Hellen Kinyua

 PROCESS CONCURRENCE: Department Name Designation Signature: Date: VERSION TRACKING: Version No: Version Date: Requested by: Approved by: Description of change: TABLE OF CONTENTS 1OVERVIEW OF FRESH PROCESSES5 2PRODUCTION INGREDIENTS REQUISITION PROCEDURES1 2.1Table 1 Production ingredients requisitions process flow1 2.2Ingredients requisition process controls2 3INTERDEPARTMENTAL TRANSFERS FOR STORE INGREDIENTS REQUISITIONS3 3.1Interdepartmental transfer process flow4 3.2Process controls5 4MILK ATM AND WATER DISPENSER UNIT PURCHASES AND STOCK TAKE6 4.1Process controls7 5BUTCHERY PRODUCTION AND STOCK TAKE10 5.1Process controls13 5.2Butchery SOP templates16 5.3Butchery cleaning procedure20 5.4Master cleaning schedule.22 5.4.1Equipment25 5.4.2Personal hygiene28 5.4.3Butchery equipment maintenance policy guide29 5.4.4Wastage SOP33 6CPU PRODUCTION AND STOCK TAKE35 6.1Process controls37 6.1.1Product reprocess guide38 Table 12 Product reprocess guide38 6.1.2Ingredients requisition39 Table 13 Ingredients requisition39 6.1.3Quality41 Table 14 Quality41 6.1.4Production42 Table 15 Production42 6.2Master cleaning schedule44 6.2.1Hygiene44 6.2.2Personal hygiene46 Table 17 Personal hygiene46 6.2.3Bakery weekly cleaning checklist.50 7Bakery Production and Stock Take51 7.1Processes controls53 7.1.1Stocktake53 7.1.2Development of production plans54 7.1.3Product reprocess guide55 7.1.4Ingredients requisition56 7.2Bakery SOP worksheets57 8DELI PRODUCTION AND STOCK TAKE GUIDELINES61 8.1Process controls64 Table 24 Process controls64 8.2Master cleaning schedule.72 8.2.1Deli hygiene72 8.2.2Equipment77 8.2.3Personal hygiene.80 Table 2 Ingredients requisition process controls2 Table 3 Interdepartmental transfer process flow4 Table 4 Interdepartmental transfer process controls5 Table 5 Milk ATM and water dispenser process controls.7 Table 6 Butcher Processes and Procedure Chart Flow12 Table 7 Butcher’s process controls.13 Table 8 Master cleaning schedule22 Table 9 Equipment25 Table 11 CPU process controls37 Table 16 Hygine44 Table 18 Bakery production and processes chart flow52 Table 19 Stock take53 Table 20 Development of production plans54 Table 21 Product reprocess guide55 Table 22 Ingredients requisition56 Table 23 Deli Production and processes chart flow63 Table 25 Deli cleaning process75 Table 26 Equipment78 1 OVERVIEW OF FRESH PROCESSES FRESH PROCESSES PROCESS OVERVIEW PROCESS OWNER Production ingredients requisitions process Involves the head of fresh departments developing production plan that has ingredients used of the production that will guide them on what they have to produce daily/weekly Head of fresh departments Branch manager Section team leaders Section managers Interdepartmental Transfers for Store Ingredients Requisitions This procedures shall be used when making production ingredients requisitions by the fresh team (bakery, butchery and deli) from the shop floor. Baker/Butcher/Chef Section assistants Branch Manager/ Administrator Milk ATM and water dispenser unit purchases and stock take This shows the procedures and process flow chart for Milk/Water section Supplies receiving, dispensing and stock take in fresh department form the fresh store Head of fresh departments Milk Attendant. Branch manager Butchery Production and Stock Take This is a process flow chart for Butchery Supplies receiving, production and stock take in fresh department for the fresh store. Head of fresh departments Butchery CPU production and stock take. This is a process flow chart for Bakery Supplies receiving, production and stock take in fresh department for the fresh store. Gives the daily guideline on the operations within the CPU department. Head of fresh departments CPU Bakery production and stock take. This is a process flow chart for Bakery Supplies receiving, production and stock take in fresh department for the fresh store. Gives the daily guideline on the operations within the bakery department. Baker Baker assistant Admin. Branch manager Deli production and stock take. This is a process flow chart for Deli for receiving, production and stock take in fresh department for the fresh store. Gives the daily guideline on the operations within the deli department Deli assistant Team leader Branch manager Admin. 2 PRODUCTION INGREDIENTS REQUISITION PROCEDURES Process description Project objectives Process owner 1. Involves the head of fresh departments developing production plan that has ingredients used of the production that will guide them on what they have to produce daily/weekly. i. Develops production plans ii. Raise the internal ingredients requisition order iii. Generate ingredients received note Head of fresh departments Deli Butchery Bakery CPU 2.1 Table 1 Production ingredients requisitions process flow PROCESS PROCEDURES 1. Baker/chef/butcher: Develops production plans on Production plan Templates Production Plans are done weekly and are divided to individual Daily production plans Production Plans are assigned reference numbers. and queued for approval 2. Branch Manager/admin, reviews and amends with due consultation the queued plans and approves. 3. Baker/butcher/chef gets the approved production plans. 4. Production plans guide requisitions of ingredients from either IDT or fresh store. On approval of production plans, the baker/butcher/chef raises internal ingredients requisition Order from: Fresh Store within the outlet. 5. Internal Ingredients requisition Order is assigned a reference no. derived from production plan reference no. 6. The Ingredients requisition Order (IRO) is signed by manager/admin 7. Security team (omega and/or Jeff) use Ingredients requisition Order (IRO) to receive physical inventory from the fresh store. 8. Ingredients Received Note (IRN) is generated by back office clerk (BOC) and items should be adjusted by the back office deducting from fresh inventory stock. Double checkers sign and stamp. 9. Baker/ butcher/chef, to commence production. 2.2 Ingredients requisition process controls Table 2 Ingredients requisition process controls Process System Controls Manual Controls Process owners A Developing Production plans 1. Availability of production plan templates in the system for weekly and daily production 2. Production plans are assigned Reference numbers on approval in the system 3. If production plans are declined by Manager/admin the system cancels them off 4. Approval of production plans is done online by branch manager/ administrator 5. Digital signature applied to production plan on approval 6. Data base of approved production plans maintained in for future references and analysis 1. Approved production plans printed out for records Baker/Butcher/ Chef Section assistants Branch Manager/ Administrator B Ingredients requisitions 1. Approved Production plans derive the ingredients needed for production. 2. The baker/butcher/chef raises Internal ingredients requisition Order online to Fresh Store in the outlet 3. The Ingredients requisition order is assigned a reference number derived from production plan reference no 4. Ingredients Received Note is generated by baker/chef/butcher, based on actual inventory received. The received items are automatically deducted from fresh inventory database in the system. 1. The Ingredients requisition Order is printed out, signed by manager/admin 2. Double checkers use Ingredients requisition Order to receive physical inventory from the fresh store. Double checkers sign and stamp. 