Production analysis for a bakery

analysis-process-production-bakery

Introduction

From the beginning of humanity, the first inhabitants had the need to consume products but they had the disadvantage that these, on repeated occasions, were not available in the place where the plaintiffs were settled or at the time when they wanted. In order to cover these needs, it is necessary to transfer the goods and their consequent storage, a problematic issue when the product had a very short shelf life, hence these people were forced to live near the production sources or, on the contrary, consume a small group of products. Since then, the need for an established transportation, storage and distribution system for goods has been evident.

This is how logistics arises, as a human need aimed at minimizing processes, making them as efficient as possible; hence the importance in the current global context and, specifically, of Cuba, a country with so many restrictions, both in terms of resources and capacities, as well as opportunities for commercialization abroad.

An extremely important element is the issue of the quality of the products offered to end customers, who expect a good that meets their expectations at the right time. The 200g hard crust bread is not an exception to this topic, especially when it is consumed by the majority of the Cuban population.

A primary aspect when preparing the aforementioned product is the correct use of both inputs (quality, quantity) and electrical equipment and other means, hence the importance given to the Process Assurance Model (MAP) of production of the 200g bread of hard crust.

The present project sets out as a general objective to design the production process for 200g of hard crust bread in the Güines II bakery, using the Process Assurance Model, outlining the following specific objectives:

Carry out an exhaustive bibliographic review related to the issues of business logistics and process assurance model. Characterize the entity under study. Describe the production process of 200g of hard crust bread in the Güines II bakery. Characterize each of the elements. of the Process Assurance Model for the production of 200g hard crust bread in the Güines II bakery. To develop the content of three elements of the Process Assurance Model for the production of 200g hard crust bread in the Güines II bakery. Describe the functions of a container used in the Güines II bakery and auxiliary materials.

In order to respond to the proposed objectives, an analysis of the bibliography on the subject as well as the information donated by the company was carried out and the interview and brainstorming techniques were used.

The project consists of two chapters: in the first one allusion is made to the theoretical aspects related to the subject and that are of vital importance for understanding it, and in the second, after describing the unit under study and the production process of the 200g hard crust bread, an analysis is made of the MAP elements and the selected container.

Business logistics: brief overview of the evolution of its conception.

The first written references to a major logistical problem appear in the Holy Scriptures: in "Genesis" or the first book of the Old Testament (storing food during fruitful years to be consumed in periods of scarcity) and in "Exodus" or book second of the Holy Scriptures (construction of warehouses for a logistics distribution and export network.

However, the best-known original definition of the term logistics is located in a purely military context: "technique of the movement of troops, their transportation and supplies" (Larousse Usual, 1994, p. 376).

A clear and subsequent definition to those offered above is the following: "set of activities related to the transfer and storage of products that take place between the points of acquisition and the points of consumption" (Ballou, 1991, p. 21). This axiom shows that logistics constitutes a group of interrelated activities, which are coordinated.

For their part, doctors Gómez and Acevedo in "Modern logistics in the company", propose the following logistics concept: "It is the action of the labor group aimed at guaranteeing the design and management activities of material, informational and financial flows, from their sources of origin to their final destinations, which must be carried out in a rational and coordinated manner in order to provide the customer with the products and services in the quantity, quality, terms, costs, location and with the information demanded, with high competitiveness and guaranteeing the preservation of the environment. ”

The above definitions show how logistics constitutes, beyond an isolated technique or subsystem, a process that assumes both the direction and the management of all the flows of economic activity, crossing the entity diagonally and involving all the agents of the economic process with a customer focus; thus showing its character as a system and its integrating role.

Process Assurance Model (MAP).

A process is a set of activities or events (coordinated or organized) that are carried out or happen (alternatively or simultaneously) under certain circumstances for a specific purpose. This term has different meanings depending on the branch of science or technique in which it is used.

A production process consists of consecutive stages throughout which various inputs undergo some type of transformation, up to the constitution of a final product and its placement on the market. It is, therefore, a succession of integrated design, production and distribution operations, carried out by various interconnected units as a current, involving a series of physical, technological, economic and human resources; hence, it ranges from the extraction and manufacturing process of the raw material to final consumption.

