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Quality Assurance Store Audit Report

February 22 March 10, 2010 by:

Maida S. Gamboa
R&D/QA Department
March 18, 2010

Objectives
Maintenance of Gold Standard Quality Products across all stores Evaluation of the holding and storage equipment and temperatures Evaluation of product conditions during storage and holding Assurance of FIFO implementation Assessment of the Good Manufacturing Practices of the stores

Scope
Product Quality Audit Product Storage and Holding Quality Audit Good Manufacturing Practices Inspection

Product Quality Audit

Product Quality Audit

General Presentation

Product Presentation Serving Portion Serving Temperature (for rice, soup and soup based products)
Color/Appearance Aroma Taste/Flavor Texture/Mouthfeel Consistency

Organoleptic Properties

Rating

Category Scaling

1 Poor 2 Fair 3 Good 4 Very Good 5 Excellent

Rice

13% of the stores met gold standards


Major 79% Minor

Deviations
Below standard serving temperature (70C) Dark and Dry Stale Underportioned

40% 7% 25%

Rice

Findings

Possible Causes

Prolonged opening of the rice warmer Steaming beyond standard time Holding beyond standard time Incorrect rice: water ratio Refilling of steamed rice into used rice keepers Loosely packing of rice into rice scoopers

Soup

27% of the stores met gold standards


Major 64% Minor

Deviations
Below standard serving temperature (70C)

Without pechay leaves

50%

Soup

Findings

Possible Causes

Prolonged opening of the soup kettle Broken soup warmer knob Failure to follow the standard serving portion Unavailability of vegetables

Core Products
Beef Caldereta Laing Sweet Garlic Chicken Fried Lumpia

Beef Caldereta

50% of the stores met gold standards


Major 7% Minor

Deviations
Underportioned (3pieces) Thick sauce Prominent oil separation Tough meat chunks (connective tissues)

7% 13% 7%

Tough potato

7%

Beef Caldereta

Findings

Possible Causes

Inadequate portioning Undercooked meat chunks Particularly those containing connective tissues Undercooked potatoes Failure to comply with standard holding procedures Mixing of products every 15 minutes Troubleshooting

Laing

7% of the stores met gold standards


Major 73% Minor

Deviations Olive brown color

Dry

27%

Laing

Findings

Possible Causes

Cooking beyond standard time Holding beyond standard time

Sweet Garlic Chicken

36% of the stores met gold standards


Major 36% 27% 18% 9% Minor

Deviations
Tough, dry and dark meat Undersized Dried up honey garlic sauce Thin sauce consistency

Sweet Garlic Chicken

Findings

Possible Causes Over thawing Frying beyond standard time Extensive holding Storage of honey garlic sauce in frozen condition

Fried Lumpia
Deviations
Soft and oily wrapper Pale

Major 100%

Minor

7%

Burnt filling due to wrapper holes


Soft filling (carrot strips)

13%
13%

Fried Lumpia

Findings

Possible Causes

Holding beyond standard time Holding at ambient conditions after frying (not immediately transferred into fried warmers) Horizontal arrangement of the product during holding Too thin lumpia wrapper; prone to chilling injury Thawing Loosely sealed lumpia wrapper Overcooked filling

Merienda
Spaghetti Palabok Miki Bihon

Spaghetti

68% of the stores met gold standards


Major Minor

Deviations

Watery; bland

25%

Underportioned noodles

7%

Spaghetti

Findings

Possible Causes

Noodles were not thoroughly drained Noodles were under weighed: 100g

Palabok

93 % of the stores met gold standards


Major Minor

Deviations

Watery

7%

Palabok

Findings

Possible Causes

Noodles were not thoroughly drained

Miki Bihon

38% of the stores met gold standards


Major 22% Minor

Deviations
Soft vegetable toppings Bland bihon concentrate and garlic flavors Dry and salty noodles

22%

22%

Miki Bihon

Findings

Possible Causes

Overcooked vegetables Incorrect proportion of ingredients Excessive evaporation of bihon concentrate Overholding

Kontra Init
Halo Halo Mais con Yelo Saba con Yelo Sagot Gulaman

Halo Halo

100% of the stores met gold standards

Mais con Yelo

100% of the stores met gold standards

Saba con Yelo

37% of the stores met gold standards


Major Minor 63%

Deviation
Saba had uneven dark patches of brown Dark saba

7%

Saba con Yelo

Findings

Possible Causes

Saba was not mixed while held with the syrup Steamed syrup and saba were held beyond standard time

