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!
