Pizza Hut Commissary Workshop
Pizza Hut Commissary Workshop
India ‐ Bangalore
April 4th – April 6
April 4
April 6th 2012
Franchisee Technical Commissary Workshop
•
•
Technical Workshop Outline
Audience: Commissary Production
Audience: Commissary Production Tuesday, April 3, 2012 –Arrivals (No scheduled events)
Wednesday, April 4, 2012
•
Overview
•
Organization Structure
•
Job Description & Profile, Labor Planning
•
Commissary Process, workflow, layout & controls
•
Mumbai Layout
•
PHD Store Visit – Lunch
PHD Store Visit •
Introduction Commissary Compliance Audit ‐ CCA
Dinner Buffet
Thursday, April 5, 2012
•
HACCP, Key Systems & Processes
•
Website
•
Training Resources
•
Dough Quality & trouble shooting
Lunch
•
Commissary Visit – Equipment Tear Down & Troubleshooting (Hands On)
Commissary Visit Equipment Tear Down & Troubleshooting (Hands On)
•
India Best Practice
Recognition Dinner
Friday, April 6, 2012
•
Commissary Visit – CCA Hands On Audit
•
Lunch
•
CCA Summary
•
Startup, finalize SOP, process capability, & Hand‐over local ops
Wrap up and Departures
Dates: 4‐ 6 April
Leader QA maintenance
Leader, QA, maintenance 9:00 am
9:30 am
10:30 am
11:15 am
12:00 pm
12:30 pm
12:30 pm
3:00 pm
7:00 pm
Steven
Steven
India Team
Amarjit
Pandurang
Team
Daniel
9:00 am
10:00 am
10:30am
10:45am 11:45 pm
12:45pm
4::30 pm
6:30 pm
Meghann/Daniel
Steven
India Team
Amarjit
8:00 am
1:30 pm
2:30 pm
3:30 pm
4:30 pm
Meghann/Daniel
Lunch
Daniel/Amarjit
Amarjit
Steven
Steven/Supplier
India Team
Aidan
Pizza Hut Commissaries Around the world
2007
2008
2009
2010
2011
2012
Pizza Hut Commissaries And Stores
32 COMMISSARIES
500 STORES SUPPORTED
2012
27 COMMISSARIES
338 STORES SUPPORTED
2011
15 COMMISSARIES
195 STORES SUPPORTED
2010
6 COMMISSARIES
163 STORES SUPPORTED
2009
2008
# of Commissaries
3 COMMISSARIES
71 STORES SUPPORTED
# of PHD’s
2007
1 COMMISSARY
21 STORES SUPPORTED
50
100
150
200
250
300
350
400
450
Commissary Roles & Responsibilities of Dallas vs. Field
Dallas
•
Define & Develop :
–
–
–
–
•
QA/Sanitation Policies
Training Materials
Facility/Ops processes & systems
Commissary Contract
Approve:
– Critical equipment specs
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– Layout & Workflows
•
Review Committee process for exceptions to recommended layout
exceptions to recommended layout and business model.
•
Central Repository for all necessary information
BMU/FBU
• Field all initial Franchise commissary requests
• Resource to:
Resource to:
– Define 10 year Growth Potential
– Cascade & review Financial Model
– Approve Site Selection
– Approve Construction of facility conforming with latest manual
– Start
Start‐up
up Support
Support
– Make each facility ready for CCA & STAR audit
– Right to operate Commissary Contract al Agreement
Contractual Agreement
YRI Commissary Classification System
Class “C1”
Class “C2”
Class “C3”
Class “C4”
• Supplies
Supplies 1
1‐15
15 PH PH
Restaurants
• Produce, Warehouse, & Distribute PHD dough & Par Bake • Supplies
Supplies 16
16‐200
200 PH Restaurants
• Produce, Warehouse, & Distribute PHD dough & Par Bake • Supplies
Supplies 200+ PH 200+ PH
Restaurants
• Produce, Warehouse, & Distribute PHD dough & Par Bake • Supplies
Supplies any any
number of PH Restaurants
• Produce, ,
Warehouse, & Distribute PHD dough, Par Bake, Prep Vegetables, & Other Approved P d t
Products Commissary 3‐Step Process
Key Take Aways from Workshop
• Self Sufficiency!
Self Sufficiency!
– Able to advise on all aspects of Commissary from Identifying the Market Potential with 7‐10
Identifying the Market Potential with 7
10 year year
horizon to Commissioning of Facility.
– Understand the Exposure of Maintaining Food Understand the Exposure of Maintaining Food
Safety & Meeting Product Demand:
• CCA will be required every quarter starting July 1st, 2012.
• STAR audits will commence January 1st, 2013.
– Commissary Website = Information Portal!
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Commissary Organization Structure
India – Bangalore
April 3rd 2012
April 3
Recommended Org Structure C2
Facility Manager –
Oversees All Ops & QA
Administrative
QA Manager
Ops Manager Maintenance Mgr Ordering/Logistics
CCA Management
Forecast/Production
Facility Upkeep
Accounting
Training/Certification
Yield & Efficiency KPI
Equipment PM/Clean
Shift 1 Lead –
Shift 2 Lead –
Shift 2 Lead –
QC/Ops Documentation
QC/Ops Documentation
QC/Ops Documentation
Daily Production
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Daily Production
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Daily Production
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Job Description and Profile
PHD Production Manager
JJob purpose: To ensure a smooth production & supply chain process by maintaining highest standards of b
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quality and hygiene, achieving business goals of commissary unit. Key responsibilities and accountabilities:‐
1. Maintaining & providing highest service levels to stores:
a. Indent Compliance
b. Time Compliance
c. Temperature Compliance‐Data Logger
d Store problem redressal
d. Store problem redressal
2.Maintaining hygiene & quality standards in Commissary:
a. Implementation & execution of sanitation programs
b. Daily cleanliness checklist
c. Uniform
d. Pest Control
Job Description and Profile
3. Inventory Management
a) Maintaining minimum stock levels.
b) Re‐ order levels
c) No stock outs
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k
d) FIFO to be followed.
4. Production Planning & Control
a.Daily Production as per indents
