PRODUCTION CONTROL

PRODUCTION CONTROL

The term production means conversion of raw products into cooked meal or product. The
production control consists of Production planning and Production control. Production
Planning involves establishing of criteria so that the standard products may be produced and
served.

Aims & objectives of production control are as follows:

 It reduces waste specially leftovers

 Reduces higher cost pertaining to over production
 It eliminates incorrect portion size

There are four techniques that are used to achieve the above

1. Volume forecasting
2. Standard yield
3. Standard recipe
4. Standard portion size

VOLUME FORECASTING-

It is a systematic method of predicting volume of sales for a specific future period. It is also
referred as production planning. Volume forecasting is a technique of predicting the volume
of sales of the restaurant for a specific future period. The total sales are broken down into
sales of various outlets individually and then a final consolidation wherein the actual figures
are compared with those of the potential figures.
Following are the objective of volume forecasting-

 To predict the choice of menu item by customer.

 To facilitate the purchasing of raw material.
 To reduce the problem of left over & over production.
 To ensure the availability of all the ingredients.
 To control the food cost in relation to sales or cost limit in non-profit making
establishment.
 To enable the food controller to compare between actual and potential sale and for
corrective action to be taken if necessary.

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For accurate forecasting, following tools of production planning are used:

Portion-Sales Analysis: This record is obtained by having the food checker record i.e. no of
portions of each menu item served for each meal

Popularity Ratio: It is computed by expressing the no. of solid portions as a percentage of

the total no. of covers served

Portion-Sales History: No. of Portions served & the ratio to the total served is entered as
portion sales history.

Occupancy of the Hotel: No. of guest staying in the hotel directly effects that will be served.

Special events in town.

Weather

Season of the year: As it affects the popularity of certain dishes.

Holidays/public holidays or weekends.

Our Sales History: This is a detailed record of actual sales & potential
Sales of an outlet in the hotel.

METHODS OF VOLUME FORECASTING- Volume forecasting is done in two stages.

1. Initial forecasting
2. Final forecasting

INITIAL FORECASTING-It is generally prepared one or two weeks in advance and

following factors are considered before arriving at sales figure.

 PAST RECORDS- We would look for the figure recorded last year showing sales
figure of last year for the same period and also note the demand for each menu items.

 ADVANCE BOOKING- this refers to total advance booking in hotel for that day
and also the banquet booking for that day.

 CURRENT EVENT- These are the any event that is being planned for that period
i.e. Games, international cricket match, trade fairs etc.

 CURRENT TRENDS- Current food taste of region should also be considered.

 FESTIVALS- These are also considered for initial forecasting.

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  NUMBER OF DOMESTIC & INTERNATIONAL TOURIST- These figure can
obtain from ministry of tourism and ministry of aviation to arrive at the figure of total
arrival in the city for that period.

On the completion of initial forecast, following should take place,

1. The predicted sales are converted into quantities of foodstuffs. The total for each food
item required for each meal period are itemized and listed and are used for writing
requisition. To convert the predicted sales of menu item in quantities, the standard
recipe and portion size is used.
2. With the help of requisitions, the purchase officer places the purchase order, taking
into account EOQ and storage facilities.

FINAL FORECASTING

Final forecasting takes place a day before the preparation or service of the previous
day especially in banquets where pre-preparation has to begin after considering the
latest changes in the number of pax. The weather conditions are also considered in the
final forecasting

FIXING OF STANDARDS (QUANTITY & QUALITY)

The word Standard is synonymous with the phrase “what it should be?” both quantitatively
and qualitatively.

Different standards for production control

1. Standard portion size

2. Standard recipe
3. Standard portion cost
4. Standard yield

The final approval for the use of these standards should be obtained from the Management.

STANDARD PORTION SIZE- It represents the amount (weight, count, volume) of each
food item that is sold to the guest and should be established for all items.

Objectives of Standard portion size

 It helps to in check portion size

 It assists in the costing of each dish

 Assists in purchasing of raw materials

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ADVANTAGE

 Customer satisfaction as he/she is receiving the same amount every time.

 Food cost is controlled.
 Avoid pilferage by staff.
 Over portioning is avoided.
 Reduces the amount of leftover.
 Helps in indenting.
 Helps in reducing wastage.
 Less of training is required for newly appointed staff.

EQUIPMENT USED IN PORTION CONTROL.

 Serving spoons, Ladles.

