Quality AssuranceStore Audit Report

February 22 – March 10, 2010

by:Maida S. GamboaR&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) Organoleptic Properties

Color/Appearance Aroma Taste/Flavor Texture/Mouthfeel Consistency

Rating Category Scaling

1 – Poor 2 – Fair 3 – Good 4 – Very Good 5 – Excellent

Rice 13% of the stores met gold standardsDeviations Major MinorBelow standard serving temperature (70°C)

79%

Dark and Dry 40%Stale 7%Underportioned 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

Deviations Major MinorBelow standard serving temperature (70°C)

64%

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 standardsDeviations Major MinorUnderportioned (3pieces)

7%

Thick sauce 7%Prominent oil separation

13%

Tough meat chunks (connective tissues)

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 standardsDeviations Major Minor Olive – brown color

73%

Dry 27%

Laing Findings

Possible Causes Cooking beyond standard time Holding beyond standard time

Sweet Garlic Chicken 36% of the stores met gold standardsDeviations Major MinorTough, dry and dark meat

36%

Undersized 27%

Dried up honey garlic sauce

18%

Thin sauce consistency

9%

Sweet Garlic Chicken Findings

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

Fried LumpiaDeviations Major MinorSoft and oily wrapper

100%

Pale 7%

Burnt filling due to wrapper holes

13%

Soft filling (carrot strips)

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 standardsDeviations Major MinorWatery; 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

Deviations Major MinorWatery 7%

Palabok Findings

Possible Causes Noodles were not thoroughly drained

Miki Bihon 38% of the stores met gold standardsDeviations Major MinorSoft vegetable toppings

22%

Bland bihon concentrate and garlic flavors

22%

Dry and salty noodles

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 Sago’t 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 Deviation Major MinorSaba had uneven dark patches of brown

63%

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

Sago’t Gulaman 100% of the stores met gold standards

Dessert Buco Pandan

Buco PandanDeviations Major MinorNot within the standard serving temperature

100%

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

Deviations Major MinorOvercooked yolk 7%

Too brown edges

13%

Fried Egg Findings

Possible Causes Cooking beyond standard time Cooking beyond standard temperature

Hotdog 87% of the stores met gold standardsDeviations Major MinorHad an off-flavor 7%

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 standardsDeviation Major MinorPale 13%

Longganisa Findings

Possible Causes Undercooked

Tocino 37% of the stores met the gold standardsDeviations Major MinorIrregularly shaped slices

63

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 AuditDeviations Major MinorProper stacking of products not observed

47%

Chiller temperature below the standard (-3.0)

7%

Products stored in the chiller and freezer without cover

80%

Product Storage Quality AuditDeviations Major MinorChilled products stored in frozen conditions

20%

Due to limited storage space

13%

Product Storage Quality AuditDeviations Major MinorProducts stacked beyond the maximum stacking height

40%

Contents of opened packs not transferred into covered containers

53%

FIFO not observed in stacking

7%

Product Holding Quality AuditDeviations Major MinorBroken Baine Marie knobs

13%

Broken soup warmer knob

7%

Product Holding Quality AuditDeviations Major MinorBaine Marie temperature set below 80°C (40, 60, 70 °C)

20%

Products in the Baine Marie not mixed every 15 minutes

40%

Good Manufacturing Practices

Good Manufacturing Practices

Deviations Major MinorDirty kitchen and dining area floor (wet; with stains)

53%

Flies coming in contact with the food and customers

53%

Baine Marie knobs were broken

13%

Good Manufacturing Practices

Deviations Major MinorRoaches were visible in the dining area

13%

Assemblers were serving without face mask on

33%

Assembler and other staffs were serving without gloves on

73%

Good Manufacturing Practices

Deviations Major MinorMODs not wearing hairnet within the hairnet zone

80%

Crates with deliveries were placed on the floor without underliners

7%

Poor water supply 7%

Good Manufacturing PracticesDeviations Major MinorProducts withdrawn from the chiller were placed on top of trash bin

7%

Used knives were used in opening boilable bags (steamed)

13%

Good Manufacturing PracticesDeviations Major MinorWarm in the dining area making unwanted odors very perceptible

7%

Same chopping board was used in slicing meat and vegetables

13%

Good Manufacturing Practices

Deviations Major MinorKitchen leader/assembler with unshaved beard and mustache

20%

Dining area ceiling had spider webs that harbored dusts

7%

Rice keepers were not thoroughly washed and dried prior to refilling

7%

Good Manufacturing PracticesDeviations Major MinorAssembler used the toilet with apron, hairnet and face mask on

7%

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

7%

Good Manufacturing Practices

Deviations Major MinorAssemblers/KLs wipe the BM area without removing gloves

13%

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 Sago’t 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

Minor MODs without hairnet within the hairnet zone

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!