b.New product launches
c.Manpower distribution for adequate results.
5.Logistics :‐
Support logistic vehicle route planning. 6. Stores Inventory Management ( Commissary)
a. Follow FIFO
b. No expired material in stores.
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c. Nothing to be stacked near the walls & on the floors.
d. Temperature compliances
e. Cleanliness
f. Maintaining quality standards while receiving goods.
Job Description and Profile
PHD COMMISSARY MANAGER
7. Service to the stake holders.
a. Proper maintenance of commissary equipments.
b. Reducing manpower to increase per person yield.
c. Look for lowering cost without diluting quality in supplies.
8. Statistical information recording & analysis – Reports.
8. Statistical information recording & analysis 9. International OERs:
a. Follow international guidelines
b. Make improvements systems
C Maintain current standards
C. Maintain current standards.
10.Vendor Management:
a. Maintain good relationship with suppliers
b. Timely projections to the vendors
c. Vendor audits
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d. Ensure timely release of payments
11. Service to the accounts department
a. Checking , verification & signing of vendor bills in absence of Commissary Manager
b. Checking of all records being updated related to receiving of goods e.g. MRN & MRR
c. Check bills and MRN rates
d. Commissary Imprest to be checked
Job Description and Profile
PHD COMMISSARY MANAGER
12.Legal & License compliance as per the Factory Act.
13. Manpower Recruitment and Training to whole team.
14. Overall Commissary P & L statement, monthly reconciliation of all goods and
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,
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services, expenses.
15. Industrial Relations with local regulatory agencies and ensure compliance of PFA at Commissary unit and stores under that Commissary supply area
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Labor Planning – Team Member
1.
2.
3.
4.
5.
Labor Requirement‐ Skilled and Unskilled
Schedule – Process flow and Operational need.
Training ‐ On Job
Minimum labor turnover
Safety – Food and Labor Commissary Process
Lay out
Unit Operations
Unit Operations
Critical Control Parameters
Environment Control
Why Commissary …
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“The purpose is to take the dough production out of the BOH t
to central location to improve dough production efficiency”
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”
 Key to reduce PHD store build cost
Key to reduce PHD store build cost
 Improves quality/ consistency
 Reduces
BOH labor and
Reduces BOH labor and improves productivity
 Corner stone of Competitor models
Commissary Dough Types
• Traditional : Dough Ball
Traditional : Dough Ball
• Pan : Par ‐ bake
COMMISSARY PHD DOUGH PROCESS
Ingredient storage
scale
Mixing
Divider/rounder
Proofer
Tray
Oil spray
Cooler
Bag Storag
e
Baking
Walk in Cooler
To delivery area
Cooling & Packing Cooling
& Packing
Room
Traditional Dough Commissary : QCP
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y
•
~15 C Water
Batch
Pre Weigh
Pre-Weigh
Mixing :
Dough temp :
23+2 C
Clean Trays
Dividing /
Molding
Place Dough
Balls place in
Trays & spray
with oil
Refrigerated Storage :
48 hours of
Fermentation at 1
1-4
4C
Refrigerated Storage 1- 4°C
Air Conditioned 16-18°C
Conditioned < 24
24°C
C
Par‐Bake Pan Commissary : QCP
Mixing
‐ Flour moisture : 14
Flour moisture : 14+2
2 %
%
‐ Dough temp : 26 + 2C
‐ Prevent drying of DB
‐‐ Room Temp : 18 C
Divide / Round
‐5
5 % lower Dough weight
% lower Dough weight
‐Use dough in < 20 min
‐‐ Room Temp : 18 C
Proofing
‐Retard for min 1 hour
‐ Control Temp to 1‐4 C
Par‐Bake
‐2.5 min at 220 C
‐ PHD Oven fingers : FB II
‐ Cooked height : 20 ‐30 mm
Cooked height : 20 30 mm
‐‐ Bake to color spec
‐Proof at 37+2C
‐ Proof to upper edge of pan P ft
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line Pre‐packing cooling
‐ Cool to less than 30 C
Sheeting
‐Sheet to within 1 cm from pan edge ‐ Max exposure time : 20 min ‐‐ Keep dough covered
Pan Up
‐ 2/3rd the amount of Oil
Pack & Store
Pack & Store
‐Pack PBP max 5 high
‐ Store at 1‐4 C
‐‐ shelf life : 5 days
shelf life : 5 days
COMMISSARY PAR BAKE PROCESS
Ingredient storage
Oiling
scale
Oiled Pans
Proofer
Cart
Mixing
Divider/rounder Resting
Sheeting
Retard
Ovens
Bag Storage
Baking Room
Baking Room
Walk in Cooler
To delivery area
PBP Cooling & Packing Room
Commissary Layout
Commissary Layout
Commissary Layout
Dough Blends & Recommended Batch Sizes
• Traditional PHD Dough :
Traditional PHD Dough :
– Batch size : 100 Kg flour
– One 5 kg bag of Improver plus 270gr Yeast ( IDY )
One 5 kg bag of Improver plus 270gr Yeast ( IDY )
• Par‐Bake Pan:
– Batch size : 100 Kg flour
– One 4 kg bag of Improver plus 1.25kg Yeast (IDY )
Ingredient Storage
& Batching
Temperature: 18C
Increased Air Changes
Increased Air Changes
Tem
mpering
Dough
D
h
Processing
T
Temperature: 1–
1 4C
Retard
&
Cold Storage
Cold Storage
Bake
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Ambient Conditions
C di i
Ingredient Storage
& Batching
Dish
Wash
Shipping
Proofing
Temperature: 37+2C
YUM! RESTAURANTS
INTERNATIONAL
COMMISSARY TRACKING SYSTEM
PBP Process
Mixing
<20 Minutes
Dividing
18 C
18 C room
Fl tt i
Flattening
Sheeting
<20 Minutes
Panning
18 C room
Edge Spraying
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60 Minutes Proofing
60 Minutes Retarding
2‐3 Minutes Baking
30 Min to <30C
In 18 C room with enough condenser Tempering