3. Ingredients Received Note is printed out and filed against the Respective Internal Requisition Order Baker, Butcher, Chef Sections assistants Branch manager or administrator Double checkers. Inventory controller. C Cost Recognition 1. Costs of production are guided by the shared recipes on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note Baker, Butcher, Chef Sections assistants Branch administrator 3 INTERDEPARTMENTAL TRANSFERS FOR STORE INGREDIENTS REQUISITIONS Process description Project objectives Process owner 1. This procedures shall be used when making production ingredients requisitions by the fresh team (bakery, butchery and deli) from the shop floor. i. This is a process where the department need to raise a document when the ingredients are not within the department ii. Update the inventory within the system. Head of fresh departments Deli Butchery Bakery CPU 3.1 Interdepartmental transfer process flow Table 3 Interdepartmental transfer process flow PROCESS PROCEDURES 1. Baker/chef/ on verifying that ingredient items required for production are not in the fresh store: Raise an Internal Transfer Requisition. The order is raised to the shop store otherwise referred to as an Inter-Departmental transfer. Internal transfer requests should be raised utmost, twice a week. 2. Internal transfer requisition is assigned a reference no. 3. The Internal transfer requisition is submitted to the management office and signed by manager/admin. 4. The outlet store supervisor and Double checkers use approved internal transfer requisition to receive physical inventory from the shop floor or store. Double checkers, store supervisor and baker/chef sign and stamp. 5. The physical inventory from inter-departmental transfers is received in the system to adjust the store inventory and move to the fresh inventory stock. 6. Internal Goods transferred note is generated by back office clerk online to record physical items received in the fresh inventory stock 7. Internal Goods transferred note is printed out by Back office clerk and filed under Inter- departmental transfer records. 3.2 Process controls Table 4 Interdepartmental transfer process controls Process System Controls Manual Controls Process owners A Inventory requisition 1. The database of items/ingredients to be considered for internal transfers from shop store to fresh store is maintained in the system. This limits items to be transferred to only those in the system database provided 2. Internal Transfer Requisitions (AKA IDTs) are raised online by outlet Baker or Chef 3. Internal transfer requests are should be raised at most, once a week. 4. Internal transfer requisition is assigned a reference no. 5. The Back office clerk posts actual physical inventory transferred from shop store to fresh store using the double- checked Internal transfer requisition note from store manager. He/she posts actual Inventory transferred in the fresh inventory database in the system 6. Internal Goods Transferred note is generated by back office clerk online to record physical items received in the fresh inventory database 1. The Internal Dept. Transfer booklet is used at this point, signed by manager/admin for approvals to proceed. 2. The outlet store supervisor and Double checkers use approved IDT to receive physical inventory from the shop floor or store. 3. Double checkers, store supervisor and baker/chef sign and stamp the IDT if all is ok. 4. Internal Goods Transferred note is printed out by Back office clerk and filed under Inter- departmental transfer records. Baker/Chef/Butcher Branch Manager/ Administrator Back office clerk Store supervisor Double checkers B Cost recognition 1. Items transferred from shop store to fresh store are posted at unit cost assigned in the POS; the document used is the IDT and Internal goods transfer note. 1. Items transferred from shop store to fresh store are posted at unit cost assigned in the POS; the document used is the IDT and Internal goods transfer note. Back-office clerk 4 MILK ATM AND WATER DISPENSER UNIT PURCHASES AND STOCK TAKE Process description Project objectives Process owner 1. This shows the procedures and process flow chart for Milk/Water section Supplies receiving, dispensing and stock take in fresh department form the fresh store. i. Stipulate the procedures and processes to be adhered to. ii. Documentation of the processes done Head of fresh departments Milk Attendant. 1. Receiving Batch Records. At the receiving point note the invoice quantity and quality, weighing is done to confirm the quantities. The section attendants confirm the quality at the receiving point. Kindly note the supplies should be delivered on daily basis. Physical tally to confirm the empty bottles received against GTN by receiving clerk 2. Stock take Records. Stock is weighed and recorded at the receiving by staff attendant At the close of business, weighing of closing stock is done and recorded. The tally and recording of empty bottles received, opening stock and closing stock is done daily. 3. Dispensing Sales Records. It’s tasked to the staff attendant at the sections to do a manual record at the sales point to be shared with the admin at the close of business. Records of sold empty bottles done and same shared by close of business as well. 4. Requisition Orders. Requisitions orders are raised on estimation of previous sales where a store is easier to estimate its quantities sale on a daily basis. Decision is reached by the Branch manager/Admin on the quantities to order for. Strict on timely orders to ensure smooth flow of operations at that point. 4.1 Process controls Table 5 Milk ATM and water dispenser process controls. Process System Controls Manual Controls Process owners A Receiving Milk Batches and Empty bottles. 1. The database of supplies received and Dc orders will be reflected at the receiving point once fed in the system. This limits manual records done at the receiving point to only those in the system database provided. 2. Projected requisition will be provided for by the system and Orders are raised online by outlet section attendant. 3. System will allow smooth flow of these orders done timely and should be raised on a daily basis to ensure quality is maintained i. The section attendant needs to be available at the receiving point together with the receiving clerk. The invoice quantity and quality, weighing is done to confirm the accuracy ii. The staff attendant confirms the quality at the receiving point to ensure that hygiene standards are ensured. iii. Kindly note the supplies should be delivered on daily basis to ensure quality and fresh ability. iv. Physical tally to confirm the empty bottles received against raised order and recorded. Milk/Water Attendant. BranchManager/ Administrator. Receiving clerk. Inventory Controller. Double checkers. B Stock take Records. 1. The attendant starts his day by counting the stock at the section that is, weighing and recording of Litres and empty bottles tally. Each of the products available at time of opening shall be recorded in the Stocktaking Worksheet. 2. Double checker/inventory will be present to confirm that stock taking has been accurately done. 3. The milk attendant will give the branch management team a duly filled Stocktaking Worksheet to generate the Stock Movement Worksheet 4. Previous day’s BDSR will be reconciled and deviations addressed at this point i. Stocked liters are weighed and recorded at the receiving as received supplies. ii. At the close of business weighing of closing stock is done and recorded. iii. The tally and recording of empty bottles received, opening stock and closing stock is done. Milk/Water Attendant. Inventory controller. Process System Controls Manual Controls Process owners C Dispensing Records. 1. For every dispensed liter’s sold the system keeps records at the POS sale point. 