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©Copyright 2015 AIB International
May not be reproduced without
written permission.
AIB International
Troubleshooting Bread Products
AIB International
Troubleshooting Bread Products
Troubleshooting—What Does It Mean?
• Who is a Troubleshooter?
• What exactly is a Troubleshooter?
AIB International
Troubleshooting Bread Products
Troubleshooting
Definition
• Webster defines ‘‘trouble shooter’’ as “a skilled workman employed to locate trouble and make repairs in machinery and technical equipment”.
AIB International
Troubleshooting Bread Products
Troubleshooting
Definition of a “Bakery Troubleshooter”
• In a bakery environment, a “trouble shooter” is a skilled baker who is able to determine the cause of why a product fails to meet the expected quality standards. Not only is the baker able to determine the contributing factors, but she or he is able to make the necessary formulation and/or processing adjustments to get the product quality back to where it should be.
AIB International
Troubleshooting Bread Products
Does the thing work ?
Did you mess with it ?
Don’t mess with it
Does anyone know ?
You Dummy
Hide it Will you be in trouble ?
Can you blame someone else?
You poor man / woman
Forget it
NO PROBLEMYES
NO
YES
YES
YES
NO
NO
NO
NO
Problem Solving Flowchart
AIB International
Troubleshooting Bread Products
The Premise Behind Troubleshooting
AIB International
Troubleshooting Bread Products
Root CauseAnalysis• Define problem• Review
•Documentation•Ingredients•Process
Decision Making• Assess risk• Form hypothesis• Assess cost/benefit• Testing
Implementation• Execute plan• Make changes
Communication
Cross-departmental Interviewing Facilitation Change Management
Listening Training
Troubleshooting Model
Problem Discovery• Scoring• Self-Inspection• Customer
complaints
AIB International
Troubleshooting Bread Products
The Four Buckets• People
– Are your people well trained?– Do they have the tools and
staff they need?• Ingredients
– Are the ingredients correct, fresh, and known to the staff?
• Process– Are correct procedures being followed by staff?– Is the machinery running correctly?
• Product– What is causing product faults?
AIB International
Troubleshooting Bread Products
AIB International
Troubleshooting Bread Products
AIB International
Troubleshooting Bread Products
Troubleshooting Ingredients
• Know and understand the ingredients
• Poor ingredients will give you a poor product even if all other steps are followed correctly
• The correct ingredients are the foundation to baking!
AIB International
Troubleshooting Bread Products
Troubleshooting Ingredients
• Quality factors in supplier network
– Quality of ingredients depend on supplier
– Supplier process affects ingredient quality
AIB International
Troubleshooting Bread Products
Troubleshooting Ingredients
• Quality factors in supplier network
– Establish clear ingredient specifications
– Have a good working relationship with supplier
– Price not only consideration, also value service from supplier
AIB International
Troubleshooting Bread Products
Troubleshooting Ingredients
• Quality factors in distribution channels
– Storage temperature important for ingredients
– Once received, use proper rotation
• Use FIFO stock rotation
AIB International
Troubleshooting Bread Products
Troubleshooting Ingredients
• Quality changes over time
– Ingredients can change in storage as they age
– Ingredients can change each crop year
AIB International
Troubleshooting Bread Products
AIB International
Troubleshooting Bread Products
Troubleshooting the Process
Quality Factors in Production
• Define standards
• Monitor variations
• Give feedback
• Monitor results
AIB International
Troubleshooting Bread Products
Troubleshooting the Process
Production Standards
• Mixing times, temperatures, water absorption
• Accuracy of ingredient scaling
• Cleanliness
• Fermentation times, temperatures, pH, TTA
• Equipment maintenance
• Equipment adjustments
• Proofing and baking times, temperatures, relative humidity
AIB International
Troubleshooting Bread Products
Troubleshooting the Process
Production Variables
• People/human errors
• Ingredient variations
• Mechanical failure/ malfunction
• Atmospheric variation
• Pan variation
