging food for freezing
Storage prior to serving: heated,
refrigerated, frozen.
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Production Schedule
Should include:
Employee assignments
Preparation time schedule
Menu item
Over- & underproduction
Quantity to prepare: forecast amount for each
menu item.
Substitutions
Actual yield: portion count produced by the
recipe.
Additional assignments
Special instructions & comments
Pre-preparation
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Production Meetings
Should be held daily with employees
in the production unit.
Employees encouraged to discuss
the effectiveness of the schedule.
Free discussion of work loads.
Conclude with discussion of the
production schedule for the following
three meals.
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PRODUCTION CONTROL
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Ingredient Control
Begins with purchasing, receiving, &
storage of foods.
Continues through forecasting &
production.
Ingredient assembly – area designed
for measuring ingredients.
Standardized recipes – provides
assurance that standards of quality
will be consistently maintained.
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Advantages of Centralized
Ingredient Assembly
Contributes to the cost reduction &
quality improvement.
Redirection of cooks’ skills away from
collecting, assembling, & measuring
ingredients to production, garnishing,
& portion control.
More efficient use of labor.
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Centralized Ingredient Control
Control of unused portions is
facilitated because storage is located
centrally rather than in various work
units.
Ability to combine tasks for two or
more recipes using similar
ingredients.
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Function of the Ingredient Room
Primary function is to coordinate
assembly, pre-preparation,
measuring, & weighing of the
ingredients.
Availability of appropriate equipment
will help determine the activities to be
performed.
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Ingredient Room Organization
Should be located between the
storage & production areas.
Necessary equipment includes:
Refrigeration
Water supply
Trucks or carts for assembly & delivery
Worktable or counter
Scales
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Ingredient Room Staffing
Employees must be:
Literate
Able to do simple arithmetic
Familiar with storage facilities
Responsible for receiving, storage, &
ingredient assembly.
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Ingredient Room Staffing
Ingredient assembly personnel
considerations:
Size of operation
Frequency & time of deliveries
Size of ingredient room & location of other
storage areas
Type, number, & complexity of menu items
Number of workstation to be supplied
Schedule for delivery of ingredients to
production & serving areas
Extent of pre-preparation performed in
ingredient assembly area
©2004 Pearson Education, Inc.
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Future of Ingredient Rooms
Centralized or food factories are
being used for procurement &
production.
Prepared menu items are distributed
to several remote areas for final
preparation.
©2004 Pearson Education, Inc.
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Personnel and Equipment
Personnel assigned to the ingredient
room must be able to read, write and
perform basic arithmetic with at least
minimal ease and accuracy. Safety
precautions and sanitation standards
should be stressed in their training.
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Weighing is the quickest, easiest, and
most accurate means of measure in most
cases, so good scales are essential.
Suggested minimum equipment for
weighing and measuring includes the
following:
Worktable, 6 to 8 feet long, with one or
two drawers
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Counter scales, with gradations of one
ounce minimum to 25 pounds
Mobile storage bins for sugar, flour,
and other large-volume staples
Shelving for bulk staples and spices
Mobile racks for delivery of foods to
production areas
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Refrigeration( and freezer if frozen
foods are distributed)
Sink and water supply
Can opener
Trash containers
Counter pans with lids if canned
foods are opened
Trays for assembling ingredients
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Rubber spatulas
Measuring utensils
Scoops for dipping
Packaging materials( paper and plastic
bags, paper cups)
Masking tape and marking pens to
label ingredients
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If vegetable preparation is also done in
the ingredient room, the following
additional equipment is needed:
Double or triple sink
Waste disposal
Peeling, slicing, and dicing equipment
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Cutting boards
Assorted knives and sharpening
equipment
Plastic tubs or bags for cleaned
product
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Portion Control
Standardized portion are important not
only for cost control, but also in
creating and maintaining customer
satisfaction and goodwill. No one like
to receive a smaller serving than
another costumer for the same price.