capacity to remove
capacity to remove water
Packaging
Staging
Washing/Drying
Commissary Manual
Quality and Sanitation Program
Bangalore April 2012
Commissary Manual
•An easy guidelines to help run a flawless PHD Commissary operations
•Help you achieve consistent product quality •Provide the tool to support Food Safety and Protection initiatives
Yum! Restaurants International
Commissary
Quality & Sanitation Manual
QA / QC Program
•
•
•
•
•
•
Quality Assurance Program Over View
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i
Quality Assurance Quality Control Forms
HACCP Program
HACCP Program
Audit Requirements
Sanitation Program
Commissary Organization
Quality Assurance Program • PHD
• PBP
Operation & Control Forms • Operation & Control Forms
• Start Up Check list
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• Calibration plan
• Process Control Check Sheet :  PHD
 PBP
• Change Over Check List
• Receiving inspection log
• Raw material lot tracking
• Shipping log
• Equipment Calibration
• Maintenance for Food Safety
• Continuous Improvement
HACCP
• HACCP Program Forms
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– HACCP Team
– Product Profile : dough
Product Profile : dough
– Process Flow Diagram : dough
– Hazard Analysis
Hazard Analysis
– Master plan to eliminate Hazard
• HACCP Manual
Audit Tools
• Documents:
–
–
–
–
–
–
–
–
•
2 Audits using YUM ! Brands Food Safety Audit ( FSA)
–
–
•
FSA audit guidelines
FSA
audit guidelines
FSA audit score sheet
2 Audits using YUM ! Brands Quality System Assessments ( QSA)
–
–
•
Document Master List
Yum QSA Doc list
Yum FSA Doc list
Monthly self Inspection
Food defense Check list
Recall Plan
Customer Complaint log
Glass & Plastic inspection
QSA audit guidelines
Q
QSA audit score sheet
Transportation Audit
–
–
Trans audit guidelines
Trans audit score sheet
Sanitation
• Sanitation Program
– Master Sanitation schedule
– Daily Sanitation schedule
– Equipment sanitation
•
•
•
•
Dough mixer
Divider / Rounder
/
Sheeter
Oven
– Floor sanitation
•
•
•
•
•
Processing area
P f
Proofer
Oven room
Tempering room
Cold storage
– Microbiological Testing Schedule
HR Tools
Employees Responsibilities & Training
•
•
•
•
•
Org Chart
Org
Chart
General Manager Responsibilities
Q li C
Quality Control Manager Responsibilities
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ibili i
New Employee check list
Training Schedule
CCA Overview:
CCA Overview:
Bangalore, April 2012
Background
• Consolidation of dough production in a central location or commissary. PHD is a fast growing brand
• PHD is a fast growing brand
• Need for systems and processes that ensure food safety, quality and operations excellence
quality and operations excellence
• No tool/training to prepare for STAR FSA and QSA available • The need of a coaching/alignment tools is urgently needed
Why Commissary Compliance Assessment? •
All Current YUM! Suppliers expected to pass STAR Audit!
•
Tool to provide targeted training/guidance to commissary BMU/Commissary leaders in food safety and quality standards
•
To maintain the highest standard to which all Yum! suppliers are held. •
Development and coaching tool to prepare each facility to successfully pass first y
( )
y
y y
(
)
the Yum! Food Safety Audit (FSA) and finally the Quality Systems Audit (QSA) on an annual basis
•
Maintain standards and consistency
•
Continuous improvement tool
•
CCA
Implementing the CCA • The CCA will be conducted by a Local BMU or y
Franchisee QA team quarterly (4 per calendar year)!
• First CCA should be conducted within 3 month of Commissary opening or after officially launch
Commissary opening or after officially launch the program ( July 1st 2012)
• The CCA will be made available to each commissary via the commissary website in order to review and prepare
to review and prepare
Results
• Rating of the CCA are (similar to current FSC):
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(
)
– Pass: less than 10 Issues
– On Alert: 10‐19 issues
– Failed: >20 issues or any critical
F il d 20 i
iti l
• Scoring
Scoring will provide continuous improvement will provide continuous improvement
guide
• The CCA will help indentify gaps and prepare action plans with defined timelines to close those gaps.
gaps
CCA expectations
•
•
•
•
•
Mandatory tool for all Commissary 4 times a year
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lf
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i
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The ultimate goal is to pass this assessment after 6 month of starting using the tool
– No critical issues should be found at the Commissary y
Identify gaps
– If critical issues are found they need to be addressed Road map
– to systematically address issues and opportunities
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d
Assure Continuous improvement
– This tool should provide enough guidance to continuous increase the scoring •
Tool to meet standard
Tool to meet standard
– Ultimately the CCA will provide enough guidance to achieve Best in Class supplier level
•
Process & Facility
‐ Standardized process will provide better and consistent products
Standardized process will provide better and consistent products
CCA Sections
Sections
Deviations
1. PEST CONTROL
11
2. SANITATION & CONDITION
18
3. OPERATIONS AND FACILITIES
13
4. GOOD MANUFACTURING PRACTICES
16
5. PRODUCT PROTECTION
11
6. PRODUCT RECOVERY AND FOOD SECURITY
8
7. PRODUCT QUALITY
8
8 PRODUCT
8.
PRODUCT, INGREDIENT AND MATERIAL TRACKING
4
