ManufacturingInputIngredientsProcessMixing, chopping, bakingOutputEnd product-cake, biscuit, loaf of breadFeedbackOvercooked-cook for less, lower the

temperature

Scales of productionManufacturers decide the scale of production

depending on the number of products predicted to be sold and the shelf life.

Just in time means that the materials are delivered to the factory just in time to be turned into the products for immediate dispatch to the shops.

This means products don’t need to be stored in a factory. This cuts down waste and reduces risk of bacterial contamination.

Types of productionOne off/JobbingIs used to make

specialist products such as cakes for weddings and birthdays.

Can be costlyRely on skilled

workersGenerally don’t

require special equipment.

Types of productionBatch ProductionMakes a specific

quantity on a large scale of the same product such as biscuits or cakes.

Usually done by one person or a team.

The equipment used can make one or more product and workers need to be skilled.

Types of productionContinuous flow• This is used to make

products which are sold in large quantities and have a high shelf life. They are often made 24 hours a day, seven days a week. Products include baked beans, biscuits,

cakes and crisps. Machinery can only be

used for that product.CAM is often used in this

process.

Types of productionAutomated

manufacture• May be included in

continuous flow production lines. This method uses computers and helps to increases productivity, is safer for workers, more hygienic, assures final quality, measuring, weighing, cutting, shaping, critical control points are automatically tested.

Standard components examples include grated cheese, pizza bases, ready made pastry cases.

• Advantages• Save time• Can speed up

manufacture• Can use a less skilled

workforce• Less cross

contamination• Less equipment

needed• Less effort• Ensures consistency

of product

• Disadvantages• May forget to order

and stop production• May need special

storage arrangements

• May be more expensive

• May not be up to standard

• Same components may be used by other companies.

Consistent productA consistent product means producing something the same every time.

The use of machinery can help to do this as -

It can be faster/need less workers

Don’t need to be as skilledThere is less human errorIt can be set at a certain

speed or for a certain time.Eg using a mixer or electric

deep fat fryerIt can cut the same

thickness.eg using cuttersUse of standard components

can ensure you get the same standard.

Using computersCAD (computer aided design) and CAM (computer aided manufacture)

• Advantages of using computers

• No mistakes• Can run all day

without a break• Save on labour costs• Removes human

error• Can assess 1000s of

products in minutes• Cab detect things

that the human eyes cannot see.

Using computersCADComputer aided design• To design the physical

appearance of a product• To calculate the

nutritional profile of a product

• To model the cost• To calculate the shelf

life• To present sensory data

like profiles• To model a production

procedure• Produce packaging

designs

Using computers

CAM

Computer aided manufacture

Load cells

Measure the weight of ingredients and store the info on a computer so it knows when to reorder more.

Light refractor

Spots changes in colour such as bad crisps or burnt food

Light detector

Used to check the thickness of sauces.

Temperature

Takes and records critical temperatures of cooking and storing foods

Metal detector

Checks food for metal to makes sure safe to go to customer.

Use of flow charts

Flow chartsFlow charts usually have four symbols

The terminator (Oval) used at the start or

the endProcess (Rectangle)What activity needs to

be carried outDecision (Diamond)Usually a question with

a yes or no answerArrows which show the flow of

the chart

Quality assurance and quality controlQuality in food is

very important. Firstly it means the food is safe to eat and also it satisfies the customers needs.

So every time you buy this product as a customer you know it is going to be exactly the same.

Quality assuranceThis simply means a

guarantee of quality. Manufacturers assure their customers that the product will be of a consistent quality.

The manufacturer does not want to loose this reputation as it may cost sales

Quality controlThese are the checks

which are carried out to check the quality of the product. They are done at the designing, manufacturing and end of manufacturing stages

Quality control will check-SizeShapeAppearanceTastetexture

ToleranceProducts need to be within a

certain tolerance to be of an acceptable quality.

So the size might be measured or the temperature taken. These measurements will need to be within a certain tolerance to be acceptable. So the temperature on these pies will need to be within a few degrees or the whole batch will be throw out, for safety reasons.

Pizza may need to be between 21 and 21.5 cm. Or it will not fit in the box.

Removing hazardsManufacturers have a

legal requirement to make sure their product is safe to eat. When a new product is being designed a HAZARD ANALYSIS must be carried out. This means looking at what could go wrong and making a plan to stop it from happening.

Types of hazardBiologicalSalmonella, listeria,

E coliPhysicalHair, metal, fish

bonesChemicalCleaning materials

HACCPHazard analysis and critical control points

To produce a HACCP chart the manufacturer

Lists the processes involved in the making of the product.

Identifies the areas where risk might happen.

Decides which are critical to the safety of the consumer and plans how to reduce these risks using CRITICAL CONTROL POINTS.

A check on a cooked food to make sure it has reached the correct temperature may prevent food poisoning in a customer

CCPs check the food is safe to eat QCPs check the size and shape of

the food for quality