Observation Report on Merienda by Pan de Manila Santolan Town Plaza

branch, Ice cream hub and Pan de Manila D. Tuazon branch

April 19, 2023

Submitted by Jezra Zera S. Bakar

Summary

On April 18, 2023, we conducted a visit to the three branches under Pan de Manila,
Co., Inc. These branches are the following: Merienda by Pan de Manila (Santolan Town
Plaza branch), Ice cream hub (located at D. Tuazon) and Pan de Manila store (D. Tuazon
branch). We were able to take a tour on the production area and take down notes on the
areas that might need further improvement. We were also able to ask questions to the
employee in charge regarding the process and cite down some recommendations.

Objectives

The interns under the quality assurance department conducted the observation
report to conduct the following objectives:

• To observe and conduct monitoring to the following branches:

o Merienda by Pan de Manila (Santolan Town Plaza branch)
o Ice cream hub (located at D. Tuazon)
o Pan de Manila store (D. Tuazon branch)
• To list down necessary observations and provide recommendations that can ease
the processing flow of the production.

Introduction

As part of the internship program, we, the interns under Quality Assurance
Department visited other branches under the Pan de Manila, Co., Inc. in order to monitor
and observe the practices of the employees during their production. The following are the
branches that we were able to observe on April 18, 2023: Merienda by Pan de Manila
(Santolan Town Plaza branch), Ice cream hub (located at D. Tuazon) and Pan de Manila
store (D. Tuazon branch). Through this visit, we were given the opportunity to observe
whether the employees strictly adhere to good manufacturing processes and also to view the
entire production lay out. This visit also presents us, the interns with the opportunity to ask
any questions that they may have on the processing of the food products of the branches.
Some of the questions that were asked were about the temperature for the chillers and
freezers, material used for the packaging of food products, and process flow. In return, the
employees in charge answered the questions we asked and explained it clearly.
Procedures

On April 18, 2020, we, the interns have gathered in the head office of Pan de Manila.
By 9:00am we were already introduced to Sir Nilo who accompanied us to the Merienda by
Pan de Manila (Santolan Town Plaza branch).

At the Merienda by Pan de Manila (Santolan Town Plaza branch) we conducted the
following:

1. Hairnets were handed down so we can use it once we enter the production area.
2. We were introduced to Ma’am Janet.
3. Our bags were placed near the locker area since there were no spare lockers that we
can use.
4. We begin our observation by following the processing line where we started with
checking of the chillers and freezers holding the raw materials and ingredients to the
area where food is being prepared for cooking up until the cooking area.
5. While observing the whole production area, we are also taking down notes of any
necessary findings or observations that we have.

Around 10:50am, we were already done with our rounds of observation and so we decided
to move to the next location. Together with Ma’am Janet, we travelled from Santolan Town
Plaza to D.Tuazon to visit the Pan de Manila (D. Tuazon branch). However, since it was
already lunch time by the time we get there we first took our lunch break and proceed
conducting the observations.

At the production area of the Pan de Manila (D. Tuazon branch) and Ice cream hub (D.
Tuazon branch) we conducted the following:

1. We were asked to first wear our hairnet.

2. Our bags were placed at the store area since there were no spare lockers that we
can use.
3. We begin our observation in the Pan de Manila production area by observing how the
pandesal were made up unto where the raw materials are received and stored. At the
ice cream hub, we were toured in the production area and the area for the changing
of clothes of employees up unto the area for washing of hands and storage area.
4. While observing the whole production area, we are also taking down notes of any
necessary findings or observations that we have.
Results and discussion

In this part, the observations I was able to make during the visit will be further
discussed along with some pictures that shows the observations made.

Merienda by Pan de Manila (Santolan Town Plaza branch)

Since there were more customers by the time that we got there, the production area
appears to be busier than the usual. It is also noted that all employees from the production
up until the selling area are wearing the proper attire and protective personal equipment
(PPE) appropriate for the production area. There were also proper distributions of chores as
there were people assigned for frying and those that were assigned for chopping,
preparation and plating of food. While we were also able to observe the inside of the chillers
in the production area (refer to Figure 1 & 2), although there is an order and separation of
fruits and vegetables I can say that further elaboration on the importance of the arrangement
of foods in the chillers and freezers will be needed as in the freezer of the ingredients used
for the halo halo it is a little bit unorganized (refer to Figure 2). It may be also difficult to
conduct the principle of First In First Out (FIFO) if not stored appropriately.