9. PURCHASING AND CONTROL OF INCOMING INGREDIENTS
4
10. PRODUCT STORAGE AND SHIPPING
3
1. Pest Control
•
•
•
•
Pre requisite Program
Pre‐requisite
Program
Interior and Exterior of Facility
Prevention is key
i i k
Work with licensed vendor – They can provide support: training, look for entry points, knowledge of local risk
How many potential pest entry or harborage points do you see?
points do you see? Pest Stats
•Rat: 1 cm space, climb, swim
•Mouse: 0 5cm space jump
•Mouse: 0.5cm space, jump, burrow
•Cockroach 0.25 cm space, eggs in cardboard
2. Sanitation & Condition • Pre‐requisite Program
• Largest Section of CCA
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f CCA
• Proper training is key to success (leverage vendor where possible)
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ibl )
• Each piece of equipment should have
– Detailed cleaning instructions
– Include frequency
• Equipment design, make and condition affect cleanability
Why might it be hard to clean?
3. Operations & Facility
• Pre
Pre‐requisite
requisite Programs
Programs
• General facility cleanliness
– Inside and outside
I id
d t id
• Quality consideration
– separate par bake area from processing
• Maintenance can create food safety risk
– Tool/part reconciliation – Post‐maintenance sanitation
4. Good Manufacturing Practices (GMPs)
•
•
•
•
Pre requisite Program
Pre‐requisite
Program
Employee Hygiene and Practices
Remember visitors, contractors
b
ii
Making dough is a “hands on” process
– Handwashing is critical
– Fingernails trimmed/clean, no jewelry
Acceptable Acceptable
GMPs?
5. Product Protection
• HACCP Review
HACCP Review
• Program established
– CCPs identified with monitoring
CCP id tifi d ith
it i
– Annual program review
• Measures to prevent cross‐contamination
• Employee interviews
• Remember in dough making water is an ingredient
Bangalore Facility CCPs
6. Product Recovery & Food Security
• Pre‐requisite
Pre requisite Programs
Programs
• Aware of product location at any time
• Contact information for suppliers and C
i f
i f
li
d
customers
• Test your systems!
• Security of facility to protect employees and y
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product
7. Product Quality
• QCPs
• Use Quality Assurance Plans to guide
• Measurements/records at each critical step
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– Use charts to trend and react • Finished product testing with records
8. Product, Ingredient & Material Tracking
•
•
•
•
Pre requisite Programs
Pre‐requisite
Programs
All materials coded for tracking
Don’t forget about packaging
’ f
b
k i
Ship oldest first
Use system for tracking
All raw materials should include information for traceability traceability
9. Purchasing & Control of Incoming g
Ingredients
• Pre
Pre‐requisite
requisite Program
Program
• All ingredients in use are approved
– Certificates of Analysis
C tifi t
fA l i
– Testing
• Use Yum! Q.A. & SCM to help source and maintain approved suppliers
• Approved suppliers help start process with food safe, quality ingredients
10. Product Storage & Shipping
• Final
Final step in process
step in process
• If not managed can damage all hard work
• Trailer temperature and condition
il
d
di i
– What was being carried before?
– Could condition result in cross contamination?
• Educate drivers on proper handling
CCA Report
Commissary #
Commissary Name
Commissary Name
CCA Specialist
Raiting:
Criticals Failed:
Issues Failed:
Score: Criticals :
Deviations:
CCA Summary Report
Issues:
Franchisee Technical Commissary Workshop
•
•
Technical Workshop Outline
Audience: Commissary Production
Audience: Commissary Production Tuesday, April 3, 2012 –Arrivals (No scheduled events)
Wednesday, April 4, 2012
•
Overview
•
Organization Structure
•
Job Description & Profile, Labor Planning
•
Commissary Process, workflow, layout & controls
•
Mumbai Layout
•
PHD Store Visit – Lunch
PHD Store Visit •
Introduction Commissary Compliance Audit ‐ CCA
Dinner Buffet
Thursday, April 5, 2012
•
HACCP, Key Systems & Processes
•
Website
•
Training Resources
•
Dough Quality & trouble shooting
Lunch
•
Commissary Visit – Equipment Tear Down & Troubleshooting (Hands On)
Commissary Visit Equipment Tear Down & Troubleshooting (Hands On)
•
India Best Practice
Recognition Dinner
Friday, April 6, 2012
•
Commissary Visit – CCA Hands On Audit
•
Lunch
•
CCA Summary
•
Startup, finalize SOP, process capability, & Hand‐over local ops
Wrap up and Departures
Dates: 4‐ 6 April
Leader QA maintenance
Leader, QA, maintenance 9:00 am
9:30 am
10:30 am
11:15 am
12:00 pm
12:30 pm
12:30 pm
3:00 pm
7:00 pm
Steven
Steven
India Team
Amarjit
Pandurang
Team
Daniel
9:00 am
10:00 am
10:30am
10:45am 11:45 pm
12:45pm
4::30 pm
6:30 pm
Meghann/Daniel
Steven
India Team
Amarjit
8:00 am
1:30 pm
2:30 pm
3:30 pm
4:30 pm
Meghann/Daniel
Lunch
Daniel/Amarjit
Amarjit
Steven
Steven/Supplier
India Team
Aidan
PHD Commissary
PHD Commissary
HACCP and Key Systems for Food Safety & Quality
Why Commissary?
• Many positive aspects of central production at commissary
– Financials
– Consistency & Quality – Food Safety y
• Positive Impacts Could Easily Turn Negative
Why Food Safety is Critical
• Direct Suppliers ‐ Produce Food Safety
– TB tainted lettuce, 5%+ sales loss in Q4 06
TB i d l
5%
l l
i Q4 06
– Massive changes to how industry manages produce
• Further Up Supply Chain ‐ Sudan Red
– Knowledge of upstream suppliers
Knowledge of upstream suppliers
– Impacted all Yum!, China most significantly • In Our Restaurants ‐
In Our Restaurants Pest Control in NYC
Pest Control in NYC