2. System is able to give total quantities sold hourly and/or daily i. For every dispensed litre’s the attendant needs to keep records. ii. It’s tasked to the staff attendant at these sections to do a manual record at the sales point to be shared with the admin at the close of business. iii. Records of sold empty bottles done and same shared by close of business. Milk/Water Attendant. D Cost recognition 1. All items within this section are received at cost via the system. 2. Items purchased or transferred from Dc to fresh store are posted at unit cost assigned in the POS i. Orders raised should capture the cost aspect, to ensure the same is reflected at the receiving point. Back-office clerk. MILK ATM AND WATER DISPENSER STOCKTAKE WORKSHEET The template records stocked litres are weighed and recorded at the receiving as received supplies, at the close of business weighing of closing stock is done and recorded. The tally and recording of empty bottles received, opening stock and closing stock is done and recorded using similar template different templates. TUSKER MATTRESSES LIMITED. MILK/WATER LITRES AND BOTTLES STOCKTAKE WORKSHEET. BRANCH……………………………………… DATE………………………………………….. Batch No. ITEM CODE ITEM DESCRIPTION OPENING STOCK. PURCHASES/DC ORDERS. CLOSING STOCK. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Completed By Reviewed ByApproved By ………………… ……………………………................ Milk/ Water AttendantAdministratorBranch Manager 5 BUTCHERY PRODUCTION AND STOCK TAKE Process description Project objectives Process owner 1. This is a process flow chart for Butchery Supplies receiving, production and stock take in fresh department for the fresh store. 2. Gives the daily guideline on the operations within the deli department. i. Stipulate the procedures and processes to be adhered to. ii. Documentation of the processes done iii. Proper maintenance of equipment, surface and personal hygiene. Head of fresh departments Butchery Butchery production procedure. 1. Butcher: Start his day by counting the opening stock, as guided by the Stock Taking Worksheet The Stock taking worksheet advises the need for additional production, conversion and purchase to add to the current stock. 2. Purchases are ordered in accordance with procurement processes in place. 3. Production and conversion should be guided by the Butchery Production plan. 4. In case some ingredients are to be requested from the Central Fresh Store, Requisition process is to be followed. Similarly, IDT processes are to be followed in case the ingredients are to be received from other sections within the outlet. Butchery supplies receiving procedures: 5. Receiving Clerk. Confirms weighted weight against documentation attached. Ensure transport certificate is valid and submit the same to Store Admin/Branch manager. Together with butcher assistant ensure the transport and handling hygiene is adhered to. 6. Butchery Assistant. Confirm quality, quantity and hygiene at receiving point. All carcass received needs to be weighed again on entry at the section. Usher the supplier meat handler to the butchery section. Storage and Stock take. 7. Once supplies are received they should be stored in the cold room/ chiller/ freezer (whichever is appropriate). 8. At the close of business, stock take worksheet is done and records are kept showing: Opening stocks, purchased stock and closing stock All other products in storage 9. Production sheet records freshly done cuts and convert products. Note: Stock Movement sheet is a tool for the inventory controller/store admin to feed the data in the system as extracted from the stock and production sheet. Table 6 Butcher Processes and Procedure Chart Flow PROCESS FLOW Documentation records to keep Start KEY: Process Decision Terminator Document 5.1 Process controls Table 7 Butcher’s process controls. Process System Controls Manual Controls Process owners A Stock taking. 1. The butcher starts his day by counting the stock at the section. Each of the products available at time of opening shall be recorded in the Stock Taking Worksheet. 2. Double checker/security team will be present to confirm that stock taking has been accurately done. 3. The butcher will give the Inventory Controller/store admin a duly filled Stock Taking Worksheet to generate the Stock Movement Worksheet 4. Previous day’s BDSR will be reconciled and deviations addressed at this point 1. Stock taking Worksheet 2. Stock movement worksheet to record previous day’s closing stock and current day’s opening stock Butcher Branch Manager/ Administrator B Production plans. 1. Each branch should have a unique Production plan guided by carcass quality, available ingredients and target sales 2. Availability of production plan templates in the system for daily production 3. Production plans are assigned Reference numbers on approval in the system 4. If production plans are declined by Manager/admin the system cancels them off 5. Approval of production plans is done online by branch manager/ administrator 6. Digital signature applied to production plan on approval 7. Data base of approved production plans maintained in for future references and analysis 1. Approved production plans printed out for records. Butcher Branch Manager/ Administrator Process System Controls Manual Controls Process owners C Ingredients requisitions from Fresh store. 1. Approved Production plans derive the ingredients needed for production. 2. The baker/butcher/chef raises Internal Ingredients Requisition Order online to Fresh Store in the outlet 3. The Ingredients Requisition Order is assigned a reference number derived from production plan reference no 4. Ingredients Received Note is generated by baker/chef/butcher, based on actual inventory received. The received items are automatically deducted from fresh inventory database in the system. 5. For smooth operations, Ingredient requisition should be based on projected weekly production plans 1. The Ingredients requisition Order is printed out, signed by manager/admin. 2. Double checkers use Ingredients requisition Order to receive physical inventory from the fresh store. Double checkers sign and stamp. 3. Ingredients Received Note is printed out and filed against the RespectiveInternal Requisition Order Butcher Branch manager or administrator Double checkers D Direct supplies purchase. 1. Based on the production plan, identify the quantity to be ordered, keeping in mind not to overstock or under stock 2. The butcher raises a requisition, which is approved by the branch admin/ manager. 3. The approved requisition is taken to back office where procurement procedures are followed as stipulated by the branch. 4. The butcher follows up with the supplier on the order placed. 5. For smooth operations, Direct supplies should be based on projected daily production plans 1. Approval of requisition note 2. Purchasing procedures adhered Butcher Branch administrator Branch manager Process System Controls Manual Controls Process owners E Receiving and Storage. 1. All meat products (including ingredients) will be assigned a batch number on entry at the butchery section. 2. Beef carcass and goat/ lamb shall be hung in the cold room/ chillers where temperature will be maintained at range of 5ºC or lower, with daily monitoring and documentation 3. Poultry/ fish products will be packaged immediately and labelled, and stored separately in freezers and temperature maintained at -18ºC or lower, with daily monitoring and documentation. 4. Meat product such as meat balls, marinated meats and biltong’s will be stored separately from raw meats, either in separate coolers/freezers/rooms, or on physically separate racks/shelves. 5. No products meant for the cold rooms will be stored on the floor. 