Manufacturing
Input
 Ingredients
Process
 Mixing, chopping, baking
Output
 End product-cake, biscuit, loaf of bread
Feedback
 Overcooked-cook for less, lower the temperature
Scales of production
 Manufacturers decide the scale of production depending on
the number of products predicted to be sold and the shelf
life.
 Just in time means that the materials are delivered to the
factory just in time to be turned into the products for
immediate dispatch to the shops.
 This means products don’t need to be stored in a factory. This
cuts down waste and reduces risk of bacterial contamination.
Types of production
One off/Jobbing
 Is used to make specialist
products such as cakes for
weddings and birthdays.
 Can be costly
 Rely on skilled workers
 Generally don’t require
special equipment.
Types of production
Batch Production
 Makes a specific quantity
on a large scale of the same
product such as biscuits or
cakes.
 Usually done by one
person or a team.
 The equipment used can
make one or more product
and workers need to be
skilled.
Types of production
Continuous flow
• This is used to make products
which are sold in large
quantities and have a high
shelf life. They are often made
24 hours a day, seven days a
week. Products include baked
beans, biscuits,
cakes and crisps.
Machinery can only be used for
that product.
CAM is often used in this
process.
Types of production
Automated manufacture
• May be included in
continuous flow production
lines. This method uses
computers and helps to
increases productivity, is safer
for workers, more hygienic,
assures final quality,
measuring, weighing, cutting,
shaping, critical control
points are automatically
tested.
Standard components
examples include grated cheese, pizza bases, ready made
pastry cases.
• Advantages
• Disadvantages
• Save time
• May forget to order and
• Can speed up manufacture
• Can use a less skilled
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workforce
Less cross contamination
Less equipment needed
Less effort
Ensures consistency of
product
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stop production
May need special storage
arrangements
May be more expensive
May not be up to standard
Same components may be
used by other companies.
Consistent product
A consistent product means producing something the same every time.
The use of machinery can help to do this
as  It can be faster/need less workers
 Don’t need to be as skilled
 There is less human error
 It can be set at a certain speed or for a
certain time.
 Eg using a mixer or electric deep fat
fryer
 It can cut the same thickness.eg using
cutters
 Use of standard components can
ensure you get the same standard.
Using computers
CAD (computer aided design) and CAM (computer aided
manufacture)
• Advantages of using
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computers
No mistakes
Can run all day without a
break
Save on labour costs
Removes human error
Can assess 1000s of
products in minutes
Cab detect things that the
human eyes cannot see.
Using computers
CAD
Computer aided design
• To design the physical
appearance of a product
• To calculate the nutritional
profile of a product
• To model the cost
• To calculate the shelf life
• To present sensory data like
profiles
• To model a production
procedure
• Produce packaging designs
Computer aided manufacture
Load cells
Measure the weight of ingredients and
store the info on a computer so it
knows when to reorder more.
Light refractor
Spots changes in colour such as bad
crisps or burnt food
Light detector
Used to check the thickness of sauces.
Temperature
Takes and records critical temperatures
of cooking and storing foods
Metal detector
Checks food for metal to makes sure
safe to go to customer.
Using computers
CAM
Flow charts
Flow charts usually have four symbols
 The terminator (Oval)
used at the start or the end
 Process (Rectangle)
What activity needs to be
carried out
 Decision (Diamond)
Usually a question with a yes
or no answer
 Arrows
which show the flow of the
chart
Quality assurance and quality
control
 Quality in food is very
important. Firstly it means
the food is safe to eat and
also it satisfies the
customers needs.
 So every time you buy this
product as a customer you
know it is going to be
exactly the same.
Quality assurance
 This simply means a
guarantee of quality.
Manufacturers assure their
customers that the product
will be of a consistent
quality.
 The manufacturer does not
want to loose this
reputation as it may cost
sales
Quality control
 These are the checks which
are carried out to check the
quality of the product. They
are done at the designing,
manufacturing and end of
manufacturing stages
Quality control will check Size
 Shape
 Appearance
 Taste
 texture
Tolerance
 Products need to be within a certain
tolerance to be of an acceptable
quality.
 So the size might be measured or
the temperature taken. These
measurements will need to be
within a certain tolerance to be
acceptable. So the temperature on
these pies will need to be within a
few degrees or the whole batch will
be throw out, for safety reasons.
 Pizza may need to be between 21
and 21.5 cm. Or it will not fit in
the box.
Removing hazards
 Manufacturers have a legal
requirement to make sure
their product is safe to eat.
When a new product is
being designed a HAZARD
ANALYSIS must be carried
out. This means looking at
what could go wrong and
making a plan to stop it
from happening.
Types of hazard
Biological
 Salmonella, listeria, E coli
Physical
 Hair, metal, fish bones
Chemical
 Cleaning materials
HACCP
Hazard analysis and critical control points
To produce a HACCP chart the manufacturer
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Lists the processes involved in the making of
the product.
 Identifies the areas where risk might happen.
 Decides which are critical to the safety of the
consumer and plans how to reduce these risks
using CRITICAL CONTROL POINTS.
 A check on a cooked food to make sure it has
reached the correct temperature may prevent
food poisoning in a customer
 CCPs check the food is safe to eat
 QCPs check the size and shape of the food for
quality