– HACCP even at restaurant level, know your risks
Delivering Food Safety & Quality
• HACCP (Hazard Analysis Critical Control Point)
–
–
–
–
–
–
Started from TQM (total quality management) & NASA program (zero defects)
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TQM (t t l
lit
t) & NASA
(
d f t)
System to identify, evaluate and control hazards significant to food safety
Requires pre‐requisite programs to be in place
Control Critical Points to manage Food Safety risks
Control Critical Points to manage Food Safety risks
Reduces reliance on end product testing
Adapt / update as system changes
• CCPs (Critical Control Point)
CCPs (Critical Control Point)
•
•
a step at which control can be applied and is essential to prevent or eliminate
a food safety hazard or reduce it to an acceptable level
Food Safety Hazards = Biological, Chemical, Physical
• QCPs (Quality Control Points)
•
a step at which control can be applied to prevent, eliminate or reduce to an acceptable level a quality risk 7 Principles of HACCP
Principle 1: Conduct a hazard analysis
• Identify the potential hazard(s) associated with food production at all stages, from primary production, processing, manufacture and distribution until the point of consumption. Assess the d ti
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f t
d di t ib ti
til th
i t f
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A
th
likelihood of occurrence of the hazard(s) and identify the measures for their control Principle 2: Determine the Critical Control Points (CCPs)
• A "step" means any stage in food production and/or manufacture including the receipt and/or production of raw materials, harvesting, transport, formulation, processing, storage, etc. d ti
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t i l h
ti t
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Principle 3: Establish critical limit(s).
• Establish critical limit(s) which must be met to ensure the CCP is under control. Principle 4: Establish a system to monitor control of the CCP
• Establish a system to monitor control of the CCP by scheduled testing or observations
Principle 5: Establish the corrective action to be taken when monitoring indicates that a particular
CCP is not under control
Principle 6: Establish procedures for verification to confirm that the HACCP system is working
Principle 6: Establish procedures for verification
to confirm that the HACCP system is working
effectively
Principle 7 : Establish documentation concerning all procedures and records appropriate to these
principles and their application
Applying the 7 Principles
1.
2
2.
3.
4.
5
5.
6.
Assemble HACCP Team
Describe Product
Describe Product
Identify Intended Use
Construct Flow Diagram
O it C fi
On‐site Confirmation of Flow Diagram
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f Fl Di
List all potential hazards, conduct a hazard analysis, consider control measures
7
7.
Determine CCPs
Determine CCPs
8. Establish Critical Limits
9. Establish a monitoring system for each CCP
10. Establish Corrective actions
10
E t bli h C
ti
ti
11. Establish verification procedures
12. Establish documentation and record keeping
Traditional Dough Production
Batch
Mix
Divide/Round
Dough 23 +/‐ 2°C
Dough Weight
Ship to Restaurants
Metal Detect
1.5 mm ferrous
2.0 mm non ferrous
2.5mm stainless
.5mm stainless
Dough in Trays
Refrigerated Storage
48 hours 1‐4°C
QCP
Prevent, eliminate or reduce quality risk
CCP
Prevent, eliminate or reduce food safety hazard Par Baked Dough Production
B t h
Batch
Par Bake
Height
C l
Colour
Cool
<30°C
Mix
Dough 26 +/‐ 2°C
Retard
Time 60 min
Time 60 min
Pack
Divide/Round
Dough Weight Rest 3 min. Sh ti
Sheeting
Proof
Pan
Proofer 37 +/‐ 2°C
P f T Li
Proof to Top Line
2/3 Amount of Oil
S
Spray Edge
Ed
Metal Detect
1.5 mm ferrous
2.0 mm non ferrous
2 5mm stainless
2.5mm stainless
Ship to Restaurants
QCP
Prevent, eliminate or reduce quality risk
CCP
Prevent, eliminate or reduce food safety hazard Final Thoughts
• Consistency in food safety & quality lead to positi e financials and e perience for
positive financials and experience for customers
• Resources to develop your systems on website
Resources to develop your systems on website
• CCA is a coaching tool
– Helps identify gaps in pre‐requisite programs & l id if
i
ii
&
HACCP plan
– Prioritize risks
Prioritize risks
• Be prepared to pass STAR Audits
Resources
Commissary Website
Commissary Website
• http://phd
http://phd.yumnet.com/commissary/index.ht
yumnet com/commissary/index ht
ml
Dough Quality
&
Trouble Shooting
Trouble Shooting
Dough Technology & its
impact
p
on q
quality:
y
Mixing
Moulding
Baking
Mixing
• The HEART
Th HEART of the Dough Consistency
f th D
hC i t
77
Mixing of Dough: Objectives
• Uniformly
Uniformly incorporate ingredients
incorporate ingredients
• Hydrate all dry materials completely
• Develop the gluten for proper handling quality l
h l
f
h dli
li
and gas retention (mellowing)
78
Function of Ingredients
• Flour ‐ To hold gas and provides texture
To hold gas and provides texture
• Sugar‐ Color, flavor, yeast activity
• Salt‐
S l Flavor, Dough strength, regulate l
h
h
l
fermentation
• Edible oil‐ Produces tenderness, controls migration of sauce to crust, helps dough handling
79
PH Flour
• Moisture : 14 %
Moisture : 14 %
• Protein : 10.5 ‐11 %
– Protein provides tolerance to fermentation
P t i
id t l
t f
t ti
– Provides crispiness
– Gluten can supplement low protein flour
80
Yeast Selection is Critical ..
PADY / CADY
IDY( Commissary)
Dead yeast
Viable yeast



