I.

INTRODUCTION TO FOOD PRODUCTION

 UNDERSTANDING QUANTITY FOOD PRODUCTION

 TRENDS IN QUANTITY IN FOOD PRODUCTION
 MANPOWER PLANNING
 PRODUCTION PLANNING
 MARKETLIST, PURCHASE ORDER, AND MARKET SURVEY
UNDERSTANDING
QUANTITY FOOD
PRODUCTION
 • UNDERSTANDING QUANTITY FOOD
PRODUCTION
The food service industry is a big business in the Philippines.
Business which are engaged in quantity and institutional food
production constitute a large portion of this market.

QUANTITY FOOD PREPARATION

- Refers to the production of larger-than-normal volume of food for
a large group of people. It needs people and managers who are well-
versed in handling many facts of proportion. They must be both people
oriented and professionally component. In addition to catering events.
It’s often used healthcare and residential living facilities to cater to
clients. This requires specific elements of food production that
maximizes the continuous flow, or uninterrupted movement movement
of people and goods throughout a kitchen.
• In the past managers and staffs usually gained their
component throughout experience. Learning on the job
and often rising through the ranks from Stewards to
Chefs was not uncommon
• Technology is becoming more complex, competition is
becoming more sophisticated and business are becoming
bigger and bigger.
 WHAT IS QUANTITY/INSTITUTIONAL FOOD
PRODUCTION

 QUANTITY/INSTITUTIONAL FOOD PRODUCTION

- Is an organized group of workers using special
equipment and facilities to produce food for the
consumption of others.
 “NOCHE BUENA”
- Is not considered as a part of quantity/institutional
food production.
 3 ASPECTS OF QUANTITY/INSTITUTIONAL FOOD
PRODUCTION:
• VOLUME
- We are considered with larger output quantities. Regular
production volume may vary from 25, 100, 200 or more. Recipes have to
be enlarge to such proportions. This brings about special problems and
concerns in storage, equipment, purchasing and preparation that may be
very different from those of smaller volume production kitchen.
• ORGANIZATION
- In quantity food production organization is quite complex. It
requires workers that are skilled and knowledgeable in the different
aspects of food production.
- Organization must be fitted to the task to be accomplished,
facilities and work must be evaluated and designed such that task of
producing high quantities can be best and consistently achieved.
• MADE OF OPERATION
- Quantity food preparation requires specialized knowledge
such as recipe quantification, proper production planning and use
of specialized equipment that could handle large volumes of
production.
- It employs convenience products, standards and techniques
that are needed to ensure the quality and consistency of end
products. It must also observe the most rigid standards of
sanitation and safety.
- Basically, the aim of quantity food production is to come-up
with the consistent products that would satisfy the consumers. We
must consider that we concerned here with producing large
quantities of a product. It may be simple enough to cook for 3
people and expect each one receive the same quantity and
quality. All that may be required Is the recipe, purchasing the
ingredients and following the procedures written in the recipe.
 TO FULLY UNDERSTAND QUANTITY FOOD PRODUCTION,
WE MUST ALWAYS LOOK AT THE 3 ASPECTS AS WE GO
ALONG

• FIRST, We must know what is to be produced. We must have a clear

picture of what the expected output should or must be. This is
known as the “STANDARD”
• SECOND, We must know what knowledge must be applied to get
desired results. One must not only known what to do but also why it
is done. These are called “PRINCIPLES”
• LASTLY, We must known how to go about it. We must be
acquainted with the steps and procedures involved in production
and always keep in mind that these have to be followed to achieved
the standard set. These are called “TECHNIQUES”
 TO IMPROVE THIS, LET US SAY FOR EXAMPLE
SOMETHING WENT WRONG WITH THE PRODUCT
• FIRST, We will only known if something is indeed wrong if we had
something to compare it with in the first place. Just like in a recipe in a
picture, we always compare our end-product with this picture. This
picture here is nothing but the standard.
• SECOND, If something is indeed wrong, it would be useless to known this
if we did not know why it was or where we went wrong. This is the use of
the knowledge of principles.
• LAST BUT NOT THE LAST, Even if we knew where we went wrong, it
would be useless if we did not know how to correct the error. This is now
the use of the techniques order has learned. As you can see, these three
basic aspects not only give you guide to understanding quantity food
production better than also gives you a repair kit than may come-in
handy in your future production problems. Hopefully, you would try to
organize the knowledge that you gain using these three aspects as you do
the activities in quantity food production.
TRENDS IN QUANTITY
IN FOOD
PRODUCTION
The biggest trendsetter in quantity food
production is the advances in technology itself.
Advances in the field of nutrition, information
technology and other sciences are shaping the
facing quantity food production today. Besides
these, the fact that consumer are becoming
smarter and well informed poses new challenges
to the industry.
 NUTRITION AS A TRENDSSETTER

