picassio: picadillong siomai operations maual

Operations Manual Aviles, Jannie Gracelyn Leynes, Vonn Orland

Mortel, Pia Adelie Ras, Kimbo

Tolentino, Ma. Yvette

1 | P a g e

Picassio Operations Manual

Introduction

Siomai, a deliciously tasty dumpling of Chinese origin, is loved by many Filipinos. It

may be prepared in different ways, but the base is always pork. Some substitute a part of the pork with shrimp meat. Siomai is commonly served with a dip mixture of soy sauce, calamansi extract, and chili sauce. On the other hand, Picadillo, from the Spanish word “picar” which means to “to mince”, is a traditional dish in the Philippines and some other parts of the world, and is a favorite stuffing for several dishes and also a viand in several occasions. It is generally made from ground meat, usually that of beef. Piccasio, or PicadillongSIOmai, is a healthy combination of Picadillo and siomai. The name of the product, Picassio, is due to the fact that the ingredients in this dish are somewhat similar to that of the well-known Picadillo.

The highlight ingredient of this dish is the malunggay leaves (Moringa oleifera) which is being promoted for the health of the students by the Department of Education. It is at the same time being promoted by the Department of Health and the World Health Organization as a low-cost health enhancer and contains remarkable medicinal value. This manual should explain the logistics of the firm’s operations. It should discuss the production plant’s location and layout, its infrastructures, facilities, equipment, and materials. The manual should also deal with the firm’s staffing plan, the production process, the plant production capacity and an estimate of the firm’s financial viability. Goals and plans of the company in the long run is also mentioned in the manual.

2 | P a g e


The company’s market should be the people of Laguna, especially in Los Baños and Calamba City, because the start-up outlets should be placed in these sites to be near the office and production branch in Los Baños. Picadillong siomai shall be positioned as a healthy snack due to the vegetables in its ingredients. It should be priced Php 30 per serving with each servings containing 3 Picadillong siomai and a pack of sauce.

3 | P a g e


Infrastructure, Facilities, Equipment, and Materials

Since heat is involved in the production process, a fire extinguisher is placed inside

the production area. One fire alarm switch should be placed at both the input and output section of the kitchen.

There are three available and entry exit routes: front door and two back doors. A CCTV camera should be installed in the production area in order to monitor the process and watch over the area even during non-production days. Further installation of cameras outside should be implemented once there is sufficient budget.

Two stoves are installed in order to accommodate simultaneous cooking of the filling and the sauce. A stove hood should be positioned on top of each stove for smoke ventilation. Exhaust fans should also be installed in order to cool the production area.

Three carrier vans, two of which are cooler vans, should be bought to aid the transportation of raw materials and finished products in and out of the plant. Both the input and output section should have a cold storage room. Specific cooking materials required are frying pans, steamers, measuring cups, LPG gas, food processors and other kitchen utensils. Given below are the ingredients for the production of 36 pieces of siomai.

4 | P a g e


Table 1. Picassio siomai and sauce ingredients.

*Yields 20-22 servings with 3 pieces each.

For the filling: Quantity Ingredient 50 mL Cooking oil 10 Grams garlic(minced) 25 Grams onion(minced) 500 Grams ground beef 123 Grams corn(shredded) 150 Grams carrots 7 Stalks malunggay 2 Pcs. med.

sized Eggs(beaten) 25 Grams cornstarch 230 Grams molo wrappers

(small) 15 Grams Iodized salt 1 Gram ground pepper 1 Gram seasoning

For the sauce: Quantity Ingredient 25 mL cooking oil 10 grams garlic 25 grams green pepper(minced) 30 grams Sugar 120 mL soy sauce 7 mL calamansi juice

5 | P a g e


Layout Planning

Figure 1. Picassio plant floor plan.

The firm’s plant is a one story building featuring a lobby, an office room, a meeting hall, two restrooms, a production area, two storage rooms and a parking lot at the back of the building. The lobby is the connecting room between the administrative staff’s area and the production area. The administrative staff’s area is divided into the office room and the meeting hall. The office room is where the internal supervisor and the

6 | P a g e


external supervisor work. The meeting hall is where the employees can dine during their break-time and where meetings are held.