High level of dead yeast
Low activity
Reduced retard shelf life due to dead yeast




SPM ( YUM)
Low level of dead yeast cells
Mid / Low activity ‐ no over‐proofing
Good retard shelf life Foil and Vacuum packed




Low level of dead yeast
High activity –
Reduced retard shelf life due to over proofing
over‐proofing
No Foil pack
Lower cost
Dough Development
Gas Production
Gas Production
Gas Retention
Gas Retention
The generation of The
generation of
carbon dioxide by yeast
The ability of the gluten
The
ability of the gluten
to retain and trap the gas
produced within its extremely thin membranes and to expand without breaking until it finally
it finally
sets in the oven giving baked g
cell structure and eating quality
82
Mixing Stages
• Moisture
Moisture Pick up: dough is sticky, cold, lumpy
Pick up: dough is sticky cold lumpy
• Initial development: dough is getting warmer, smoother and drier
smoother, and drier
• Clean up: dough is at maximum stiffness. The d
dough will slap around the mixer and come h ill l
d h
i
d
together as one mass
83
Mixing Stages Cont’d
• Final
Final development: dough is at correct development: dough is at correct
temperature and handling quality. A gluten film is apparent
film is apparent.
• Letdown: dough is too warm and sticky. The dough lacks elasticity and has too much flow
dough lacks elasticity and has too much flow
• Breakdown: dough is beginning to liquefy
84
Continuation of Mixing
85
Continuation of Mixing
86
Final Development
87
Letdown
88
Breakdown
89
Factors Which Affect Mixing Time: Machineryy
•
•
•
•
Speed of mixer (RPM)
Speed
of mixer (RPM)
Mixer design
Dough size in relation to mixer capacity
h i i
l i
i
i
Dough temperature : effected by water & Flour temperature
90
Factors Which Affect Mixing Time: Ingredients
g
• Flour (protein)
Flour (protein)
• Water amount
• Amount of oil
f il
91
Types of Mixers
•
•
•
•
•
•
•
Hand mixing
Hand
mixing
Blending plus dough break
S i l i
Spiral mixer : Thunderbird
h d bi d
Vertical mixer
Horizontal mixer
High speed mixer
High speed mixer
Continuous mixer
92
Spiral Mixers
• Very
Very versatile: product mix and range of versatile: product mix and range of
capacities
• Relatively inexpensive
Relatively inexpensive
• Good tolerance to over mixing
93
Spiral Mixer
94
Dough Mixing
• Mix
Mix pizza dough at 2 minute at low ( 130 rpm) pizza dough at 2 minute at low ( 130 rpm)
and 4 minutes at high speed (260 rpm).
• Maintain dough temperature
Maintain dough temperature
– PHD Traditional : 23 + 2 C
– Pan :26 +
P 26 2 C
2C
95
Dough Forming
• Dough ball
Dough ball
– AM Mnf corporation
– Speed : 30 DB / min
p
/
• Dough Sheeting
– Provides consistent sheeting vs. manual
Provides consistent sheeting vs. manual
– Supplier: Doyan
96
Proofing
• The
The purpose is to have smaller uniformly purpose is to have smaller uniformly
distributed bubbles
• Proofer conditions : 37 +2 C
Proofer conditions : 37 +2 C
• Proofing in a closed environment : keep the d
dough covered
h
d
– Maximum 7 high pan stack
97
Retarding
• The
The purpose is to have dough with constant purpose is to have dough with constant
temperature going into the Oven for consistent baking
consistent baking
• Retarding conditions : 1‐4 C for minimum 1 hour
98
Baking
• Baking
Baking Oven : Middleby or Lincoln with FB II Oven : Middleby or Lincoln with FB II
fingers for gentle bake
• Baking conditions:
Baking conditions:
– Temperature : 220 + 5 C
– Time : 2 ½ +
Ti
2 ½ ½ minutes
½ i
• Bake to color spec per color guide
99
Retard Stability