This nutrition conscious can be well seen on the labels of

canned and bottled goods itemizing the nutritional value of its
food content.
In some countries, especially in Europe restaurant menus even
specify the calorie content of a particular dish and the
percentage recommended daily allowance (RDA) of individual
dishes.
The nutrition value of meal is now as important as its flavor and
presentation and thus must be integral part of menu planning.
Foods service establishments that can provide such special
nutritional needs will enjoy a good position in the market.
INFORMATION TECHNOLOGY AS A TRENDSETTER

Computers perhaps the most visible when we talk of

information technology or I.T.
Equipment today are “Smarter” and multifunctional. Safety
and efficiency have also improved because of technology.
Equipment are now built based on the workers body design
making its use not only comfortable but safe as well.
 FREEZING STORAGE, AND PACKAGING
TECHNOLOGY AS A TRENDSETTER

Storage and packaging off food production have also

dramatically improved.
Shelf life of perishable products has increased through
improved handling, freezing, preserving and packaging.
The science fiction of completely dehydrated pizza and
other food products that are then dehydrated through a
special oven may not be too far off.
ENVIRONMENTAL RENEWAL AS A TRENDSETTER

There is a move towards a “Greener-industry”.

This means both the market, government and business
establishment are realizing impact of their activities
environment.
This leads to the use of equipment and raw ingredients that are
not only more energy efficient but also product that least
amount of pollution and environmental impact.
This environmental awareness although not yet on the top of
the list among Filipinos will play an important factor in the
food service establishments success in the future.
 CONVENIENCE FOOD AS A TRENDSETTER
Convenience food is changing and shaping the face of quantity
food production today.
Convenience products offer the food service operations
numerous advantages.
They bring benefits in personnel planning, storage and cost by
reducing the amount of preparation time needed for a product.
Other advantages of using convenience products include
flexibility during fluctuation’s in demand, continuity of quality,
independence from season ability of ingredients lesser waste,
and more exact control.
 CONVENIENCE FOOD

Are food products with a higher processed level as its raw or

natural state.
In comparison to raw food products, convenience food have
undergone a certain level of industrial pre-processing.
Convenience food are closer to its servable state, allowing the
labor that would normally be required to bring it to this to be
used elsewhere.
 CONVENIENCE PRODUCTS CAN BE DIFFERENTIATED INTO
FOUR AS SHOWN BELOW

• These are partly processed products made ready for the kitchen.
Ready to cook
• These products must however undergo to complete cooking
process before it is ready to be served.

• This include products that have been pre-prepared and made

Half-prepared
ready such that they require only a short additional cooking
products time.

Ready to serve
• These are convenience product that have already been
completely cooked. They can be served directly in this form or
products reheated shortly before serving.

Ready-to-eat • These are consumer ready products. These are convenience

foods are pre-prepared, cooked and portioned for individual
products
consumption.
ELEMENTS OF FOOD SERVICE SYSTEM
 EXTERNAL ENVIRONMENT
The food service establishment is not an isolated island. It
interacts with an external environment that has certain demands
on it. Such groups which was call “Claimants” like customer,
suppliers, government, community, and owners have needs and
expectations that have to be answered by the food service
establishment.
The external environment is also the end receiver of the system’s
output.
FOOD SERVICE INPUT
The food service input is composed of material and immaterial
goods that act as pre-requisite to production. This means that
in the absence of these components the production activity
cannot be done. Among these food service inputs are the raw
food ingredients, standards, technique, procedures, labor and
necessary tools and equipment needed for the different
activities involved from purchasing and receiving down to
cooking and serving.
 TYPES OF FOOD SERVICE SYSTEM
These factors include availability of suppliers and the
market forms of products they offer, the amount capital
required in the business, availability of space, kind and
availability of equipment and labor, time span between
service and preparation and location of costumers in
relation to the production area.
 FOOD SERVICE SYSTEM