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Food is portioned by weight, measure or
count and begins with the purchase of foods
according to definite specifications so that
known yields can be obtained from each
food. Portioned meats, fish, and poultry;
fresh fruit ordered by price (count per
shipping box) canned fruits and other foods
in which the number of piece is specified
are examples.
©2004 Pearson Education, Inc.
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During food production, portioned are
measured by scoop or dipper or are
weighed on portioned scales. For
example the recipe for meatballs may
call for dipping the mixture prior to
cooking. The numbering system for
scoop sizes is based on the number of
scoop per quart.
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The appropriate utensil and its size for
serving the product should be indicated
on the recipe. Ladles, which are used for
serving sauces, soups, and similar
foods, are sized according to capacity.
For cakes and other desserts baked in
pan, instructions for cutting should be
included.
©2004 Pearson Education, Inc.
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In addition to the information included
on recipes, a list of portion sizes for all
foods should be made available to
employees either in an employees’
manual or posted in a convenient
location.
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
Upper Saddle River, New Jersey 07458 Spears & Gregoire
F. Product Evaluation
Product evaluation is part of the initial testing
phase of new recipe and is important for
quality control. Product evaluation or
sensory analysis is actually an ongoing
process to ensure that the yield expectations
and quality standards established during the
recipe standardization process are met each
time a menu item is produced.
©2004 Pearson Education, Inc.
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Product Evaluation
Informal Evaluation:
Visual appearance
Flavor
Ability to obtain ingredients
Cost per serving
Labor time
Availability of equipment
Employee skill
©2004 Pearson Education, Inc.
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Product Evaluation
Formal Evaluation
Select group of staff members & customers as a
taste panel.
Choose or develop an evaluation instrument.
Prepare sample recipe.
Set up sampling area.
Sampling & evaluation of products.
Summarize results.
Determine future plans for the recipe.
©2004 Pearson Education, Inc.
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G. Methods of Assembly, Delivery and
Service
Methods-Delivery and Service as
System
It refers to the transportation of
prepared foods from the production
to place of service: service involves
assembling prepared menu items and
distributing item to the consumer.
©2004 Pearson Education, Inc.
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Two Major On-Premise Delivery
System
Centralized Delivery-Service System
Prepare foods proportion and
assembled for individuals at a central
location in or adjacent to location.
Completed orders then transported
and distributed to costumers
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Fast food and restaurants, banquet
services, hospital and long term
facilities.
Close supervision and control of food
quality
Span required for service, can be
excessive long.
©2004 Pearson Education, Inc.
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Decentralized Delivery System
Bulk quantities of prepared foods are
sent hot and cold to serving gallery or
ward kitchens located throughout the
facility, where reheating, portioning, and
meal assembly take place.
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Dishes were returned to kitchen for
washing.
Facilities where a great distance
between the kitchen and the consumer
Foods travel better in bulk than plated.
©2004 Pearson Education, Inc.
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Assembly
Is piecing together of prepared menu
items to complete an entire meal. In
restaurants, assemble hot meals at the
centralized production point and serve
the meal immediately and directly to the
waiting customer.
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
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Tray Assembly
Two major systems are used to
assemble meal trays.
Food is assembled at the central
location, usually the production kitchen
using the tray line.
Transport foods in bulk to units where
it is assembled or plated as individual
meals.
©2004 Pearson Education, Inc.
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H. Factors Affecting the
Choice of Distribution System
Kinds of Food Service Organization
Size and Physical Layout of the
Facility
Style of Service
Skill Level of Available Personnel
Economic Factors
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
Upper Saddle River, New Jersey 07458 Spears & Gregoire
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
Upper Saddle River, New Jersey 07458 Spears & Gregoire
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
Upper Saddle River, New Jersey 07458 Spears & Gregoire
Energy Management
Should include:
Record-keeping system for tracking utility
costs & monitoring equipment use.
Employee training
Use of energy efficient equipment
©2004 Pearson Education, Inc.
Foodservice Organizations, 5th edition
Upper Saddle River, New Jersey 07458 Spears & Gregoire
