Production Management Tools

Production Management Tools

Recipe Scaling

• Recipe Scaling involves adjusting a recipe to yield a different number of servings.
• Considerations include converting volumes to weights and accounting for trim loss.

Example: Scaling a Banana Recipe

• Original recipe yields 10 servings.
• Ingredient: 1/2 cup banana.
• Scaling to 120 servings requires calculating the new amount of banana.
• Determine EP (edible portion) and AP (as purchased) quantities, considering the trim.

Practice Problems - Scaling

Problem 1: Scaling Factor

• Recipe serves 50, need 80 portions.
• Scaling factor: $\frac{80 \text{ servings}}{50 \text{ portions}} = 1.6$

Problem 2: Tuna Scaling

• Original recipe: 9 lb 6 oz tuna for 50.
• Convert 9 lb 6 oz to ounces: $9 \text{ lb} \times 16 \frac{\text{oz}}{\text{lb}} + 6 \text{ oz} = 150 \text{ oz}$
• Scaled amount: $150 \text{ oz} \times 1.6 = 240 \text{ oz}$
• Convert back to pounds: $\frac{240 \text{ oz}}{16 \frac{\text{oz}}{\text{lb}}} = 15 \text{ lb}$
• Alternatively: $9.375 \text{ lb} \times 1.6 = 15 \text{ lb}$

Percent Yield

• Abbreviations:
  • AP: As Purchased Quantity
  • EP: Edible Portion Quantity
• Trim: AP - EP
• Recipes often list EP quantities; adjust order based on trim.

Percent Yield Example

• Recipe requires 5 lbs sliced onions (EP).
• Need to determine the quantity of onions to purchase (AP).
• Need to know the percent yield to calculate AP.

Calculation

• If the yield percentage from AP to EP is 88% (0.88):
  $\frac{5 \text{ lb EP}}{0.88 \frac{\text{lb EP}}{\text{lb AP}}} = 5.68 \text{ lb AP} \approx 5.7 \text{ lb AP}$
• AP will always be greater than or equal to EP.

Practice Problems – Percent Yield

Problem: Apple Pies

• Recipe needs 10 lbs peeled, sliced apples (EP).
• Percent yield is 78% (0.78).
• Calculation: $\frac{10 \text{ lb EP}}{0.78} = 12.82 \text{ lb AP}$
• Round up to 13 lb AP to ensure enough yield.

How Much to Purchase Rounding

• Round to a whole number for necessary yield.
• When calculating AP (As Purchased): Round UP to ensure enough.
• When calculating EP (Edible Portion): Round DOWN to avoid too many portions.

Production in Foodservices

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

Production

• Stages of food preparation from storage through serving.
• Critical control points affect food safety.
• Effective coordination is a management challenge, including communication and efficient use of inputs.

Production - Management Perspective

• Determining ingredient quantities.
• Planning labor and equipment.
• Cooking food correctly.
• Portion control (satisfaction, nutrition, budget).

Standardized Recipes

• Making food preparation easy and accurate for staff.
• Elements of Descriptive Format:
  • Recipe Name
  • Number of Servings
  • Serving Size
  • Ingredient, Weight, Measure, Procedure

Standardized Recipe – Example

• Task: Create a new recipe for a regional hospital, scaling it up and writing in descriptive format.
• Recipe: Baked Tilapia with Garlic Butter and Pasta (originally for 2 servings, scale to 50).

Steps:

1. Find the scaling factor.
2. Calculate new ingredient amounts.
3. Fill out the descriptive recipe format.

Standardized Recipe – Ingredients (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
• 1/2 tsp pepper

Directions:

• Cook pasta in boiling salted water until al dente.
• Combine butter, garlic, and pepper in a saucepan until melted and simmering.
• Brush butter mixture on the baking dish and tilapia fillets.
• Bake tilapia at 350 degrees for 12-15 minutes, until it flakes easily.

Standardized Recipe - Problem Solving

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.

Standardized Recipe - Scaling Factor

• Scaling from 2 to 50 servings: $\frac{50}{2} = 25$
• Scaling factor = 25
• Example: Spaghetti: 4 oz * 25 = 100 oz dry = 6.25 lbs = 6 lbs 4 oz dry pasta

Standardized Recipe - Scaling Factor butter

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

Production Schedules

• Making sure multiple staff members work efficiently.
• Production schedule: a detailed document that communicates with production staff.
  • Items to be prepared
  • Who cooks or completes which task
  • The amount of time each task should take
  • Goal completion times
  • Quantity to be produced
  • Recipes to be utilized
  • Portion sizes for serving
  • Allowable variations for specific diets

Production Schedules Increase Efficiency

• Eases production problems.
  • Food waste
  • Efficiency
• Helps quality control problems.
  • Clarifies standards
• A well-written recipe includes information about time and steps required for production.

Forecasting

• Estimating Product Demand.
• Definition: Estimating future demand by using past data.
• Utilizes data from a specific period to time to create an estimate.
• Frequently, sales records are used to assess food popularity.

Forecasting - Helpful

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

Forecasting - Accuracy

• Forecasting is only as good as the historical data used
  • Accurate
  • Consistently recorded
• Varies based on the facility
  • Hospitals patient census, number of patients on therapeutic diets, or new admissions/discharges
  • Schools enrollment and production records
  • Restaurants customer count, items sold per meal period

Forecasting Example

• 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 School

• Considerations: Colder weather? Missing students?

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

• 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.