So what to understand by MAP?

According to Gómez and Acevedo, the process assurance model is the "set of resources, services and conditions that must be ensured according to certain forms, qualities, moments and quantities to guarantee the performance of a process according to certain standards", in addition expresses the way to dynamically ensure the conditions for the performance of a process based on the design carried out in it.

Each of the elements of the MAP is deployed by each of its components, and each component requires assurance that takes place in a certain cycle made up of specific activities, both in the operational, tactical and strategic cycles. The due concatenation and efficient execution of all activities is the necessary condition for achieving high effectiveness. The following is a diagram that shows, in summary form, what was previously expressed:

Each element of the MAP must present a specific content referring to:

Nomenclature Content and quality parameters Supply method: Against stock Against order Scheduled Fixed frequency Automatic By contingency Assurance procedure:

Standardized sequence of activities, each framed in its lead time, through which the efficient and effective assurance of the corresponding element is guaranteed and that goes from the emergence of the need and the formulation of the order to its use in the production system or the client of the same.

Inventory rules Consumption rules: They can be determined by various methods such as:

Analytical: Based on a specific engineering analysis of the design and technology to be used and the type of resource. The same By analogy: Use the indices of similar products as reference under similar conditions By catalog: Use the indices recommended by the manufacturers

Operating rules Cycle standards (lead time): this is no more than the period in advance in relation to the time of delivery of the product or service of the process to which reference is made, in which the assurance of each element must be concluded. Here is a diagram that exemplifies what was previously explained:

Storage and conservation conditions Reservations: they constitute a quantity of resources immobilized in the production system to be used in order to avoid that they do not appear in the results, the failure in the assurance or operation of any element. It is necessary to take into account elements such as the cost of not using the resource in reserve, the cost of the impact of the failure and the level of competition; which must be balanced

Assurance scheduling

Fixed program: Setting a given frequency. Self-regulation: A procedure is established to make an expedited replacement. Variable programming: Through a management technique, a program is determined at any time according to the existing situation. On request: Underwriting is managed when the need arises or is detected. Automatic: The resource is automatically supplied when requested. By rhythm: The resource is secured according to a certain rhythm (fixed or variable).
- Specialized Variable
Outsourcing (outsourcing) Supplier Contracting:
- Framework contracts Specific contracts Supply integration contracts
Supplier Evaluation
- Tenders

Relationship between business logistics and the process assurance model

Business logistics is responsible for integrating all the activities of each MAP resource both in the supply phase and in the production and distribution phase, that is, from the supplier and the supply market to customers and sales markets.

Characterization of the Güines II bakery

The "Güines II" Bakery, located at 77 avenue, number 8012, between 80 and 86, Güines municipality, Mayabeque province, belongs to the Cuban Bread Company of MINAL.

It has a total of 15 workers divided into two work shifts a day and in charge of delivering to the population a product of the highest quality and that meets the requirements established for each of them.

The Güines II Bakery portfolio includes:

400g hard crust bread 200g hard crust bread 100g hard crust bread 50g hard crust bread 400g whole grain bread 200g whole grain bread 100g whole grain bread 50g whole grain bread 200g (Piccolo). 100g soft bun (Piccolo). 50g soft bun (Piccolo). 50g soft bun (Round). 90g semi-soft bun (Piccolo). 90g semi-soft bun (Round).

The entity under study has the mission of "producing and marketing bread of various varieties, cookies and sticks, of high quality in national currency, products derived from flour in both currencies, milling of cereals for the food basket, with a capable collective, modern technology and a high sense of belonging ”.

Its vision is none other than “to be an efficient company, of recognized prestige, that satisfies the demand of the population with the production and commercialization of high quality bakery products in national currency, derived from flour in both currencies and milling of cereals for the food basket ”.

The company carries out its productions according to the production standards established in the technological charts and for this they use the following raw materials from the Cuban Provincial Bread Company of Mayabeque:

Wheat flour, dry yeast, kernel, refined sugar.

For the preparation of each food, different means of production are used, such as the mixer, the shaping machine, the oven, the fermentation chamber, among others, all belonging to the Italian brand TECNOPAS.

