PROJECT IN WORK METHODS DESIGN

A Flow Process Chart

In Partial Fulfilment of the Requirements

For the Course EMG131-2

Human Factors Engineering and Work Design (Ergonomics)

Salanguit, Loren L.
Introduction
Cookie Meownster is a made-to-order dessert shop that serves different kinds of cookies, and part of
their profit is used to fund the food of stray animals in their area. It's located at Golden City, Santa
Rosa City, Laguna, founded by Salanguit Sisters, Loren and Rhea. The siblings are fond of baking
cookies and stray animals, and since Covid-19 pandemic happened, the sisters were inspired to open
a dessert shop for a cause hence the launch of Cookie Meownster last July 2020.

Area of Study
The preparation and baking process of Cookie Meownster is simple. Each batch of this baking
process can produce up to 36 cookies in 56 minutes. The ingredients are readily available and stored
in their kitchen. The preparation of ingredients and materials will take about 20 minutes. To begin
with, in a large saucepan, add the (142 g) butter and melt over medium heat. Bring butter to boil by
stirring frequently. This process will take about 4 minutes. Once the butter has turned a nice nutty
brown, remove from the heat and pour it into a large liquid measuring cup to stop the cooking.
Allow it to cool down for a minute or two, give it a stir, and carefully add two to three (2-3)
tablespoons of water to the butter to bring it back up to 1 cup (240 ml) of liquid. Set aside the
melted butter to let it cool down. To help speed this process up, you can place it in the fridge for 10-
15 minutes. While waiting for it, sift and combine the dry ingredients. One (1) cup of bread flour,
three-fourths (¾) cup of all-purpose flour, two (2) tablespoons of kosher salt, one (1) teaspoon of
baking soda, and one (1) teaspoon of baking powder will be placed in a medium bowl. This process
will take just about before the butter cools down. In a mixing bowl, add a three-eight (3/8 ) cup of
muscovado sugar, three-eight (3/8 ) cup of brown sugar, three-fourth (¾) of white sugar, two (2)
teaspoons vanilla extract, one (1) teaspoon of espresso powder, and one (1) cup of cooled brown
butter. Cream together with a stand mixer until light and fluffy. It usually takes about 2 minutes.
Add one (1) large egg and one (1) large egg yolk and beat until incorporated. This process will take
another 2 minutes. Proceed to the next step by adding the dry ingredients, about ⅓ of the mixture at
a time, and beat between additions until just incorporated. This process will take about 2-3 minutes
to avoid over-mixing. After this, using a spatula, fold the three-fourth (¾) cup of chocolate chips,
one-half (½) cup of milk chocolate buttons, and one (1) bar of chopped dark chocolate into the
dough. This process will take another 3 minutes. Using a four (4) cm scooper, scoop the cookie
dough. It will take 5 minutes to scoop all the dough. After this, an inspection will be made by
checking if all the scooped dough looks the same. The next procedure will be placing the scooped
dough evenly on a parchment paper-lined baking sheet which will take about 2 minutes. Sprinkle
some salt on the top of the cookie dough which will only take 5 seconds. The parchment paper-lined
baking sheet will be placed on trays and will be transferred to the fridge. The dough will be in the
fridge for 36 hours for optimal flavor. The next process will be preheating the oven to 350˚F
(180˚C). Place the cookie dough in a preheated oven for 10-12 minutes. When the baking process is
done, let the cookies cool on the baking sheet for 2-3 minutes before transferring them to their
packaging. The packaging process includes 10 cookies per box and only takes 30 seconds. The
finished product of Cookie Meownster will now be ready for pick-up or delivery by a 3rd-party
delivery application.
FLOW PROCESS CHART

Location: Cookie Meownster

Activity: Preparation for baking classic cookies SUMMARY
Date: EVENT COUNT
Operator: Ms. Loren Salanguit Operation 14
Present Method Proposed Method Transportation 2
Type: Man ( ✔ ) Machine ( ) Material ( ) Delay 4
Remarks: Inspection 0
Storage 1
Time (in mins) 2180
Distance (in ft) 15
Event Description Symbol Time Distance Remarks
(in mins) (in feet)

