Production Management Tools

Production Management Tools

Recipe Scaling

• Breaking it Down: Recipe scaling involves adjusting a recipe to yield a different number of servings.
• Example: Scaling a recipe from 10 servings to 120 servings.
• Considerations:
  • Converting between volume (cups) and weight (pounds, units).
  • Accounting for trim loss.

Practice Problems - Scaling

• Scaling Factor: To scale a recipe from 50 servings to 80 servings, the scaling factor is calculated as follows: $\frac{80 \text{ servings}}{50 \text{ portions}} = 1.6$
• Tuna Example:
  • Original recipe: 9 lb 6 oz of tuna for 50 servings.
  • Convert 9 lb 6 oz to ounces: 9 lb 6 oz = 150 oz
  • Calculate the amount needed for 80 servings: 150 oz * 1.6 = 240 oz
  • Convert 240 oz to pounds: $\frac{240 \text{ oz}}{16 \text{ oz/lb}} = 15 \text{ lb}$
  • Alternatively: Convert 9 lb 6 oz to pounds: 9.375 lb * 1.6 = 15 lb

Percent Yield

• Abbreviations:
  • AP: As Purchased quantity.
  • EP: Edible Portion quantity.
  • Trim: AP - EP.
• Most recipes list ingredients as EP, requiring adjustments to order the correct AP amount considering trim.

Percent Yield Example

• A recipe requires 5 lbs of sliced onions (EP).
• To determine the purchase quantity, the percent yield needs to be known.

Percent Yield Equation

• Equation: $5 \text{ lb EP} * \frac{1 \text{ lb AP}}{0.88 \text{ lb EP}} = 5.7 \text{ lb AP}$
  • Double Check: AP will always be greater or equal to EP

Practice Problems – Percent Yield

• Apple Pie Example:
  • Recipe requires 10 lbs of peeled, sliced apples (EP).
  • Percent Yield = 0.78 (unrounded).
  • Calculation: $\frac{10 \text{ lb EP Apples}}{0.78} = 12.82 \text{ lb AP}$
  • Rounding: Round up to 13 lb AP to ensure enough yield.

How Much to Purchase Rounding

• Rounding Guidelines:
  • When calculating AP, always round UP to ensure sufficient quantity.
  • When calculating EP, round DOWN to avoid over-portioning.

Production in Foodservices

• Define production in foodservices.
• Review standardized recipe and production schedule formats.
• Discuss forecasting to improve accuracy and decrease waste.

Production

• Stages of food preparation: Production includes all stages from storage to serving.
• There are many critical control points that can affect the safety of food throughout production
• Coordinating effective production foodservices is a management challenge, especially in communication and efficient use of inputs

Production - Management Perspective

• Tasks:
  • Determining quantities of ingredients to produce.
  • Planning labor and equipment.
  • Cooking food correctly (management functions).
  • Portion control (satisfaction, nutrition, budget).

Standardized Recipes

• Making food preparation easy and accurate for your staff

Standardized Recipe Format

• Elements:
  • Recipe Name
  • Number of Servings
  • Serving Size
  • Ingredients (Amount, Weight, Measure)
  • Procedure (Descriptive Format)

Standardized Recipe Work Together

• Scenario: Creating a baked tilapia recipe for a hospital, scaling from 2 to 50 portions.
• Tasks:
  1. Find the scaling factor.
  2. Calculate the new ingredient amounts.
  3. Fill out the descriptive recipe format.

Standardized Recipe Ingredients

• Ingredients for 2 servings:
  • 4 oz dry spaghetti, cooked
  • 4 – 3 oz portions of tilapia
  • 3 cloves of garlic
  • 2 Tbsp of salted butter
  • 6 oz of broccoli
  • ½ tsp pepper

Standardized Recipe Directions

• Directions:
  • Cook pasta in boiling salted water until al dente (about 12 minutes).
  • Melt butter with garlic and pepper in a saucepan.
  • Brush butter mixture on tilapia fillets and bake at 350 degrees for 12-15 minutes.

Problem Solving Standardized Recipes

• Steps:
  1. Start with the procedures.
  2. Add the ingredients in order of the procedures.
  3. Resize the ingredient based on scaling.
  4. Fill out the amounts section, if possible.
  5. Check that the procedures still make sense with the scaling.