6. Non meat products should not be put inside the cold room. 1. Temperature monitoring checklists. Butcher Branch administrator Branch manager F Cost recognition. 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note. Butcher Branch administrator 5.2 Butchery SOP templates BUTCHERY STOCKTAKE WORKSHEET The Stock taking Worksheet records stock movement trends to record previous day’s closing stock and current day’s opening stock verses the wastage produced TUSKER MATTRESSES LIMITED. BUTCHERY STOCK TAKE WORKSHEET SAMPLE/FORMAT BRANCH……………………………………… DATE………………………………………….. Item code Item description Stock (Physical count) Waste (if any) Completed By.Reviewed By.Approved By. ……………………… …………………… …………………… Butchery Attendant.AdministratorBranch Manager BUTCHERY PRODUCTION PLAN. The template registers each branch unique Production plan guided by carcass quality, available ingredients and target sales, available production plan acts/are assigned as reference numbers and should be printed and filled for daily basis guide. TUSKER MATTRESSES LIMITED. BUTCHERY PRODUCTION PLAN. BRANCH……………………………………… DATE………………………………………….. BEEF MAIN PRODUCTS Mon Tue Wed Thu Fri Sat Sun BEEF SECONDARY PRODUCTS BEEF ORGANS Completed By. Reviewed By. Approved By. ……………………………………………….. ……………………….. Butchery Attendant. Administrator Branch Manager BUTCHERY PRODUCTION WORKSHEET This template, has recording of all the days’ production. Once a particular cut from the carcass is produced, weighed and then recorded on this template. The essence of this template is to be able to see what has been produced on a daily basis, and compare it against wastage. This helps to know whether we are over producing or under producing. Before starting the day’s production the team leader has to look at this template, to guide him or her in the day’s production. TUSKER MATTRESSES LIMITED. BUTCHERY PRODUCTION WORKSHEET. BRANCH……………………………………… DATE………………………………………….. RAW MATERIAL (INPUT) OUTPUT Item code Item description Qty Item code Item description Qty Completed By.Reviewed By.Approved By. ………………… ………………… …………………… Butchery Attendant.AdministratorBranch Manager BUTCHERY PRODUCTION WORKSHEET. This template details the above template as per brief recordings stated, more for better accountability. TUSKER MATTRESSES LIMITED. BRANCH……………………………………… DATE………………………………………….. Item code Item description Opening stock Purchase/ transfer in Production Sales / Transfer out Conversion Waste Closing stock Physical count Variance Completed By. Reviewed By. Approved By. ……………………… ……………………….. …………………….. Butchery Attendant. Administrator Branch Manager 5.3 Butchery cleaning procedure Process description Project objectives Process owner To document and effect programs  for cleaning and sanitizing food contact surfaces and  critical non‐food contact surfaces 1. To ensure compliance to the hygiene standards in the food selling and production location is maintained. 2. To provide and maintain good confidence of customers by ensuring provision of quality meat that is fit for consumption. 3. To ensure compliance to local authority requirements Branch Manager Butchery Attendants Control Documents:   Master Cleaning Schedule  SSOPs Routine Cleaning checklist and verification checklist  General Cleaning Guide 1. All detergents, sanitizers and disinfectants are used according to label directions, including those for use on food contact surfaces, and are applied so that contamination of nearby meat and meat products is prevented. 2. Cutting knives, mincer knives, bone saws and other cutting equipment that contacts meat and meat products are cleaned and sanitized on a scheduled basis as outlined in the Master Cleaning Schedule. 3. Sanitation Standard Operating Procedures developed outline and document the cleaning procedures, equipment and chemicals used for items and areas listed in the Master Cleaning Schedule.  4. The Master Cleaning Schedule lists items and areas to be cleaned and/or sanitized, how cleaning is to be done and by whom. 5. Cleaning shall be carried out as scheduled in the Master Cleaning Schedule. 6. Storage of all cleaning materials and detergents shall be provided and shall be under lock and key. 7. All loose debris, soils and dust must be removed prior to the use of any water. 8. Since the drainage system is, essentially, designed for the purpose of removing liquids, debris and meat particles should NOT be swept on top of drain covers for collection. Floors should be designed to fall towards the drains and therefore it is sensible that dirt and debris should be swept downwards but only to a point near the drain cover for their collection and removal. 9. All drains containing solid traps must be lifted and any filter type container be removed for emptying. When cleaned they should be replaced and the procedure be repeated again after the washing of the premises and before application of sterilants. 10. All accessible walls, pipes, ledges and static fixtures (excluding any electrical, electronic devices or other items which are sensitive to such procedures) should be thoroughly wetted with water, hot water when available. 11. All detergents, sterilants and soaps must be held in a secure place in order to comply with the basic requirements of good hygienic practice. 12. A full inspection, using the standard checklist should be made after the completion of cleaning by an authorized member of staff who should also sign. 13. Any breakages, or damage to equipment, machinery, the fabric or decor of the building should be noted and reported in writing. 14. Only those detergents, sanitizers, sterilises and soaps approved by Tuskys and listed in the schedule to the programme should be used or held on the site. 15. All persons who use any chemical cleaning agent must take all reasonable precautions to protect themselves, and others, from any risks that may be applicable from the use of those cleaning agents. 16. Cleaning, as with other tasks, does require some training for the work to be done properly and formal training should be undertaken. 5.4 Master cleaning schedule. Table 8 Master cleaning schedule Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Floors Daily Butchery attendant Suma Extend D3 Hard Broom Floor Mop Bucket Squeegee Rubber Gloves 1. Prepare mopping solution (1ltTiket in 20lt of hot water) 2. Apply solution using floor mop 3. Scrub the floor with a hard broom 4. Rinse with clean water 5. Squeeze excess water and allow to air dry. Surface – Food Contact Daily Butchery attendant Suma Bac Conc D10 Spray bottle Sponge cloth Scourer None required During Processing 1. Fill up the bottle with water. Insert bottle in the Diver mite dispenser and push once (10 ml / 750 ml). 2. Remove any excess soil from the surface. 3. Spray onto surface to be cleaned. 4. Leave for 5 minutes and wipe surface clean. 5. Rinse food contact surfaces thoroughly with clean water and allow to air dry. End of Shift Use at a concentration of 4 pushes (60 ml) in 6L of hand hot water 1. Remove excess soil from surface 2. Apply solution with cloth or brush 3. Clean via washing thoroughly the food contact surfaces and the non-food contact surfaces. 4. Brush in between the spaces where the cloth cannot reach. 5. Leave for 2 to 5 minutes and wipe surface clean 6. Rinse food contact surfaces thoroughly with clean water and allow to air dry. Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Fridges Weekly Butchery attendant Suma Bac Conc D10 Spray bottle Sponge cloth Scourer None required 1. Remove all food to another refrigerator 2. Switch off the fridge. 