Getting the recipe and materials in 15

the storage room.
Preparation of the recipe and 5
materials
In a large saucepan, add the butter 0.5
and melt over medium heat.
Boiling the butter and frequently 5
stirring it.
Pouring liquid butter into large 0.5
measuring cup
Cooling down of heated liquid 15
butter
Adding 2-3 tablespoons of water 1
Setting aside to cool to room 15
temperature
Sift together the flour, salt, baking 8
powder, and baking soda.
Add all ingredients in a large bowl 2
Add the egg and yolk and beat until 2
incorporated.
Add the dry ingredients, about ⅓ of 5
the mixture at a time, and beat
between additions until just
incorporated
Fold the chocolate chips, chocolate 4
buttons, and chunks into the dough
Scoop the cookies 5
Cover and refrigerate for 36 hours 2160
Preheat the oven to 350˚F 15
Evenly space the dough apart from 0.5
one another on a parchment paper-
lined baking sheet. Sprinkle a pinch
of salt on the top of the dough.
Bake in a preheated oven for 10-15 15
minutes
Let the cookies cool on the baking 2-3
sheet for 2-3 minutes before
transferring to a cooling rack to
cool completely
Finished product of the classic 15
cookies

Pareto Analysis
A total of 228 cookies are baked throughout a week's worth of output. Some customers have issues
about the product, and Cookie Meownster wanted to come up with a plan to significantly lower such
issues. The following list of consumer complaints about cookies is categorized using Pareto
analysis:
 15 cookies – uneven texture (UE)
 10 cookies – too salty (TS)
 72 cookies – fewer chocolate chips (FCC)
 36 cookies – almost burnt (AB)

Category FCC AB UE TS
No. of Complaints 72 36 15 10
Cumulative 72 108 123 133
Cumulative 54% 81% 93% 100%
Percentage
STOPWATCH TIME ANALYSIS

1. Breakdown of operation into elements

There are three (3) steps in the cookie packing process at Cookie Meownster. After the
cookies are baked, the baker will scrape the baked cookie batter and sprinkle a little salt on
top. The cookies will then be left to cool for three minutes on the tray. 10 freshly baked
cookie pieces will then be packaged in a cookie box.Consequently, the elements of this
operation are:
(a) Scraping the Monay
(b) Cooling the Monay
(c) Sealing the Monay

2. Computation of number of cycles

The group carefully observed and analyzed the packing operation of freshly baked
monay at Ate Len’s Bakery for about 10 cycles. During each cycle, 6 pieces of monay were
packed successfully. The observed time for each cycle is presented at the table below.
3. Setting up Westinghouse Rating Factor
After observing the performance of the workers of Ate Len’s Bakery, a Westinghouse
Rating Factor is utilized to calculate the performance rating of the workers at every element of
this operation.
For the Scraping the Monay process, the assigned worker has his skill to be Excellent
(B1), his effort to be Good (C2), and his consistency to be Excellent (B), and the conditions
were deemed to be Ideal (A).
Rating Factor = 0.11 + 0.02 + 0.03 + 0.06 + 1 = 1.22 * 100 = 122%
For the Cooling the Monay process, the assigned worker has her skill to be Good (C1),
her effort to be Excessive (A1), her consistency to be Average (D), and the conditions were
considered to be Excellent (B).
Rating Factor = 0.06 + 0.13 + 0.00 + 0.04 + 1 = 1.23 * 100 = 123%
For the Sealing the Monay process, the assigned worker has his skill to be Average (D),
his effort to be Good (C1), his consistency to be Good (C), and the conditions were considered
to be Excellent (B).
Rating Factor = 0.00 + 0.05 + 0.01 + 0.04 + 1 = 1.1 * 100 = 110%
4. Setting up the Allowances Utilizing the Allowance Table
During the observation, no allowances are considered due to the time constraint in
baking the products.
5. Computation of the standard time using the above data