Recipe Scaling Example - Butter Garlic Tilapia Pasta with Broccoli

• Recipe Name: Butter garlic tilapia pasta with broccoli
• No Servings: 50
• Serving Size: 2 fish filets, 1 cup cooked pasta (2 oz dry equv), and ½ cup broccoli
• Procedure steps with ingredients and scaled amounts

Problem Solving - Scaling Factor

• Scaling from 2 to 50 portions: $\frac{50}{2} = 25$
• Spaghetti Calculation: 4 oz dry spaghetti * 25 = 100 oz dry / 16 oz per lb = 6.25 lbs ≈ 6 lbs 4 oz dry pasta

Problem Solving - Butter Calculation

• 2 tbsp butter * 25 = 50 tbsp butter /16 tbsp per cup = 3.125 cups ≈ 3 cups, 2 tbsp butter
• Weight conversion: 1 lb butter = 2 cups (Table 4.2)
• 3. 125 cups * (1 lb/2 cups) = 1.5625 lbs ≈ 1 lb 9 oz butter

Scaled Recipe - Butter Garlic Tilapia Pasta with Broccoli

• Recipe Name: Butter garlic tilapia pasta with broccoli
• No Servings: 50
• Serving Size: 2 fish filets, 1 cup cooked pasta (2 oz dry equv), and ½ cup broccoli
• Amounts updated for 50 servings:
  • Spaghetti, dry: 6 lb 4 oz
  • Butter: 1 lb 9 oz
  • Garlic: 75 cloves
  • Pepper: ¼ cup pepper
  • Tilapia, 3 oz portions: 100 – 3 oz portions (18 lb 12 oz)

Production Schedules

• Making sure multiple staff members work efficiently

Production – Assignments and Scheduling

• Production schedule: a detailed document that communicates with production staff to specify:
  • Items to be prepared
  • Who cooks or completes which task needed for the menu that day
  • The amount of time each task should take
  • Goal completion times (which meal service)
  • Quantity to be produced
  • Recipes to be utilized
  • Portion sizes for serving
  • Allowable variations for specific diets (modified or for units like the cardiac wing)

Production Schedule Example

• Operation: XYZ Cafe
• Service time: 11:00 a.m.
• Service date: 3/10/23
• Includes Menu Item, Portion Size, Number of Portions, Quantity of Portions, Recipe Number, Person Responsible, and Prep Time.
• Example Items: Tilapia/rice (brown), Cheese lasagna, Chocolate chip cookies

Production Schedules - Increased Efficiency

• Eases production problems:
  • Food waste
  • Efficiency
• Helps quality control problems
  • Clarifies standards
• A well-written recipe would include information about the time and steps required for production. This would be incorporated into the schedule.

Forecasting

• Estimating Product Demand

Forecasting - Definition

• Estimating future demand by using past data
• Forecasting utilizes data from a specific period to time to create an estimate. The time period could be the time of year, specific combinations of foods, etc.
• Frequently, sales records are used to assess food popularity

Forecasting Benefits

• Enhances the ability of food service facility to purchase and produce the needed amount of food while also maintaining a consistent standard
• Benefits:
  • Preventing under/over production
  • Maintaining standards
  • Maintaining customer satisfaction

Forecasting - Considerations

• Forecasting is only as good as the historical data used
  • Accurate
  • Consistently recorded
• Varies based on the facility:
  • Hospitals may utilize daily patient census, number of patients on therapeutic diets, or new admissions/discharges
  • School utilize enrollment and production records (tracks all foods produced including regular meals and a la cart)
  • Restaurants utilize customer count, items sold per meal period

Forecasting Example - School

• Consider how you would use the data to forecast.
• Cottonwood Unified Food Services would like to serve the same combination of items next month as the following production record.
• This production record was from December and one class was on a field trip this day.
• What things might you adjust based on forecasting?

Forecasting Example - Data

• Missing students?
• Colder weather?

Forecasting Programs

• Forecasting and menu development are commonly completed using foodservice computer programs
  • Hospitals tend to use CBORD, Computrition, etc
  • Schools may use Nutrikids, HealthE Meal Planner Pro, etc
• These programs frequently have modules for forecasting, ordering, nutrient analysis, costing, production, and recipe databases

Forecasting Models - Moving Average

• On a given item, the average of 7 days is calculated. Moving forward one day, the calculation is repeated. This is especially helpful with static menus.
• Example of calculating the weekly average. $\text{Weekly Average} = \frac{\sum_{i=1}^{7} \text{patients on day i}}{7}$

Next Time

• Preparation Food Safety