CONVENTIONAL CENTRALIZED COOK AND CHILL ASSEMBLE AND

OR FREEZE SERVE

DECISION TO ADOPT DEPENDENT ON

AVAILABILITY MARKET FORMS AVAILABLE AVAILABLE

OF SUPPLIER AVAILABILITY CAPITAL SPACE

AVAILABLE SKILLS LEVEL AND TIME DIFFERENCE LOCATION OF

EQUIPMENT COST OF LABOR BETWEEN SERVICE CUSTOMER RELATIVE
AND PRODUCTION TO PRODUCTION

ILLUSTRATION 2: TYPES OF FOOD SERVICE SYSTEM

 CONVENTIONAL TRADITIONAL SYSTEM
The conventional system otherwise is called “Traditional”
is characterized by a complete kitchen and dining set up.
All of these pre-preparation, preparation and service is
done under the roof.

Both the kitchen and service areas are fully equipped.

AT THE POINT IN TIME WHEN A CUSTOMER PLACES AN
ORDER, THE FOOD MAY BE PREPARED ACCORDING TO
THE SYSTEM
 MAKE-TO-STOCK
- The product kitchen makes a sufficient amount of product
buffet stock which held on a heated display unit.
- This products have limited holding time that must be
observed, otherwise the products quality deteriorates.
 ASSEMBLE-TO-ORDER
- The production area make sufficient amount mise-en-place
or partially finished dishes once the order is received the
production and simply combines the prepared to come-up with a
product.
 MAKE-TO-ORDER
- Few restaurants still use this in its pure form. Usually there
would be set mise-en-place and the items would be prepared cook
when the order made.
 CENTRALIZED (COMMISSARY OR SATELITE) SYSTEM
- The centralized or commissary system is characterized by the
used of central production area or kitchen.
- the satellites units which may be found in several different
location that act as distribution centers which receive the product
either it fully or partially finished form.
 COOK AND CHILL OR FREEZE SYSTEM

This system involves the production large of batches of

food products which are then either chilled or frozen until
service time.

This system requires good food storage facilities since the

service time and preparation time are far from each
other.
 ASSEMBLE AND SERVE SYSTEM
Assemble and serve system require very minimal production
facilities.
The establishments has very little to do which actual
preparation of products.

This type of system also require good forecasting skills since

shortages may be harder to cover especially if suppliers have a
provision for such emergencies.
This assemble and serve system must however trade-off its cost
saving with flexibility.
CONVENTIONAL P H S
Short holding time up to one hour, hot storage (67˚C)

ASSEMBLE TO ORDER P H S

MAKE TO ORDER P S
No holding time

MAKE TO STOCK P H S
Very short holding time up to 20 minutes at about 67˚C
COOK AND CHILL
P H S
Intermediate holding time of up to a week at a chilled storage of -1 to 3˚C

COOK AND CHILL P H S

Long holding time of up to 3 months at frozen storage -20˚C

LEGEND:
P – Production
H – Holding
S - Serve
MANPOWER PLANNING
MANPOWER PLANNING

 Manpower planning is the process of estimating the optimum

number of people required for completing a project, task or a
goal within time.
 Manpower planning includes parameters like number of
personnel, different types of skills, time period, demand and
supply trends, and organizational strategy.
 Is also called RESOURCE PLANNING
QUALITATIVE PRODUCTION MANPOWER
REQUIREMENT
 What are the qualities of an effective food production staff?
Skills and competence is perhaps one of the major required for
food production staff. They must be well-trained in the different
aspects of their work. They must possess the culinary knowledge
and skills as well as know and apply the principles of safety,
sanitation, nutrition and environmental management. All of this
skills have to be strengthened to achieve the goal in providing
quality meals in quantity food production.
 The following are the Qualities required of an effective food
production staff