Fig 1. Refrigerator for vegetables and fruits Fig 2. Refrigerator for ingredients for halo halo

The cleaning materials were also placed between the oven for the pie and the
refrigerator (refer to figure 3). Other usually used vegetables were also stored in the open
(refer to figure 4).

Fig 3. Cleaning materials between the oven and refrigerator

 Fig 4. Vegetables in the open area

Some of the plastic packaging was placed on top of the Inverter Sensor Cook (refer
to figure 5).

Fig 5. Plastic packaging on top of the inverter

Other than that, everything were appropriate ingredients were properly stored,
packaging material were placed in a dry place. At the selling area, everything was also
organized there were no empty spaces although there was some a product that was not
standing upright (refer to figure 6) and the vibes in the area were aligned to the mission and
vision of the company which is to give a feel good vibes.

Fig 6. Product was not place upright

 Fig 7-8. Merienda by Pan de Manila (Santolan Town Plaza)

Ice cream hub (located at D. Tuazon)

Here since there was an ongoing maintenance on the air conditioner of the
production area all production for the ice cream had been halted. This was done in order to
prevent contamination of the product. Still, we were able to conduct our observation through
the help of Sir Nilo and Sir Kenneth. First, we were brought to the office area before we were
able to tour around the production area once the maintenance working for the air conditioner
leave, Sir Nilo show us the chiller used to store the different flavors of the ice cream.

Fig 9-10. Freezer for storing ice cream

Followed by accompanying us to the production area where he show us the machine used
for mixing the base ice cream for all the flavors and even demonstrated how the heat sealing
for the ice cream is conducted. They also showed us the place where the employees change
their clothes, the area for washing the hands, area for cleaning the fruits and vegetables
upon receiving (refer to figure 11) and their restrooms.
 Fig 11. Sink for rinsing received fruit

The production layout is good since it is aligned with the process flow. There were also
several signatures that highlight the importance of washing the hands and reminding the
employees of the pest control program. However, there were still a few visible pests (refer to
figure 12) in the area which means there is a need to further strengthen this pest control
program.

Fig 12. Small roach near the restroom for employees

Pan de Manila store (D. Tuazon branch)

For the production area for the breads, I find it pleasing as all of the employees were in
complete uniform and PPEs. They were also still in the process of producing the pandesal
when we get there and it was done in a hygienic way. On the other hand, similar to the
remarks on the pest control program of the ice hub although they do have proper signage
that reminds them of adhering to the pest control program, there is still a few visible fly in the
area (refer to figure 13).

Fig 13. Small fly in the production

Also there were two entrances toward the production area where the finished breads
are placed near it.

Fig 14. Point of view in the entrance

Lastly, there were few medicines in the first aid kit. The vibes were also aligned to the
mission and vision of the company to provide a feel good environment and a feeling closer to
home.
 Fig 15. First aid box of the Pan de Manila store

In general some observations that I was able to make on our visit is that there is a slight
differences in the temperature of the freezer for the ice cream cake in the Merienda by Pan
de Manila (Santolan Town Plaza branch) and Pan de Manila (D. Tuazon branch). Since the
temperature of the freezer in Merienda was at -16C while -11 at the Pan de Manila Store.

Recommendation

The following are the recommendations I can make based on the derived observations:

Merienda by Pan de Manila (Santolan Town Plaza branch)

As stated in the results and discussion part, it is recommended that there is a proper
storage arrangement for the refrigerators and freezers. For example, in the freezer that holds
the ingredients for halo halo they can arrange it where the pints of ice cream are placed in
the upper area and the other ingredients are arranged at the lower area. While for the
cleaning materials such as the mop and the water for cleaning, it might be better to place it
in the comfort room for employees.

Ice cream hub (located at D. Tuazon)

Here, it is recommended that they further strengthen their Pest control program and
also have an area designated for washing their hands inside the production area after they
change their clothes. It is also recommended that the cleaning materials in the sink for
rinsing fruits be placed away from the sink.

Pan de Manila store (D. Tuazon branch)

Here, similar to the ice cream hub it is recommended that they further strengthen
their Pest control program and also stock up more on their first aid kits. It is also
recommended that they do one way in and one way out in entering the production area.