Protein Quantity
Protein
Quantity
Protein Quality
Starch Damage
Starch Damage
Low
Poor / Weak
High
100
Dough Quality Optimization : done locally because of flour quality variation
q
y
Should take place region by region lead by regional Technical Should
take place region by region lead by regional Technical
Manager ( if absolutely necessary) and should be signed off by the PSC
1. Optimize flour quality ‐ Grist, milling technique according to PH Specification
2. Optimize water addition ‐ 52% + 3% 3. Optimize mixing time / dough development –
1.
1
2.
Low speed : 2 minutes
Low
speed : 2 minutes
High speed : 4+1 minutes
101
Remember ...
A flour can be A
flour can be ‘to
to spec
spec’ but
but
not perform as a Pizza Hut flour
ALWAYS
test samples using the
Brand Standard
Cuttings Toolbox
Cuttings Toolbox
THIS IS THE ONLY
REAL TEST OF FLOUR QUALITY !
102
Trouble Shooting
Problem
D
Dough
h ttoo ti
tight
ht
Dough too slack
Possible Cause
Corrective Actions
T much
Too
h flflour or nott enough
h water
t
Checkk recipe
Ch
i and
d weighing
i hi
accuracy
Check scales and the weight of bags
of flour
Check flour moisture content
Too little flour or too much water
Check recipe and weighing
accuracy
Check scales and the weight of bags
of flour
Dough over mixed /too warm
Too much starch damage in the
flour
Retarder / delivery truck
temperature too high
Check water / dough temperature .:
PHD Traditional : 23+2C
PBP
:26+2C
Reduce high speed mixing time
Check flour quality
Check and adjust Retarder / delivery
truck temperature.
Evaluate night delivery for places with
very high outside temperature
Trouble Shooting
Problem
Under mixed
dough – dough
will be cool and
not smooth
Over mixed dough
– dough will be
warmer, soft and
maybe too sticky
Dough balls
don’t rise over
shelf life
Possible Cause
Mixer time too short or timer not
working. Water too cold.
Ingredients pitched in wrong order,
wrong speed of mixing
Mixer timer not working or mixed too
long.
Corrective Actions
Check mixer timer & speed recalibrate if
necessary, Check pitching order.
Check dough temperature & adjust water
temperature if needed
Check mixer timer & speed recalibrate if
necessary.
Water too warm
Check dough & water temperature.
Check yeast level / activity and
addition, check shelf life of yeast,
check storage of yeast
Check weighing procedure and scales.
Check yeast storage ( once opened yeast
should be stored in airtight container and
used in 3 days)
Check Salt/Sugar level in dough
improver
Too much salt or sugar can stop yeast
fermenting- check weighing records
/ i
/recipe.
Dough and water temperature
Dough storage temperature
Dough water temp should not be below
15 C
Dough
g should be held at 1-5 C.
Do Not store below 1C as this will stop
the yeast fermentation.
Trouble Shooting
Problem
Dough balls
ferment too
quickly or over
fermented
Possible Cause
Corrective Actions
Check recipe - too much yeast, too Check recipe and weighing procedures
little salt or sugar
Check water temperature and mixing time
Dough temp too warm - too much
mixing or too high water temp
Check and adjust Retarder temperature
and
d air
i fl
flow
Doughballs not correctly cooled
Doughballs stored at too high a
temperature
Dough should be stored at 1-5 C. Above 5
g will start to ferment
C ,,the dough
Doughballs will slowly ferment over shelf
life and so dough over 1 week old will look
much larger and be more fermented /
slacked
Ensure ambient temperature is stable and
air conditioning is on.
Ensure dough is divided and molded up
p
within 20 minutes of production.
Trouble Shooting
Problem
Dough balls
touch or join
together in the
trays
Dough balls
skinning at
commissary
Black spots on
dough ball
Possible Cause
Incorrect dough ball placement
Dough temp too warm
Corrective Actions
Place only the correct number of dough
balls in each tray
Ensure dough balls are correctly placed
with gaps between each
Lightly spray dough balls with oil
7” = 12
10”= 8
14” = 6
14
Check dough temperature
Doughballs not lightly oiled
Lightly oil the doughballs after production
Trays warped or not sealing fully
Mold on doughballs
Replace damaged,
damaged broken or warped trays
Ensure thorough cleaning and drying of
trays.
Ensure old / out of shelf life dough is
discarded.
This is an issue sometimes seen in older
dough and confused with mold growth. The
bran level becomes visible. Spots
disappear in oven.
Dead or undispersed yeast can sometimes
cause black spots under the dough
dough. If this
is an issue, rehydrate the yeast in a small
amount of water before adding to the
dough.
Oxidation of bran particles in flour
flour.
Spots under dough ball
Trouble Shooting
Problem
Dough bakes too
dark
Dough get holes
in the centre
Dough weight is
inaccurate
Possible Cause
Doughball is too young and not
aged correctly
Corrective Actions
Ensure dough 48 hours of fermentation
before use.
Wrong amount of added sugar
Dough rounding is not tight
Have supplier check recipe
Readjust rounder settings
Dough has skinned and cannot be
correctlyy rounded
Ensure dough is not left too long before
rounding
g
Dough rounder machine is not set
correctly
Readjust the rounder to achieve optimal
mould.
Dough batch size is incorrect for
throughput
All dough should be divided / rounded
within 15 minutes of mixing.
Dough divider has broken down
Volumetric divider is not set up
correctly
Discard any dough that has sat out for
more than 15 mins
Check weigh and adjust the system.
Dough is too warm
Review and adjust dough temperature
and/or mixing times
Air conditioning is not effective
Ensure dough production area is air
conditioned
Trouble Shooting
Problem
Dough is oily from
divider
Unusual and
excessive bubbles
i dough
in
d
h att store
t
Possible Cause
Oil from the divider is contaminating
the doughballs
Usually dough is abused during
delivery
Corrective Actions
Correctly adjust the oil output of the
divider
Check and adjust delivery truck
temperature .
Some times caused by under
Suggest longer staging time in restaurant
proofed dough – large flat bubbles
and in persistent & excessive cases
are usually from under fermentation. consider raising yeast fermentation. Talk
to Tech Manager/PSC
Commissary Visit Summary
Setting up Commissary for success
Joining dates/ formalities
To leverage the trainers and venues effectively new employees given 2 dates of joining each month for each city •1st Monday •3rd Monday
To facilitate HR compliance joining forms need to be filled on day 1 under supervision of HR
M
Managers files HR is takes responsibility
fil HR i k
ibili
Employee files, a responsibility of the Commissary manager
Crew On boarding and training
DAY 1‐3
Joining formalities Centralized Orientation
DAY 4‐30
Commence Dough Expert training
Buddy Trainer – Show and Tell, Guided practice
Practical & theoretical evaluation
DAY 31‐37
Work in make table & Pasta Station
Certification by store Coordinator
Celebrate in briefing
Celebrate in briefing
Total Training time 37 days
Training venue
Field Trainer
Training Store / Commissary Training
Coordinator
Store Training
Coordinator
Commissary Crew training .. Content overview
Centralized Orientation
•
•
•
•
•
•
•
•
•
•
•
Company History
Company vision, mission, goal
Culture training HWWT
Customer expectations
CHAMPS training
Food safety, Hygiene & HACCP training
Accident prevention
Accident prevention
Grooming Life skills
Crew Rules Training over view
Customer Mania Mindset , Perfect Pan Product workshop & HACCP training
& HACCP training
Commissary Shift In charge On boarding and training
On boarding and training
3 days 37 days
3 weeks
: Common as crew on boarding
: Common as Crew training : SM specific training (DC LAS) Total Training time 2 months
Production Manager On boarding and training
3 days
: Common as crew on boarding
3 weeks : Fast track training section training
3 weeks : SM DC training (DC LAS)
3 weeks
: SM DC training (DC LAS)
2 weeks : ARM specific training (DC LAR1)
Total Training time 2 months
Commissary Manager On boarding and training
3 days
: Common as crew on boarding 3 weeks : Fast track training section training
4 weeks : ARM DC training ( DC LAS & LAR1)
4 weeks
: ARM DC training ( DC LAS & LAR1)
2 weeks : RGM specific training (DC LAR2)
Total Training time 3 months
Modules Training Overview
Sl No
Shift In charge
1
Customer Mania
2
Cleanliness & Food Safety
3
Safety & Security
4
Emergency Situation
5
Basic HR
6
Product Quality
7
Daily Inventory
8
Shift Labor
9
Recognition
10
Conducting One on One
11
Forecasting
12
Managing , Food/Paper & Labor
13
Managing Semi Variable cost
14
Managing Facilities & Equipment
15
Basic Commissary Finance
16
Recruiting team members
17
Selecting Team members
18
Managing Training 19
Communicating with your team
20
Creating a positive & safe environment
21
Counseling your team
22
Developing your team
Production Mgr
Commissary Manager
Content‐‐ Snapshot Commissary team Training
Content
Production Mgr
Shift In charge
Crew
Commissary Mgr
Centralized Orientation