The production area is divided into two sections: the inflow section and outflow section. It is further divided into four stations: ingredient preparation, cooking, wrapping and packaging. The production area is designed to be spacious in order to regulate air flow since there is cooking involved. There should be two cold storage rooms: one in the inflow section for raw materials, and the other at the outflow section of the finished goods. The back door opens to the parking lot where cold mini carrier vans wait to transport goods to and from the outlets and the suppliers, respectively.

For efficient mass production, the stations in the production area were placed sequentially according to the procedure of making Picadillong siomai, starting from the inflow of raw materials to the outflow of finished products. The production area is also situated somewhat separate from the office area so that it could still be accessible to the delivery men during non-production days of the plant.

7 | P a g e


Front view of the plant.

Top view of interior. Lobby (middle)

8 | P a g e


Top view of interior. Meeting Hall (left) and Manager’s Office (right).

Outflow storage (left). Comfort Rooms (center). Meeting Hall (right).

9 | P a g e


Top view kitchen. Inflow section (left) and Outflow section (right).

Rear view of the plant.

10 | P a g e


Staffing

Figure 2. Picassio organizational structure.

Kitchen assistants should be in charge of the basic food preparation, unloading deliveries from the suppliers, organizing the storeroom, packaging and washing kitchen appliances, work surfaces, floors and walls. There should be a total of 8 kitchen assistants: 4 for the food preparation area and another 4 for packaging, inspecting and storing the finished produce.

Line cooks are in charge of preparing siomai and siomai sauce. Two cooks should be assigned for the cooking station while another 2 should be assigned in molo wrapping station. They are led by a head cook in taste testing and quality checking.

Head Manager

Supervisor for Internal Affairs

Head Cook

Line Cooks

Kitchen Assistants

Delivery Men & Drivers

Supervisor for External Affairs

Outlet managers

Outlet employees

11 | P a g e


The head cook leads the team of kitchen workers and is in charge of quality checking every line’s output. They are also in charge of tracking the kitchen’s inventory in order to figure out how much should be ordered.

Delivery men and drivers are in charge of the distribution of finished products to the outlets and transportation of the supplies needed for the production.

Outlet employees are in charge of selling and serving Picadillong siomai in their respective outlets. They are headed by franchise managers who in turn reports the performance of the store to the supervisors for internal affairs.

The administrative staff includes the franchise manager, the external affairs supervisor, the internal affairs supervisor and the head manager. The franchise manager mediates the demand for each outlet and maintains it given quality service. They are also in charge of orienting the outlet employees of the business operation standards. The internal affairs supervisor is in charge of human resource employment, production management and the finance related to production. The external affairs supervisor manages the franchise managers, arranges orders needed by the firm and is in charge of marketing the product. The head manager overlooks all the operations that the firm is doing from the production side to the marketing aspect. He is also in charge of the business permits and other certifications needed by the firm. Production runs for five days a week from 8am to 5pm while the outlets operate based on mall hours. Delivery times should be done daily by 9am in order to prepare before the malls’ regular opening hours.

12 | P a g e


Location Planning

The production site should be located within Los Baños. It was chosen for its proximity to the suppliers from the junction market and other supermarket stores, and to the main outlets. It is proposed that two of the outlets be situated in Vega Center and another at Robinson’s Town Mall. The other two should be situated in Crossing, Calamba. These places were chosen because of the dense economic activity in these areas. They are placed there to lessen the transportation costs from the production site.

Quality & Sanitation

Picassio shall observe, even without formal certification, the requirements in possessing good manufacturing practices. The requirements include intensive training and orientation on allergen control, cleaning and sanitation procedures, and ingredient protocols; periodic audits and inspection of the plant and the raw materials; proper documentation of activities, policies, sanitation condition, receiving records, and employee logs; and evaluation of trainings, product quality, and sanitary tests.

13 | P a g e


Packaging

Picassio or Picadillong siomai should be packed chilled in large microwaveable

plastic containers. These containers are sturdy enough to protect the pieces from distortion, and large enough to place at least two layers of Picassio inside. The sauce should be delivered in two-liter bottles. It should later on be transferred in small soy sauce dispensers by the kiosk employees.

Each serving should contain 3 Picassios with sauce. Costumers are offered chili pepper for added spice.