Sagot Gulaman

100% of the stores met gold standards

Dessert

Buco Pandan

Buco Pandan
Deviations
Not within the standard serving temperature

Major 100%

Minor

Cream sauce had thin consistency

100%

Buco Pandan

Findings

Possible Causes

Inefficiency of the salad tray to hold brine (ice + salt) for 4 hours

Breakfast
Fried Egg Hotdog Longganisa Tocino

Fried Egg

87% of the stores met gold standards


Major Minor 7%

Deviations Overcooked yolk

Too brown edges

13%

Fried Egg

Findings

Possible Causes

Cooking beyond standard time Cooking beyond standard temperature

Hotdog

87% of the stores met gold standards


Major 7% Minor

Deviations
Had an off-flavor

Wrinkled

7%

Dried up surface

7%

Hotdog

Findings

Possible Causes

Hotdog and longganisa shared a common food pan in the Baine marie Overcooked

Longganisa

87% of the stores met gold standards


Major 13% Minor

Deviation Pale

Longganisa

Findings

Possible Causes

Undercooked

Tocino

37% of the stores met the gold standards


Major 63 Minor

Deviations Irregularly shaped slices Underportioned

63

Thick, tough and dry

63

Tocino

Findings

Possible Causes

Improper slicing Holding beyond standard time

Product Storage and Holding Quality Audit

Product Storage Quality Audit


Deviations
Proper stacking of products not observed Chiller temperature below the standard (-3.0) Products stored in the chiller and freezer without cover

Major

Minor 47%

7%

80%

Product Storage Quality Audit


Deviations
Chilled products stored in frozen conditions Due to limited storage space

Major 20%

Minor

13%

Product Storage Quality Audit


Deviations
Products stacked beyond the maximum stacking height Contents of opened packs not transferred into covered containers

Major

Minor 40%

53%

FIFO not observed in stacking

7%

Product Holding Quality Audit


Deviations
Broken Baine Marie knobs

Major 13%

Minor

Broken soup warmer knob

7%

Product Holding Quality Audit


Deviations
Baine Marie temperature set below 80C (40, 60, 70 C) Products in the Baine Marie not mixed every 15 minutes

Major 20%

Minor

40%

Good Manufacturing Practices

Good Manufacturing Practices


Deviations
Dirty kitchen and dining area floor (wet; with stains) Flies coming in contact with the food and customers Baine Marie knobs were broken

Major 53%

Minor

53%

13%

Good Manufacturing Practices


Deviations
Roaches were visible in the dining area Assemblers were serving without face mask on Assembler and other staffs were serving without gloves on

Major 13%

Minor

33%

73%

Good Manufacturing Practices


Deviations
MODs not wearing hairnet within the hairnet zone Crates with deliveries were placed on the floor without underliners Poor water supply

Major

Minor 80%

7%

7%

Good Manufacturing Practices


Deviations
Products withdrawn from the chiller were placed on top of trash bin Used knives were used in opening boilable bags (steamed)

Major

Minor 7%

13%

Good Manufacturing Practices


Deviations
Warm in the dining area making unwanted odors very perceptible

Major

Minor 7%

Same chopping board was used in slicing meat and vegetables

13%

Good Manufacturing Practices


Deviations
Kitchen leader/assembler with unshaved beard and mustache Dining area ceiling had spider webs that harbored dusts Rice keepers were not thoroughly washed and dried prior to refilling

Major 20%

Minor

7%

7%

Good Manufacturing Practices


Deviations
Assembler used the toilet with apron, hairnet and face mask on

Major

Minor

7%

Food pans with steamed products were brought to the dining area (downstairs) without cover

7%

Good Manufacturing Practices


Deviations
Assemblers/KLs wipe the BM area without removing gloves

Major 13%

Minor

Other Observations

Holding of steamed products in hot water bath


Causes overcooking Further color degradation in laing leaves

Conclusion

Most common deviations from serving Gold Standard Quality Products were due to

Serving temperature Holding conditions

Conclusion

50% of the products evaluated had deviations from 50% of the stores

Rice Soup Laing Sweet Garlic Chicken Fried Lumpia Miki Bihon Saba con yelo Buco Pandan Tocino

Conclusion

50% of the products evaluated had deviations from <50% of the stores

Caldereta Spaghetti Palabok Halo Halo Sagot Gulaman Mais con Yelo Fried Egg Hotdog Longganisa

Conclusion

Storage and Holding Deviations occurring in 50% of the stores


Storing of products in the chiller and freezers without cover Not transferring the contents of opened packs into covered containers

Conclusion

GMP Deviations occurring in 50% of the stores

Major

Presence of flies in the dining, Baine Marie and kitchen areas Assembling orders without gloves on Dirty kitchen and dinning area floor MODs without hairnet within the hairnet zone

Minor

Recommendations

Products

Observe the standard serving portion and temperature especially for rice and soup Minimize over production to avoid extensive holding of products Follow the standard holding conditions

Holding time Mixing of products in the Baine Marie Troubleshooting measures

Recommendations

Storage

Store products in their appropriate storage conditions Ensure sufficient storage space for chilled products especially for high volume stores Develop stacking guidelines Orient mother stores on Standard Guidelines on the use of water bath in steaming and holding Ensure that all the products stored in the freezer and chillers are covered to avoid cross contamination Ensure immediate repair of faulty equipment

Recommendations

GMP

Review of guidelines on gloves and hairnet use More efficient pest control measures Maintenance of cleanliness within the stores

Thank You!