Customer Mania Mindset




Dough, Make & Paste expert training




Par bake dough making training




Fire Safety & First Aid Training




Perfect Pan & PHD dough workshop




HACCP & Food Safety Training




Equipment Cleaning & Usage Trng




DC Orientation



DC GRTL



DC LAS



DC Leading a team


DC Module TTT


DC LAR 1


DC LAR 2

High Impact Coaching

Field ABR session




Classroom training
Commissary Start up
Commissary Project Planning
• Planning
Start up
• Protocol
– Commissioning of each unit operation : dry run & with product
Commissioning of each unit operation : dry run & with product
– Standardizing of each unit operation: temperature / time
Mixing : mix time & speed , water amount & temperature , batch size , Dividing : weight variation within specs
Sheeting : throughput , roller gap , sheeted dough size
Proofing : stack height , time / temperature , temperature variation at full load , proof height
f
• Retarding : time of retarding
• PBP Baking: time / temperature
•
•
•
•
– Edge & center height within specs
• Cooling : time of cooling
• Traditional PHD Specs
Traditional PHD Specs
• Par‐bake Pan Specs
Start up
• Ship test :
Ship test :
– Ship product from commissary to store
– Product evaluation thru shelf life
Product evaluation thru shelf life
• Use cutting sheets
• Hand over to local team:
Hand over to local team:
– Gap analysis for process , equipment & manpower
– Finalize SOP’s
Fi li SOP’
– Regular follow up
Pizza Hut Commissary Workshop Wrap Up
India ‐ Bangalore
April 4th – April 6
April 4
April 6th 2012
Wrap Up – Project Management
Calls to Action
• Realize
Realize that there is a decision making process that there is a decision making process
– Business Model.
• Commissary website provides all resources.
Commissary website provides all resources
• Expected to Conduct a CCA by August 2012 and identify gaps in preparation for STAR d id if
i
i f STAR
audit.
• STAR Audit begins January 2013!