This bakery has adequate ventilation and appropriate spaces for the correct handling of raw materials both in the warehouse and in the production area.

Description of the 200g hard crust bread making process.

From the Güines II Bakery product portfolio, the object of study of this research is 200g hard-crust bread. Next, the preparation process will be described from the moment the raw materials used in its preparation are received.

The necessary inputs in the manufacture of the 200g hard crust bread are dry yeast, wheat flour, kernel, salt and butter. Once in the bakery, a reception report is made and then it is taken to the stowage cards.

When the raw material is going to leave the warehouse, an output voucher for production is previously formed with the quantities established according to the technological letter:

Wheat flour: 31,483kg. Dry yeast: 0.314kg. Core: 0.063kg. Butter: 1,156kg. Salt: 0.628kg.

The storekeeper delivers these materials to the master brigade chief baker and begins the process consisting of the following stages:

The operator introduces the water and salt into the mixer and once the salt is dissolved, the wheat flour is added first and then the rest of the components. This mixture is done in approximately 12 minutes. The mixture is extracted for a highness (it is a kind of box) so that it rests for an interval of 30 minutes. The dough is rubbed (this is more than dividing the dough into four parts of equal weight) to give it greater elasticity, and it is stopped again by the mixer at a higher speed about 5 minutes each part independently. The dough is extracted in raw and chopped into pieces, 270g and passed to a forming machine which gives the dough the oval shape and then the baker manually adds more shape (length). This process takes approximately 30 minutes. These pieces of 270g are put into tartar,They collect 10 units of bread. And they are part of a chariot, which is made up of 18 Tatars. This bread trolley passes into the fermentation chamber (it has capacity for four bread trolleys) for approximately two hours and thirty minutes and automatically passes the baking process in an oven (its capacity is one bread trolley) to a temperature of 190-200 degrees centigrade for 50 minutes. The bread trolley is removed from the oven and left to rest for five minutes. The bread trolley is taken out to the sales area.This bread trolley passes into the fermentation chamber (has capacity for four bread trolleys) for approximately two hours and thirty minutes and automatically goes through the baking process in an oven (its capacity is one bread trolley) to a temperature of 190-200 degrees centigrade for 50 minutes. The bread trolley is removed from the oven and left to rest for five minutes. The bread trolley is taken out to the sales area.This bread trolley passes into the fermentation chamber (has capacity for four bread trolleys) for approximately two hours and thirty minutes and automatically goes through the baking process in an oven (its capacity is one bread trolley) to a temperature of 190-200 degrees centigrade for 50 minutes. The bread trolley is removed from the oven and left to rest for five minutes. The bread trolley is taken out to the sales area.

The entire process lasts approximately four hours and forty-five minutes.

In the social aspect, it is necessary to take into account the existence of a high demand for 200g bread (marketed at 5.00 CUP), which must be satisfied at the right time and with the required quality.

In the political aspect, the bakery complies with all the laws that regulate said activity, articulating according to Resolution No. 523/2007 of the Ministry of Economy and Planning. Below are the rules that govern this activity:

Rules governing the activity of the Cuban Bread Company

Code	Year	Title
NC 09-04-78	1987	UNIFORM SYSTEM OF MOLDS, DIES, PRINTS AND MACHINE DEVICES. MACHINING DEVICE. MOVABLE CLAMPED CLAMP. PROJECT SPECIFICATIONS.
NC 19-00-08	1988	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. GENERAL TECHNICAL AND ORGANIZATIONAL MEASURES IN LABOR ACTIVITY.
NC 01-19-01	1979	SYSTEM OF PROTECTION AND HYGIENE STANDARDS AT WORK. HAZARDOUS AND HARMFUL PRODUCTION FACTORS. CLASSIFICATION.
NC 01-19-05	1980	SYSTEM OF PROTECTION AND HYGIENE STANDARDS AT WORK. GENERAL VIBRATION. GENERAL SANITARY HYGIENIC REQUIREMENTS. (MANDATORY)
NC 01-19-12	1983	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. DETERMINATION OF LIGHTING LEVELS IN PREMISES AND WORKPLACES. METHOD OF MEASUREMENT.
NC 01-19-15	1982	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. BIOLOGICAL SAFETY. GENERAL REQUIREMENTS. (MANDATORY)
NC 01-19-20	1983	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. PROTECTION AGAINST EXPLOSIONS. GENERAL REQUIREMENTS. (MANDATORY)
NC 02-02-02	nineteen eighty one	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. ELECTROTECHNICAL ITEMS. GENERAL SAFETY REQUIREMENTS.
NC 19-02-14	1988	SYSTEM OF PROTECTION AND HYGIENE STANDARDS AT WORK. REFRIGERATION AND CLIMATIZATION INSTALLATIONS. GENERAL SAFETY REQUIREMENTS. (MANDATORY)
NC 04-19-08	1988	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. INDIVIDUAL MEANS OF PROTECTION OF THE BODIES OF BREATHING. CLASSIFICATION AND GENERAL REQUIREMENTS.
NC 04-19-13	1982	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. VENTILATION SYSTEM. GENERAL SAFETY REQUIREMENTS. (MANDATORY)
NC 19-04-23	1984	SYSTEM OF RULES OF PROTECTION AND HYGIENE OF THE WORK. DERMATOLOGICAL PROTECTION MEANS. CLASSIFICATION AND GENERAL REQUIREMENTS.
NC 90-00-06-6	1983	METROLOGICAL INSURANCE STANDARDS SYSTEM. INTERNATIONAL SYSTEM OF UNITS. TABLES OF EQUIVALENCES OF OTHER UNITS OF MEASUREMENT TO THE YES.
NC 91-45	1986	HANDLING AND STORAGE OF CONSUMER GOODS. TERMS AND DEFINITIONS. (BEFORE: NC 57- 97: 86)
NC 92-09-2	1984	QUALITY CONTROL. METHODS OF SELECTION OF RANDOM SAMPLES.
NC 93-11	1986	COMMUNAL HYGIENE. SOURCES OF WATER SUPPLY. QUALITY AND SANITARY PROTECTION. (MANDATORY)
NC 107	2001	BASIC SANITATION IN PREMISES AND WORKPLACES. GENERAL REQUIREMENTS.
NC 116	2001	SECURITY AND HEALTH AT WORK. BASIC ERGONOMIC REQUIREMENTS TO CONSIDER IN JOB POSITIONS AND ACTIVITIES. (ISO 6385.1981, MOD)
NC 827	2012	DRINKING WATER - SANITARY REQUIREMENTS (MANDATORY)
NC 869	2011	SAFETY AND HEALTH AT WORK - HOT THERMAL ENVIRONMENTS - ESTIMATION OF THERMAL STRESS AT WORK BASED ON THE WBGT INDEX (GLOBE AND WET BULB TEMPERATURE)
NC IEC 60598-2-1	2001	LIGHTING. PART 2. SPECIAL REQUIREMENTS. SECTION 1. FIXED LUMINAIRES FOR GENERAL USE. (IEC 60598-2-1.1979, IDT) (REQUIRED)

Source: self made

Taking into account the ecological aspect, the bakery does not throw waste outside the previously established means for it and is maintained with the required hygiene conditions.

An essential element is the one that refers to the economic aspect, which in this case includes compliance with the daily sales plans of the bakery under study, hence it is also necessary to comply with the established quality standards and demands by the village.

Providers

The Güines II bakery is a state establishment that does not independently manage its suppliers, but rather they are previously established, hence the raw materials and materials they work with in this entity are purchased directly from the Cuban Provincial Bread Company.

Materials and energy

To make the 200g bread, a set of raw materials are required, which will be briefly described below:

Wheat flour: Cereal from Europe that can be refined or whole grain (see annex 1). Its use in bread is partly thanks to gluten, which is nothing more than a complex protein that gives bread its elasticity and consistency. Its composition is reflected in Annex 2. Dry yeast: Mushroom used for its ability to decompose through fermentation of various organic bodies, mainly sugars or carbohydrates, producing different substances. Its effect is much slower than chemical yeast because it is necessary to wait for the doughs to rise. Core: Element that is added to wheat flour to give strength to the bread dough and prevent it from compacting. pig: it is part of animal fats.Its use is frequently mixed with flour as part of the elaboration of doughs. This component is imported from Brazil and Canada. Salt: corresponds to the salt called sodium chloride, which provides food with one of the basic flavors: salty. The consumption of salt modifies human behavior towards food since it is a generator of appetite and stimulates its intake. It is mainly used in two areas: as a condiment for some dishes and as a preservative in salted meats and fish (including some vegetables), as well as in the preparation of certain pickles.The consumption of salt modifies human behavior towards food since it is a generator of appetite and stimulates its intake. It is mainly used in two areas: as a condiment for some dishes and as a preservative in salted meats and fish (including some vegetables), as well as in the preparation of certain pickles.The consumption of salt modifies human behavior towards food since it is a generator of appetite and stimulates its intake. It is mainly used in two areas: as a condiment for some dishes and as a preservative in salted meats and fish (including some vegetables), as well as in the preparation of certain pickles.

For its part, the energy that is used fundamentally is electrical energy, since all processes are carried out on machines that do not use manual labor but rather electrical energy.

To provide the electrical energy necessary for these processes, various power sources can be used. In the case of manual processes, it is more common to use constant current power supplies.

Media

There are various means in the bakery that complement the final formation of the bread and within which are the extractors, which are nothing more than articles intended for the extraction of heat once the oven is opened to remove the bread cart. This constitutes a means of protecting workers.

Another important element is the lighting that the place where the mixture is made must have, in order to have greater precision when carrying out the measurement or weighing of the components, depending on the production phase to which reference is being made.

In addition, hats are used to prevent the scalp from falling onto the finished product and aprons to protect against any splashing of the components that make up the product.

Assets

The assets used by the company to carry out the bread making process are, in order of use, the mixer, the shaper, the tartar, the fermentation chamber and the oven, all belonging to the Italian brand TECNOPAS.

Mixer: Machine whose main function is to supplant the manual kneading of the different elements that make up the bread dough. Shaper: Equipment designed to give the bread dough an oval shape. Tartares: Rectangular stainless steel trays used as a plate for the baking of the bread dough. Fermentation chamber: Equipment used in the yeast fermentation process of the bread dough, that is, to make the dough take the volume indicated in the technological charts. Oven: Machine designed to cook the dough. bread.Money

To carry out the process of making the 200g bread, the entity under study does not make any monetary outlay, but once the product is finished it is put up for sale and the corresponding collection is made.

information

For the 200g bread production process, it is very important to take into account the requirements stated in the technological letter, that is, the quantities of each component required by each unit of bread.

In addition, communication between the workers and the latter with the public is essential, that is, with those demanding the good in question, which will allow improvements in the quality of the final product and will lead to higher levels of sales.

Personal

A total of 15 workers work in the Güines II bakery, divided into two work groups per day and 8 hours per shift. These workers are the administrator, the shift manager, two master bakers, four operators, two bakeries, two relevant teachers, two vending machines and a cleaning assistant.

To select these workers, their previous skills and experiences in this type of work are taken into account, as well as their voluntariness to access the position and their learning capacity assuming that they do not have practice in the work they will do.

This center is nourished by trade schools or graduated high school personnel who previously pass a course that allows them to acquire the necessary skills to carry out their work.

The organization chart of bakeries generally appears in Annex 3.

Product-service

The company in question offers a variety of products, but the object of study of this research is 200g of hard crust bread, which has an approximate length of 30cm and a thickness of 2 inches.

In addition to preparing the product, the entity's management must take care that the treatment towards non-staff, that is, towards customers, is appropriate, taking into account the rules of respect between people and without any discrimination.

Waste

Once the manufacturing process is finished, the solid waste mix is collected and deposited in plastic or aluminum containers with lids, generally the same ones in which the imported lard is packed.

customers

The customers of a bakery is any person who has the need to consume the good in question and who has the necessary cash for it. The treatment towards these personnel is important, because this, in addition to the quality of the bread, is what guarantees that the client returns to the entity.

Development of the content of 3 elements of the MAP for the production of hard crust bread in the Güines II Bakery.

Next, the content of the tartar bread elements, fermentation chamber and ovens, belonging to the Assurance Model of the 200g hard crust bread production process at the Güines II Bakery, will be developed.