3. Remove all movable parts of the fridge into water sink 4. Scrub the surfaces and other movable parts with Scourer soaked in 5. Suma Bac D10 solution 6. Rinse with clean water 7. Allow contact for 5 minutes 8. Rinse and allow to air dry Bins Daily Butchery attendant Nobla Multiclean Suma Sol D4.8 Scourer Bucket None required 1. Pre-clean 2. Scrub the bin thoroughly with Scourer soaked in Nobla Multiclean solution inside and outside -Rinse with clean hot water 3. Sanitize with Suma Sol solution (5gms in 1lt of water) 4. Allow to air dry and insert polythene paper ready for use Walls Weekly Butchery attendant Suma Extend D3 Scourer Sponge cloth Rubber Gloves 1. Scrub the walls with Scourer soaked in Suma Extend D3 solution starting from the top coming downwards 2. Rinse with clean water 3. Wipe off the water with clean cloth to dry. Windows/ Extern al Glass Display units Weekly Butchery attendant Sanctify glass Cleaner Scourer Sponge cloth None required 1. Spray a small quantity onto a soft, lint-free cloth/paper towel and wipe the surface clean. Buff with a dry cloth/paper towel for extra shine. Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Ceiling Monthly Butchery attendant Suma Extend D3/Nobla Multi-clean Mop Bucket Soft Broom Gloves Eye Goggles Quadripod stand The attendant to use the stand to reach the ceiling. Clean 1. Apply Suma Extend D3 or Nobla Multiclean solution using the floor mop. 2. Scrub the ceiling using the broom 3. Rinse with clean water 4. Air dry. Drains Daily Butchery attendant Suma Extend D3 Bucket Hand Brush Gloves 1. Lift the drain cover and turn over 2. Scrub the cover and drain channel with brush dipped in Tiket 3. solution (D 3 Ratio.1lt in 10lts of hot water) 4. Rinse the cover and drain channel with clean hot water 5. Replace the cover. Cold rooms Monthly Butchery attendant Suma Bac D10 Scourer Hard broom Squeegee Bucket None required 1. Switch off the fan 2. Transfer all food to another cold room 3. Scrub with Scourer soaked in Suma Bac D10 solution starting from top coming downwards 4. Scrub the floor using the hard broom 5. Rinse with clean water 6. Sanitize the shelves and handle with Sponge cloth soaked in Suma solution 7. Wipe with clean cloth and leave to air dry 5.4.1 Equipment Table 9 Equipment Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Trolleys/ Trays Weekly Butchery attendant Nobla Multiclean Suma Conc D10 Scourer Whitex clot Bucket None required 1. Scrub the top and underside surface of the trolley with Scourer soaked in Nobla Multiclean solution 2. Rinse with clean water 3. Sanitize using Suma Conc D10 in a spray bottle 4. Wipe with a Sponge cloth after 3 minutes and allow to air dry Meat slicing machine/ cheese slicing Daily Kitchen steward Suma Conc D10 D10 spray bottle D10 Bucket Metal gloves for using on sharp objects 1. Wipe off any large particle. (Optional you can also use a gentle scrub pad on a cleaning wad to wipe off either side of the blade as the slicer is in motion 2. Make sure your thickness setting is at zero. Most manufacturer will not allow you to disassemble your machine unless this is set at zero. 3. Make sure the slicer is unplugged and switched off 4. Make sure the gauge plate is in fully closed position and the sharpening stone is out of the way 5. Remove product tray, slice deflector and centre plate 6. Wash, rinse and sanitise removed items using Suma Conc D10 and let them air dry 7. If you have a blade removal tool, carefully remove the blade, if you leave the blade in place, be thorough when you clean it 8. Use the Suma Bac D10 solution of 60ml into 6lts and hot water incorporate it with D10 sprayer 9. Clean front and back side of the blade with the water solution or degreaser spray, wiping from centre to outwards 10. Clean the centre of the slicer and behind the blade 11. Wipe down the exterior and all the remaining parts of the slicer 12. Rinse with hot water using a clean towel 13. Lubricate the slide rods using a food grade spray lubricant 14. Once the slicer is dry, replace the blade, face plate and product tray. ROUTINE CLEANING CHECKLIST BRANCH……………………………….. WEEK STARTING………………………………DATE………………………………… PLACE / ITEM CLEANED CLEANING AGENTS PROTECTIVE EQUIPMENT FREQ CLEANED BY CONFIRMED SIGN MON TUE WED THU FRI SAT SUN Floors Nobla Multiclean Rubber Gloves After emptying Work Surface – Food Contact Suma Bac Conc D10 None required After each usage Bone saw, mincer Suma Bac D10 None required After each usage Chopping boards Suma Bac D10 None required After each usage Utensils, knives Suma Bac D10 None required After each usage Trolleys/ Trays Nobla Multiclean &Suma Conc D10 None required DAILY Chiller Display units Suma Conc D10 (Inside) & Sactif glass Cleaner (Outside) None required DAILY Cleaning equipment Nobla Multiclean None required DAILY Drains Suma Extend D3 Gloves DAILY Bins and buckets Nobla Multiclean None required DAILY Freezers Suma Bac Conc D10 None required WEEKLY Walls Nobla Multiclean Rubber Gloves WEEKLY Cold rooms Suma Bac D10 None required WEEKLY Ceiling Nobla Multiclean Gloves Eye Goggles WEEKLY BRANCH MANAGER COMMENTS (Tick Applicable): Cleaned properly, Not cleaned properly, Not cleaned at all, Training on cleaning required SIGNATURE……………………………………… DATE…………………………………….. 5.4.2 Personal hygiene Objective To effect personal hygiene amongst staff in the butchery section Tuskys Personal Hygiene Guidelines 1. The requirements for personal hygiene shall be documented, adequately communicated to all personnel and enforced at all time. 2. Watches shall not be worn. 3. Jewellery shall not be worn, with the exception of a plain wedding ring. In the event of such exception, the ring shall be completely covered 4. Rings and studs in exposed parts of the body, such as ears, nose, tongues and eyebrows, shall not be worn. 5. Fingernails shall be kept short, clean and unvarnished. False fingernails shall not be permitted. 6. Excessive perfume or aftershave shall not be worn. 7. Hand cleaning shall be performed on entry to the production areas and at a frequency that is appropriate to minimize the risk of product contamination. 8. Any staff in direct contact with meat and/ or meat products should be in possession of valid health certificate from a recognized government facility. 9. All cuts, open wounds or lesions on exposed skin shall be covered by an appropriately colored bandage that is different from the product color (preferably blue). These shall be company issued and monitored. Where appropriate, in addition to the plaster, a glove shall be worn. 10. Processes and written instructions for staff shall be in place to control the use and storage of personal medicines, so as to minimize the risk of product contamination. Medical Screening 1. The company shall have a procedure which enables notification by employees, including temporary employees, of any relevant infection, disease or condition with which they may have been in contact or be suffering from. There shall be documented procedures for employees, contractors and visitors, relating to action to be taken where they may be suffering from or have been in contact with an infectious disease. Expert medical advice shall be sought where required. 5.4.3 Butchery equipment maintenance policy guide Objective The objective of this policy is to provide a clear guidance on equipment repair and maintenance. The goal of this SOP is prevention of microbial, chemical, and physical hazards from occurring as a result of improperly maintained equipment. Policy Statement It is the responsibility of branch management to ensure all equipment are working and in good condition. Branch management shall ensure full compliance of the laid down procedures. Control Measures: 1. Equipment used in processing (bone saws, meat mincers, and shrink wrapping machine) are maintained on a regular basis according to Equipment maintenance schedule to assure that they are in proper working order and does not contribute to product contamination. 