1. HIGH LEVEL COMPETENCE AND SKILLS

1.1 Culinary and technical skills
1.2 Communication and social skills
1.3 Learning and adapting skills
1.4 Management skills
2. PHYSICAL QUALITIES
2.1 Excellent physical health
2.2 Good grooming
2.3 Endurance
3. PERSONALITY TRAITS
3.1 Customer/Service oriented (courteous, hospitable, friendly,
warm)
3.2 Team oriented (work well in a group)
3.3 Efficient and organized
3.4 Self-motivated
3.5 Self-disciplined
3.6 Quality oriented
3.7 Loyalty, honesty, dependability, and punctuality
 QUANTITATIVE PRODUCTION
MANPOWER REQUIREMENT
 How is the quantitative manpower requirement for food
production determined?
The amount of the needed by a production team depends
on many factors. Each one must be carefully considered by
the planner in order to ensure the workload can be handled
by the team and the cost of labor kept to a minimum.
 Quantitative Manpower/Labor Requirement

Job description Sales

Layout Equipment used
and Work load Volume

Hours of Rate of
Menu Staff Needs
Operation Service

Production Method
 FACTORS AFFECTING THE QUANTITATIVE
MANPOWER REQUIREMENT

 JOB DESCRIPTION AND WORKLOAD

The starting point of planning how many food production staff
is needed in determining for what needs to be done. The duties
and responsibilities of each position must be reviewed properly.
The procedures involved have to be properly designed and the
workload of each worker take into account. Only then can proper
planning be done.
 SALES VOLUME
An important source of information about the manpower
requirement of the production area, the sales volume, represents
the amount of potential covers that have to be served. The sale
volume also provides information about the peak and slack periods
of operation. This must be considered to ensure that employees
are kept busy a greater amount of the time. The slack period
should have the fewest staff on duty and the busiest hours the
most amount to make sure that the productivity is its highest.
Moreover, the planner must also consider the maximum
productivity capacity of employees to ensure that the workload
does not came excessive stress and strain to the food production.
Monitor and Analyze daily and hourly covers and sales history. This would equip
the planner with information’s to find periods when production personnel are
needed. See the table on the next slide.

This can be done through several ways.

1. DINING ROOM CUSTOMER TALLY (manual)
- The dining manager counts and records the number of customer
seated in the dining room per hour. Then he/she records this in a cover
tally sheet and then later summarize the information and determines
the average requirements for the different meal periods.
2. GUEST ORDER TALLY (manual)
- Guest checks the time stamped in the kitchen as the order is
given then this information is collected and summarized at the end of
the day into tally sheets. This provide more accurate and timely
information since customers may stay longer in the dining area without
actually ordering.
3. CASHIER TALLY (manual)
- The cashier simply keeps a tally of the guest check as it is
settled then it is summarized by the cashier at the end of the day
as part of their reports. Care must however be taken in the use of
these information since the order and settling of guest bills maybe
far from each other because of production delay or delays from the
guest themselves.
4. MIS (Management Information System) (automated)
- Many software today like MICROS offer alternative and
automated solutions to keeping track of customer information.
Many ordering, production and cashiering system are now
interconnected through a computer, this provides the planner with
more accurate and timely information.
Illustration 1: Sample Tally of Covers per Hour

Weather: Date: February 16, 2022

Rainy
Period Count Summary of Covers
A.M Shift
10-11 iiiii-iiiii-iiiii-iiiii-iiiii 25
11-12 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii 35
Afternoon Shift
12-1 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii 65
1-2 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iii 33
2-3 iiiii-iiiii-iiiii-iiiii 20
3-4 iiiii-iiiii-iiiii-i 16
4-5 iiiii-iiiii-i 11

Evening Shift
5-6 iiiii-iiiii-iii 13
6-7 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iii 38
7-8 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii 60
8-9 iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii-iiiii 45
9-10 iiiii-iiiii-iiiii-iiiii 20
10-11 iiiii-iiiii-iii 13
11-12 iiiii-i 6

Prepared by:
Illustration 2: Number of Covers Served per Day

500

400

300

200

100

0 COVERS
Mon Tue Wed Thu Fri Sat Sun
 TYPE OF RATE SERVICE

As we have seen in the discussion of the different types of

food service system, different service and production system
require different amounts of manpower. A’ la carte menus
require a large number of highly skilled staff compared to a
Table d’ hote. Plated service also requires more personnel
compare to a buffet. The types of service also affects the
service rate.
For example:
A buffet runs a lot faster compared to Table d’ hote. A’ la
carte takes much longer service time varying from one hour to
two hours to finish the meal.
 POSSIBLE PLANNING FOR THE DIFFERENT TYPES OF SERVICE AND MENU
TYPES OF NO. OF MEALS TYPES OF MENU APPROXIMATE
ESTABLISHMENT PRODUCTION STAFF
REQUIREMENT