Process: Production of 200g of hard crust bread.

Element: Tartar of bread.

Nomenclature	Bread tartar
Content and quality parameters	2mm thick stainless steel with dimensions of 90 x 50cm. It must be covered with grease and must not show any bumps
Delivery method	Programmed based on defects, and pre-established consumption standards.
Assurance procedure	When it breaks, an order is placed.
Consumption standard	18 per bread cart.
Existence rule	162 Tatars.
Operating rules	144 tatars.
Storage and conservation conditions	In dry places, they are stored horizontally resting on the floor.
Bookings	18 tatars
Supply schedule	Does not exist.
Provider	Cuban Bread Company.
Executor	Operators and master baker.

Source: Own elaboration based on data provided by the company.

Process: Production of 200g of hard crust bread.

Element: Fermentation chamber.

Nomenclature	Fermentation chamber
Content and quality parameters	Dimensions of 2.5m high x 3.5m long x 2.5m deep. It must be lit hermetically closed. It has a capacity of 4 bread carts
Delivery method	Programmed based on defects, and pre-established consumption standards.
Assurance procedure	When it breaks, it is repaired.
Consumption standard	2 cameras.
Existence rule	2 cameras.
Operating rules	2 cameras.
Storage and conservation conditions	In dry places, they are stored horizontally resting on the floor.
Bookings	They do not exist.
Supply schedule	Does not exist.
Provider	Cuban Bread Company.
Executor	Operators and master baker

Source: Own elaboration based on data provided by the company.

Process: Production of 200g of hard crust bread.

Element: Oven.

Nomenclature	Oven
Content and quality parameters	It has a capacity for a bread cart. It works automatically at a temperature between 190-200 degrees centigrade.
Delivery method	Programmed based on defects, and pre-established consumption standards.
Assurance procedure	When it breaks, we proceed to repair it.
Consumption standard	2 ovens.
Existence rule	2 ovens.
Operating rules	2 ovens.
Storage and conservation conditions	In dry places, they are stored horizontally resting on the floor.
Bookings	They do not exist.
Supply schedule	Does not exist.
Provider	Cuban Bread Company.
Executor	Hornero.

Source: Own elaboration based on data provided by the company.

Description of the container.

Packaging description: sacks of wheat flour.

Features

Protective: it protects the flour from humidity and different contaminating agents, and maintains the consistency of the product. Rationalizing: the bag does not carry any auxiliary material that allows rationalizing the wheat flour when it is used. Information: the container contains information about ingredients, expiration date, weighing in Kg and storage conditions. Promoter: contains the manufacturer's brand. Distribution: facilitates product handling.

Auxiliary materials

Auxiliary materials are those that complement containers and packaging so that they fulfill the functions for which they were conceived. They can be closure, sealing, identification, protection, promotion, etc.

In the case of wheat flour sacks, these are sealed with a thread cooked to the sack in order to close it, in order to avoid spillage of the product packaged in it.

Conclusions

Once the investigation was completed, the following conclusions were reached:

The bibliographic review was carried out, delving into the issues of business logistics and specifically in relation to the Programmed Procurement Model. A brief description was made of the Güines II Bakery, located in the Mayabeque province. The research on the production process of the 200g of hard crust bread and described how it occurs. The content of three elements of the Process Assurance Model in the Güines II Bakery was developed: the bread tartares, the fermentation chamber and the oven. The functions were described of the wheat flour container.

Bibliography

Ballou, R. (1991): “Business logistics. Control and planning ”. Editorial Díaz Santos. Madrid.Bowersox, DJ, DJ Closs, et al. (2002): "Supply Chain Logistics Management." Bowersox, Donald J; Closs, David J; Cooper, M. Bixby; "Supply Chain Logistics Management." Michigun State University.Fernández Gutiérrez, Alfredo (2007): "Business management in its basic components, marketing, negotiation and trade." Gómez and Acevedo Suárez (2007): "Modern Logistics in the company." LOGICUBA, Havana.Larousse Usual (1994): Ediciones Larousse SA de CV México. Seventh Edition. Technical norms - ONN. National Office of Tax Administration, ONAT, Cuban Norms. National regulations - Official Gazette of Cuba.

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