 Cups, glasses and moulds,
 Scoops.
 Measuring cup
 Weighing scale
 Automatic vending machines
 Portion bowl/ dish, etc.
 Jiggers
 Shot glasses

Scoop soufflé mould ladle

Jigger Shot glass Entre dish

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STANDARD RECIPE-This is written document contains list of ingredient and method of
preparation for particular dish in menu card. It contains the following:

Name of the dish

Number of portions

Cooking time

Temperature

The required ingredients

The method of preparation

Nutritional value of the dish

Presentation & accompaniments

Preferably a photograph

Method of service

OBJECTIVES OF STANDARD RECIPE

1. To determine the quantity and quality of ingredient to be used.

2. To obtain the yield obtainable from a recipe.
3. To determine the cost per portion.
4. To determine the nutritional value.
5. To facilitate balance menu planning.
6. To facilitate portion control.
7. It helps in costing of dishes, pricing menus for banquet.
8. It helps in uniform quality and taste.
9. Require less supervision.
10. Easier for a newly appointed employee as they can refer to it.
11. Establishes food cost control.

STANDARD RECIPE CARD

ABC HOTEL

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 STANDARD RECIPE AND COSTING CARD

Recipe for: Recipe no.

No. of Portions

Portion Size Date

Sl no. Ingredient Quantity Unit Cost Total cost Remarks

Total cost

Cooking Time Cooking Method:

Cost per Portion

Nutrition Value

STANDARD RECIPE AND COSTING CARD SAMPLE

STANDARD PORTION COST: it is defined as the amount which a portion would

cost considering all standard production processes are followed. Though it is fixed by
the management. The standard portion cost is calculated for every item in the menu if
the ingredients, proportions, production methods and portion sizes are standardized.

Objectives of standard portion cost

1. It helps to check the portion size of the dish

2. It assists in costing of each dish
3. It assists in purchasing of raw materials

Formula:

STANDARD PORTION COST= PURCHASED PRICE/ NO. OF PORTIONS

STANDARD YIELDS- Yield may be defined by the number of portions you get or as a
yield percentage. A number of portions would be, for example, eight 10 ounce steaks from
tenderloin or four servings of potatoes from a one pound bag. A yield percentage is the

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percent of useable product. The term ‘standard’ is synonymous with the phrase ‘what it
should be’, standards are aids to management for the control of food and beverage
department and for the measurement of efficiency of kitchens and bars and specially butchery
department. After establishing the standard yield for all the major items it is possible to plan
the menu costing and pricing. It also helps in volume forecasting for specific items into raw
material requirements. The control department should weight the standard portion size at
random to maintain the portion standard.

OBJECTIVES OF STANDARD YIELD

 To establish a standard for the quantity and number of proportions obtainable from a
specific item of food.
 To establish a standard for comparison with operating results and thereby measuring
the efficiency of the production department.
 To establish an objective method of further evaluating standard purchase
specification.
 To establish the standard cost factor for the items of food.
 To assist converting forecast requirement into raw material requirements.
 Acts as double check for the purchasing department.
 Aid to menu pricing and food cost control.

Percentage of Yield = (Weight after cooking/ Weight before cooking) X 100

Edible portion = (As purchased – shrinkage during preparation)

Percentage of Shrinkage = (Losses during shrinkage / As purchased) X 100

STANDARD YIELD TEST

 TRIM TEST- The trim test determines the excess fat that has been left over by
butcher.
Trimming Yield Percentage = Fully trimmed meat/ Meat before trimming x 100

 AGING YIELD- Certain cuts of meat are required to be aged for varying length of
time. Aging causes to lose weight due to loss of moisture in the meat. Normally 5% to
10% shrinkage occurs in the first two weeks of aging with lesser shrinkage upon
further aging. There is no convenient method to determine the aging yield percentage.

 BONNING YIELD- This yield gives you amount of edible meat without bones.

 COOKING TEST – All meat product will shrink during the cooking process due
loss of moisture. The amount of shrinkage depends upon the degree of temperature at
which it is cooked. The method of cooking effect the shrinkage.

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COMPUTATION OF STAFF MEALS

There are different methods used to find out cost of staff meals.

1. SEPARATE REQUISITION
 This method is suitable for large hotels and F&B outlets.
 Employees are given food other than what is prepared for customers.
 All food used for the preparation of employee meal is issued separately to a
requisition.
 All such requisitions are priced separately to determine the cost of employee meal.

2. PRE-ESTABLISHMENT COST
 The management decides the cost per meal and directs the chef
 To prepare specific meals that will cost NO MORE than the established cost.
 This amount will be credited to the food cost per employee.
 A record is kept of the employees who are fed each day.
 This number is multiplied by pre-established meal cost which gives the cost of
employee meal per day.



Source:
Adapted from Food and Beverage: Management & Cost Control by Jagmohan Negi,
ISBN-8173912548
Adapted from Principles of Food, Beverage and labor cost control for hotels and
restaurant by Paul R Dittmer & Gerld g Grifin
ISBN 0-8436-2087-0
Food & Beverage Management by Partho Pratim Seal

ISBN 10:0-19-946983-0

Authorship : Subhankar Mondal

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