14 | P a g e


Process

Since the firm should initially produce one product, mass production can be achieved by following a line process with a line flow strategy. Measuring utensils should also be used in order to maintain the exact amount of ingredients in each product. The suppliers for each ingredient should be outsourced from weekend markets or in supermarkets. Finished products should be stored and distributed to the outlets through mini cold carrier vans to preserve the freshness of the product. First is the preparation of ingredients. Garlic, onion, carrots and malunggay leaves are washed along with shredded corn. Garlic, onion and carrots are peeled, rewashed and chopped, malunggay leaves are prepared, and eggs are beaten. Next, the pan is pre-heated. When warm enough, cooking oil should be greased on the pan. The minced garlic, minced onion should be sautéed until brown. After that, beef is added and cooked for 15 minutes. When the beef is cooked, shredded corn, chopped carrots and malunggay leaves added. Cook for 2 minutes and then dash with salt, pepper and seasoning to taste. When done, the pan is removed from the fire and cooled. The filling is transferred to a large bowl where cornstarch should be added with beaten eggs and then mixed well. Once the filling is prepared, it should be wrapped in a molo wrapper. The filling for each molo wrapper should be weighed for consistent quantity of content. The batch of molo-wrapped Picadillong siomai should be steamed for 20-30 minutes. The product should then be ready for packaging. For the sauce, minced garlic and green pepper are sautéed. Soy sauce and sugar are added to taste. It should also be remove from fire and cooled. Calamansi

15 | P a g e


juice should be added to enhance the taste of the sauce and then set aside for packaging. Quality checking is done all through-out the process by each kitchen workers and by the head cook in order to make sure that the meat and other ingredients are cooked well. For the packaging, a batch of Picadillong siomai are placed in large microwavable plastic containers. They should be stored in the refrigerators of the storage area for finished products until they are taken out for delivery.

16 | P a g e


Capacity

Based on the quantity of the ingredients given on Table 2, the firm could produce 20-22 servings of Picadillong siomai with 3 pieces each per batch. Assuming that the production can make 36 siomai per batch, it was approximated that the production capacity of the firm is 720 siomai per operation day. This 720 siomai should first be divided and distributed equally to the four outlets. This yields a total of 5 batches of Picadillong siomai with 180 siomai per outlet in Los Baños and Calamba City. These siomai should be held in the storage area for finished goods until its delivery time in the morning.

17 | P a g e


Financial Viability

Table 2. Cost estimate for producing 20-22 servings with 3 Picadillong siomai and sauce.

*Total cost may still increase if other variable costs other than the ingredients are accounted.

The selling price of the product should be Php 30 pesos per serving. This pricing incurs a 50% contribution margin rate. Note however that the variable cost accounted were only those of the ingredients. Therefore, actual amounts could still vary.

Quantity Inputs Price 75 mL Cooking oil Php 10.00 20 grams garlic(minced) 5.00 25 grams onion(minced) 5.00 500 grams ground beef 145.00 123 grams corn(shredded) 17.00 150 grams carrots 12.00 7 stalks malunggay 8.00 2 Pcs. med.

sized Eggs(beaten) 15.00 25 grams cornstarch 5.00 230 grams molo wrappers (small) 29.00 15 grams Iodized salt 1.00 1 gram ground pepper 5.00 1 gram seasoning 3.00 25 grams Green pepper (minced) 15.00 30 grams Sugar 3.00 120 mL Soy sauce 3.00 7 mL Calamansi juice 10.00 Total variable cost Php 291. 00

18 | P a g e


Assuming that all 240 servings of Picadillong siomai should be sold daily, maximum sales of Php 7,200 per day should be earned. Deducting the variable cost per day of Php 3,174.55, the daily maximum contribution margin should be Php 4,025.46.

During medium sales when 180 servings are sold per day, maximum sales is Php 5,400, variable cost is Php 2,380.91 the contribution margin should be Php 3,019.09.

During low sales when only 120 servings are sold per day, maximum sales is Php 3,600, variable cost is Php 1,587.27, and the contribution margin should be Php 2,012.73 per day.

19 | P a g e


Perspective

Shall Picassio grow and prosper as a well-known siomai brand, the company plans to expand its infrastructure and its products line. The expansion of its facilities should cater a greater capacity and more varieties of dim sum products. Upon maturity of the business, Picassio shall tie up with larger long-term suppliers of materials and ingredients. New ingredients should be needed for the introduction of new recipes. Picassio should start opening itself for franchising and the brand should be offered to supermarkets and malls within Laguna.

picassio: picadillong siomai operations maual

Small Business & Entrepreneurship