Small-scale 100-200 Lunch and A’ la carte and Table 2 supervisors, 4

Restaurant Dinner d’ hote cooks, 4 helpers

Hospital Food Service 450/day Breakfast, Cyclic/cycle Menu 6 dietitians, 9 cooks,

Lunch, Dinner 18-20 Food Service
Staff

School Food Service 1350/day Breakfast, Fixed Menu 1 dietitian, 1

Lunch, Dinner & supervisor, 3 cooks, 2
Snacks cooks helper

Coffees Shop with 300-400 Lunch and Table d’ hote and 4 supervisor, 7 cooks,
Buffet Dinner Buffet Menu 7 helpers

Industrial Cafeteria 400/day Breakfast, Selective Menu 1 dietitian, 4 cooks, 4

Lunch, Dinner & cooks helper
Snacks
 POSSIBLE PLANNING FOR THE DIFFERENT TYPES OF SERVICE
AND MENU

 EQUIPMENT
- We have to take into account that the more manual the
production area is, the more personnel is required. If the
production area uses equipment that increases the manufacturing
work area, then the lesser staff is required.
 LAYOUT
- The amount of staff required is also affected by how space is
used in the production area. Proper layout improve the
performance of task and thus reduce the manpower requirement.
This can be done by simplifying work and eliminating equipment to
much walking.
 PRODUCTION METHOD AND MENU
- The degree to which the food production area uses convenience
food also affects amount of staff needed. The amount of manpower
needed is directly related “degree convenience” the production area.
This means that the more fully prepared, pre-portion and partly
processed the food ingredients used in the kitchen, the lower it’s
manpower requirement.
 HOURS OF OPERATIONS
- Some establishment do not serve breakfast while other do not serve
dinner. The more meal periods serve therefore the more manpower is
required. Many food production establishment used split shift in order to
cut down on manpower.
 STAFF NEEDS
- Lastly, the planner must consider the personal situation of the
individual in coming up with the weekly or monthly schedule.
 How is the staff schedule done?

The staff schedule is usually done by the kitchen

supervisor. This can usually either be the Demi-chef de
Partie, or even the Junior Sous Chef and Sous Chef. There
are many ways of making the staff schedule. However, it is
not unusual for supervisor to base the schedule on past
experience. Although this system alone is not completely
bad, it is however also not completely accurate nor does it
assure cost efficiency. It is always important to remember
the different factors that affect manpower or labor
requirements discussed earlier.
 Illustration 4: Staff forecast based on forecast sales

For period of February 5 – February 15

Hours of Anticipated Manpower Requirement

Operation Sales Volume
(no. of covers) Helper Commis Chef de Sous Chef
Partie

10-11 40 1 1 1 1
11-12 100 3 2 1 1
12-1 113 3 2 1 1
1-2 65 2 2 1 1
2-3 54 2 2 1 1
3-4 38 1 1 1 1
4-5 45 2 1 1 1
5-6 45 2 1 1 1
6-7 89 3 2 1 1
7-8 158 4 2 1 1
8-9 130 4 2 1 1
9-10 75 3 2 1 1
10-11 50 1 2 1 0
11-12 28 1 1 1 0
 Illustration 5: Daily Schedule Worksheet
For the period : February 2022
Staff 10-11 11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 8- 9- 10- 11-
9 10 11 12
A

G
 Illustration 6: Staff Weekly Schedule

For the Period of February 7 2022 to February 13, 2022

Staff Mon Tue Wed Thu Fri Sat Sun

A 10-6 10-6 Off 10-6 10-6 10-6 10-6

B Off 4-12 4-12 4-12 4-12 4-12 4-12

C Off 10-12 10-12 10-12 10-12 10-12 10-12

/ / / / / /
6-7 6-7 6-7 6-7 6-7 6-7
D 10-6 Off 10-6 10-6 10-6 10-6 10-6

E 4-12 4-12 Off 4-12 4-12 4-12 4-12

F 1-9 1-9 1-9 Off 1-9 1-9 1-9

G 10-6 10-6 10-6 10-6 10-6 10-6 Off