2. Temperature probes, supporting hardware and software used to monitor temperatures in cold rooms, display chillers and chest freezers are maintained and calibrated on a regular basis according to the equipment maintenance schedule to assure that all equipment is in proper working order and does not contribute to product contamination. 3. Cleaning and maintenance checks are scheduled regularly on equipment used for processing and cooling, either at production areas, retail display unit or storage areas so that they function properly and do not contribute to contamination of butchery products. 4. Only food grade lubricants are used on food contact surfaces and machinery.   5. Equipment, tools and used parts are removed after servicing an area.  6. The butchery attendant shall always the following records are kept and updated: Equipment maintenance schedule Master calibration schedule Calibration records  Verification checklist Procedures for maintenance, calibration and repairs a) Repair and Maintenance procedure guide 1. The branch manager shall send via email details of the equipment requiring repair to the Repair & Maintenance Coordinator. 2. The Repair & Maintenance Coordinator shall review the problem reported to ascertain whether to engage a service provider and/ or internal repair team. b) Repair by Service Provide 1. Where service provider is to be involved: 2. A technician shall be sent to inspect and assess the problem. 3. The technician shall inspect the faulty equipment and provide technical report to the branch manager. 4. The branch manager shall then notify the Repair & Maintenance Coordinator about the findings. 5. The Repair & Maintenance Coordinator shall then prepare the LPO. 6. The Repair & Maintenance Coordinator shall obtain quotation from the service provider and forward the same to Senior Operations Manager for approval. 7. Upon obtaining approved LPO, the Repair & Maintenance Coordinator shall forward the same to the service provider. 8. The technician shall proceed with the repair of faulty equipment. 9. Upon completion of repair work and to the satisfaction of the branch manager, the technician shall raise a job card, detailing the nature of the problem and any parts fitted. 10. In case of parts delivered, the double checker verifies, signs and stamp on the delivery note. 11. The job card shall then be approved by the branch manager after confirming that the equipment is operating efficiently and in good condition. 12. The service provider shall then raise the invoice and attach job card and delivery note (in case of spare parts fitted). 13. Invoice shall be submitted to Head office for payment processing. c) Repair by Internal Team 1. Upon accessing the repair work to be done, the facility in charge instructs the internal repair team to visit the branch. 2. The repair representative appointed proceed to the branch and conduct inspection. 3. The repair representative provide the inspection report including spare parts required. The necessary spare part delivery note is raised and part updated in the bin card and/or register. PREVENTIVE EQUIPMENT MAINTAINANCE CHECKLIST BRANCH NAME_________________________________________________________ TYPE OF SYSTEM/COMPONENT INSPECTED  Heating  Electrical  Cooling  Plumbing  Mechanical  Air Conditioning  Other _________________________ Person making observation: _______________________________________________________ Date and Time of Observation: __________________________________________________ Location of Component: _________________________________________________________ ______________________________________________________________________________ Description of Component Inspected: _______________________________________________ ______________________________________________________________________________ Description of Defect or Issue: __________________________________________________ ______________________________________________________________________________ Recommended Corrective Action: __________________________________________________ Reviewed by (branch manager)…………………………Date……………………. Confirmed by (Tuskys repairs manager)…………………Date……………………. EQUIPMENT REPAIRS CHECKLIST BRANCH NAME_________________________________________________________ TYPE OF SYSTEM/COMPONENT INSPECTED  Heating  Electrical  Cooling  Plumbing  Mechanical  Air Conditioning  Other _________________________ Name and contact of person doing the repair: ________________________________________ Date and Time of repair: __________________________________________________ Name and contact of person who authorized the visit: _________________________________ Details of repair work Description of breakdown: _______________________________________________ ______________________________________________________________________________ Description of how breakdown was addressed: ______________________________________ ______________________________________________________________________________ Recommended follow-ups: __________________________________________________ ______________________________________________________________________________ Reviewed by (branch manager)…………………………Date……………………. Confirmed by (Tuskys repairs manager)…………………Date……………………. 5.4.4 Wastage SOP Summary The purpose of this policy is to provide guidance on how to treat products damaged in freezer or chiller. POLICY STATEMENT Branch management shall comply with the company laid down procedures and policies and non-compliances will not be tolerated. a) Timelines Freezer/Chiller breakdown MUST be reported to operation department immediately to plan for repair work. Damaged products shall not be held in the store for a period exceeding one week. All documentation and /or reporting for the purpose of insurance claim shall be completed within one week. b) Handling procedures for the Damaged Products Damaged products shall be segregated or separated from other good products for health reasons. Quantification of damaged products A list of damaged products shall be compiled. Damaged Products The template is very crucial for our HACCP Certification just like all the above, of which track records of supplies quality stating damages and detailed description on the same. TUSKER MATTRESSES LIMITED Branch………………………….. Date…………………………… Damaged Products Item Code Description Supplier Quantity PREPARED BY CHECKED BY APPROVED BY ………………… …………………. …………………… SECTION REP. SECTION HEAD/IC//ADMIN BRANCH MANAGER 1. Where damaged products are to be returned to supplier A Goods Return Note (GRN) shall be generated in time and communication to supplier copying Purchasing Manager. 2. Posting of Damaged Products not to be returned to supplier Posting in the system shall be done immediately and report generated for record and submission purpose. 3. Photos for damaged products shall be taken. 4. A Destruction Certificate shall be raised in the standard format as provided. All the necessary approval including confirmation by the contracted double checkers shall be obtained. 5. Disposal of Damaged Products After all documentation is done and confirmed. A contracted Garbage Disposal agent and/or local authority shall be engaged to dispose the damaged products. 6. Submission of documents to HO The following documents shall be submitted to HO within stipulated time. Duly completed Destruction Certificate. Photos taken for the Damaged Products. Freezer/Chiller technical report. Damages posting report (NAV system generated report) Approval Prepared by:Confirmed by: ...………................... .