• Differences in judgment
AIB International
Troubleshooting Bread Products
Troubleshooting Tools
AIB International
Troubleshooting Bread Products
Troubleshooting Tools:
• Calibrated thermometer
• Oven temperature logger
• Hygrometer
• pH meter and buret for TTA
• Process or line audit checklist
AIB International
Troubleshooting Bread Products
Calibrated Thermometer
• Sponge set and return temperature
• Dough temperature out of the mixer
• Pan return temperature
• Dough temperature out of proofer
– < 95°F (35°C)
• Internal temperature of product out of oven
– > 200°F (93°C)
AIB International
Troubleshooting Bread Products
Oven Temperature Logger
• Use of recording thermometers (oven-rated)
– Check side to side variations
– Check temperature at each level or zone
– Used to monitor internal temperature of dough
– Check temperatures over time
– Such as M.O.L.E. or Scorpion
AIB International
Troubleshooting Bread Products
Temperature Profile of Oven
AIB International
Troubleshooting Bread Products
Hygrometer
• Two thermometers
– Dry bulb
• An ordinary thermometer
– Wet bulb
• Thermometer with a wick on it
AIB International
Troubleshooting Bread Products
pH Meter
• Check pH and TTA
– Fermentation
– Proofed dough
– Finished product
AIB International
Troubleshooting Bread Products
Process or Line Audit Checklist
• Record of:
– Times
– Temperatures
– Equipment settings
– Relative humidity
– Scaling weights
AIB International
Troubleshooting Bread Products
AIB International
Troubleshooting Bread Products
Troubleshooting a Fault (Product)
AIB International
Troubleshooting Bread Products
Evaluating Product
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Troubleshooting Bread Products
Score Sheet
AIB International
Troubleshooting Bread Products
External Characteristics
• Volume: too big or too small
• Crust color: too dark or too light
• Symmetry: uneven or even
• Evenness of bake: light or dark spots?
• Break and shred: bursting, wild
• Character of crust: tough or brittle
AIB International
Troubleshooting Bread Products
Objective Tool—Volume Meter
• Objective measure of finished product volume
AIB International
Troubleshooting Bread Products
Internal Characteristics
• Grain: appearance of cell structure
• Texture: feel of surface of slice
• Color of crumb: color of open slice
• Slicing: ragged or thick/thin?
• Aroma: off aroma or yeasty?
• Taste: off flavors
• Mouth feel: dryness or gumminess
AIB International
Troubleshooting Bread Products
Conducting a Bake Test
• Variables to consider testing:
– Mixing series
– Absorption series
– Fermentation series
AIB International
Troubleshooting Bread Products
Conducting Bake Test
• Mix Time Series
Under mixed- 2 minutes6 minutes
Control 8 minutes
Over mixed+ 2 minutes10 minutes
AIB International
Troubleshooting Bread Products
Wheat Bread Mixing Series
AIB International
Troubleshooting Bread Products
Conducting Bake Test
• Absorption Series
Under absorbed- 2% water
58%
Control 60%
Over absorbed+2% water
62%
AIB International
Troubleshooting Bread Products
Absorption Series
AIB International
Troubleshooting Bread Products
Wheat Bread Absorption Series
AIB International
Troubleshooting Bread Products
Conducting Bake Test
• Fermentation Series
Lessfermentation
3 hours
Control 4 hours
Morefermentation
5 hours
AIB International
Troubleshooting Bread Products
Wheat Bread Fermentation Series
AIB International
Troubleshooting Bread Products
Conducting Bake Test • Combinations of variables (9-point bake)
Mix time
Absorption
Control
+ 2%
- 2%
Control- 2 minutes + 2 minutes
AIB International
Troubleshooting Bread Products
Conducting Bake Test
• Combinations of variables (5-point bake)
Mix time
Absorption
Control
+ 2%
- 2%
Control- 2 minutes + 2 minutes
AIB International
Troubleshooting Bread Products
Conducting Bake Test
• Combinations of variables (3-point bake)
Mix time
Absorption
Control
+ 2%
- 2%
Control- 2 minutes + 2 minutes
AIB International
Troubleshooting Bread Products
Top 5 Troubleshooting Faults
• Mold or poor shelf-life
• Rounded corners/rough, ragged break and shred/open crumb structure
• Poor flavor
• Unattractive crust (spots and blotchiness)
• Grain (too open or too closed)
AIB International
Troubleshooting Bread Products
Thank You!!
Questions?????