…………………………... Phylis Njunge.Josphat N. Gichure Head of FreshButchery Manager 6 CPU PRODUCTION AND STOCK TAKE Process description Project objectives Process owner a) This is a process flow chart for Bakery Supplies receiving, production and stock take in fresh department for the fresh store. b) Gives the daily guideline on the operations within the CPU department. i. Stipulate the procedures and processes to be adhered to. ii. Documentation of the processes done iii. Proper maintenance of equipment, surface and personal hygiene. Head of fresh departments CPU Central Bakery Production and Process Chart Flow 1. Baker: Start the day with a production plan, as guided by the Production targets and Templates Stocks status advises the need for additional supplies purchase to add to the current stock. 2. Direct purchases and DC orders are done in accordance with the processes in place. 3. Receiving point requires so many conforming platforms. Receiving Clerk. Confirm deliveries against the accompanying documentation. Bakery Assistant. Confirm quantities received. 4. Storage and Stock take. Once supplies are received should be stored as per storage instructions, the received items are recorded in stock worksheet as added stock for the records. Opening stocks, added stock and closing stock have provision to record. All other products in storage should be tallied and recorded 5. Production and usage sheet records production, ingredient usage and damages. 6. Ingredients Stock sheet is a tool for the inventory controller to feed the data as extracted from the stock and production sheet. Table 10 CPU Production and processes chart flow PROCESS FLOW Documentation records to keep Start KEY: Process DecisionTerminator Document 6.1 Process controls Table 11 CPU process controls Process System Controls Manual Controls Process owners A Stock taking. 1. The baker starts the day by counting the stock at the section. Each of the products available at time of opening shall be recorded in the products Stock sheet. 2. Double checker will be present to confirm that stock taking has been accurately done. 3. The baker will give the Inventory Controller a duly filled Stock Taking Worksheet 4. Previous day’s BDSR will be reconciled and deviations addressed at this point 5. Final product stock take 6. Ingredient stock take 1. Stock taking Worksheet 2. Product Stock worksheet to record previous day’s closing stock and current day’s opening stock Bakery staff Branch Manager/ Administrator B Stock management 1. The bread section representative will record all the ingredients used in the store section. 2. Cake representative will record all the ingredients use and the production yield cake section. 3. The product packaging and dispatch will take stock of all the finished products and the crates. These reports shall be presented to the admin or the manager Production and ingredients usage work sheet Finished products work sheet 1. Bread section 2. Cake section 3. Sliced products Manager/admin Fine bakery supervisor Bread section supervisor C Production planning and processes 1. The plan will be drawn by the admin or the manager based on the stocks availability and branch requests. 2. The production plan will have targets that should be achieved by the end of the day 3. The production is done following the formulations and methodologies. 4. All the production usage is recorded 1. Production plan worksheet 2. Formulation chart 3. Production and ingredients usage Manager /Admin 6.1.1 Product reprocess guide Table 12 Product reprocess guide Process System Controls Manual Controls Process owners A In line reprocess Damages product reprocess N/A 1. Products that doesn’t conform before baking can be reprocessed by addition of the missing ingredients 2. All the damaged products will be reprocessed into bread crumbs and bread crusts and recorded in the rejects provisions worksheet 3. The two items are recorded in the ingredients and production worksheet as new stock. Bakery assistants. 6.1.2 Ingredients requisition Table 13 Ingredients requisition Process System Controls Manual Controls Process owners Orders from warehouse Direct orders from the suppliers Warehouse 1. The bread section supervisor and the fine bakery supervisor raises Internal ingredients requisition and send to the back office to send request to the warehouse 2. Ware house generates GTN and the good are released 3. The goods are received in the system and put in storage Direct purchases 1. The Ingredients requisition order is sent to the purchasing department 2. The purchasing assistant raises an LPO 3. The LPO is sent to the supplier and CPU awaiting for the delivery of the goods 4. Ingredients Received Note is generated by the admin, based on actual inventory received. . Warehouse 1. The bread section supervisor and the fine bakery supervisor raises Ingredients requisition based on stock levels. 2. The requisition is approved by the manager/admin. 3. One staff is assigned to the DC to collect the goods and deliver to CPU 4. The staff presents the GTN to the double checker to confirm the goods received and stamp. 5. The CPU admin receives the items in the system and generate goods received Note Direct purchases 1. The supplier presents the Lpo and the invoice of the goods delivered. These two documents are checked and confirmed by both the double checker and admin or manager. The admin receives the goods in the system then the goods received note is generated Bread section supervisor Fine bakery section supervisor Branch manager /administrator Double checkers Receiving 1. The supplier is allowed in through the receiving section. 2. The supplier present the LPO, delivery note and or invoice of the goods ordered to the receiving clerk 3. The goods quantities, quality and delivery mode is confirmed in presence of the receiving clerk, supplier, Admin/manager or any other authorized CPU staff. 4. Once both parties are in agreement, the delivery note or the invoices is stamped and signed by the receiving clerk and admin/manager or authorized cpu staff 5. The goods are received in the system 1. LPO 2. Supplier invoices 3. Supplier delivery notes Receiving clerk Admin/ manager Branch orders and goods transfers 1. The branches send their orders to the CPU before 16:00HRS 2. Once received, all the orders are tabulated into a dispatch plan work sheet 3. The goods transfer note is generated 4. The work sheet is issued to the night shift for top up and distribution of goods to the respective branches 5. The goods are double checked on dispatch 6. The delivery truck must be accompanied with duplicate which is to be stamped after receiving the goods and returned to CPU 1. Dispatch plan work sheet 2. Goods transfer note 3. Crate movement work sheet Admin/manager CPU staff Double checker Returns 1. The returns from the branches must be accompanied by GRN and should in good condition. 2. The returns are recorded per branch of origin 1. Goods return note 2. Returns work sheet Double checker Cost recognition. 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note. Baker Branch administrator 6.1.3 Quality Table 14 Quality Areas of focus Requirement Control Responsibility Ingredients sourcing Only best quality ingredients should be purchased Testing The results should be better or a perfect much of what is in current use Quality control Transportation The mode of transport must protect the ingredients from possible contamination and adulteration Inspection The delivery vans must be covered and clean both in the inside and outside Receiving personnel Receiving All products received must conform to standards Checks Expiry dates Damages Quantitative checks like weights Receiving personnel Storage The store must be clean and well organized and labelled. Should have shelves for proper organization Ingredients are arranged neatly and should not be in contact with the floor Non-food ingredients like soap are kept separate The items are labelled Proper stock rotation must be enforced Bakery staff 6.1.4 Production Table 15 Production Areas of focus Requirement Control Responsibility Ingredients weighing All the ingredients MUST be weighed without any approximation The scales must be working and well calibrated. The amount of spent dough should be very minimal Actual checks if the scales are really used Mixing man Mixing Must be done appropriately till Start mixing at slow speed Adjust to high speed Observe the mixing direction The dough should not be over mixed or under mixed Mixer man Moulding The moulds must be done with dusting and long enough The mould should be smooth and touches the tin from end to end Bakery staff Proofing The proofer must be warm and humid The proofer should have steam (80RH%) and heat of (40 – 50OC ) The products must reach appropriate level to prevent under proofed and over proofed products Bakery staff Baking The products must be baked at appropriate conditions Preheat the oven to appropriate temperature. Inject appropriate steam Set the correct temperature and time Oven man Deppaning The breads are removed from the tins immediately after baking and arranged in cooling racks No breads should cool in the tins Production staff Cooling All the breads must cooled on the racks before slicing Breads that stays overnight on the racks must be covered Sales staff Slicing and wrapping Only slice and pack fully cold bread Check the seal dates Deformed breads Too tight and loose bread Sales staff Display Only good products are displayed in very clean and well lit displays. Observe planograms (all the products of the same kind are displayed together) Sales staff Display maintenance The display is refreshed after continuously to maintain the presentation All the products in the display must always be of good quality Sales staff 6.2 Master cleaning schedule 6.2.1 Hygiene Table 16 Hygine CLEANING AREA FREQUENCY/CLEANING TIME REQUIREMENTS RESPONSIBILITY FLOOR Mixing area Slicing area Proximity to the proofer and oven Storage area Sink area Clean as you go Clean as you go Clean as you go Clean as you go Clean as you go Mop stick and detergents, rubber gloves Brush and mops Mop stick and detergents, rubber gloves Mop stick and detergents, rubber gloves Mop stick and detergents, rubber gloves Mixer man User Oven man Mixer man Production team WALLS Behind the mixers Entire bakery wall Sinks Under the sink Daily after production Weekly during weekly cleaning After every use Every evening after work Scotch/super brite/detergent Scotch/super brite/detergent Scotch/super brite/detergent Mop stick and detergents Production team Bakery team Users Production team EQUIPMENT Tables (production and slicing ) Cake mixer Bread mixer Bread slicer Sales display Proofer surfaces and floor Oven surfaces, inspection glass and floor Oven inside walls, canopy, Trolleys Baking trays Bread tins Clean as you go Clean after every use Clean as you go After every use Every morning In the morning In the morning Weekly during general cleaning Weekly during general cleaning Weekly during general cleaning Weekly during general cleaning Scotch/super brite/detergent Scotch/super brite/detergent Scotch/super brite/detergent Hand brush Hand brush, glass cleaner, t/cloth Scotch/super brite/oven cleaner Scotch/superbrite/oven cleaner/rubber gloves Scotch/super brite/oven cleaner/rubber glove Scotch/super brite/oven cleaner/hot water Scotch/super brite/oven cleaner/hot water Scotch/super brite/oven cleaner/hot water Production team User Mixer man User Sales staff Oven man Oven man Production team Bakery staff Bakery staff Bakery staff SPECIALIZED CLEANING Oven and proofer top surfaces Electrical panels Inspection glass removal and cleaning Electrical trucking Ducts During service During service During service Bakery technician Bakery technician Bakery technician GENERAL CLEANING The entire bakery, walls, floor, equipment, Sales display, Once a Week Use all the appropriate cleaning material and ingredients, protective clothing and foot ware All the bakery staff 6.2.2 Personal hygiene Table 17 Personal hygiene The requirements for personal hygiene shall be documented, adequately communicated to all personnel and enforced at all time. 1. Watches shall not be worn. 2. Jewellery shall not be worn, with the exception of a plain wedding ring. 3. Make ups and strong perfumes are not allowed in the bakery. 4. Exposed parts of the body which can lead to direct contamination such as head, beards, hands must must be covered, 5. Fingernails shall be kept short, clean and unvarnished. Nail extensions shall not be allowed. 6. Hand cleaning shall be performed on entry to the production areas and at a frequency that is appropriate to minimize the risk of products contamination. 7. All cuts, open wounds or lesions on exposed skin shall be covered by an appropriately. 8. Processes and written instructions for staff shall be in place to control the use and storage of personal medicines, so as to minimize the risk of product contamination. 1. In the event where wedding rings worn, the ring shall be completely covered with a hand glove and must be checked for always to ensure that it is intact 2. The make ups must be washed off before entering production and service area 3. Wear protective clothing such as hair nets, masks and gloves 4. Regular checks of the figure nails. 5. Hand washing basins should be available in strategic points together with a soap dispenser and hand towels 6. the staff should not come into contact with the food materials until Medical screening 1. The company has procedure of regularly carrying out medical screening for all employees. Which enables notification by employees, including temporary employees, of any relevant infection, disease or condition with which they may have been in contact or be suffering from. 1. Any staff in direct contact with the bakery products should be in possession of valid health certificate from a recognized government facility. INGREDIENTS This template captures all ingredients utilisation as our recipes states hence guide records are done as facet to assure quality measures are achieved. INGREDIENTS B/ FLOUR W. M FLOUR S.P PUREE SUGAR MARGARINE FAT SALT YEAST V/GLUTEN BRAN M/ SEEDS BRAN YIELD DAMAGES GOOD 1 2 3 4 5 6 7 8 9 10 11 12 BAKERY PRODUCTS REPROCESS WORKSHEET. The template records rejected products tally at the end of production, packing and sorting processes, so as to keep track on their reproduction to output produced and record in batches as rejects tally. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTS REPROCESS WORKSHEET. BRANCH……………………………………… DATE………………………………………….. No.  REJECTED PRODUCTS QUANTIES REJECTED BREADCRUMBS (230954) BREADCRUSTS -. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Completed By.Reviewed By.Approved By. ………………………………………….………………….. Bakery Attendant.AdministratorBranch Manager BAKERY PRODUCTS AND INGREDIENTS STOCK TAKE WORKSHEET The template takes tally of both ingredients and final products on daily basis, this compliments the production worksheet. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTS AND INGRIDIENTS STOCKTAKE WORKSHEET. BRANCH……………………………………… DATE…………………………………………..  No. ITEM CODE ITEM DESCRIPTION OPENING STOCK. ADDED(ORDRES /IDTS) CLOSING STOCK. 1 2 3 4 5 Completed By.Reviewed By.Approved By. ………………………………………..………………….. Bakery Attendant.AdministratorBranch Manager APPROVAL Prepared by:Confirmed by: .…………………………....…………………………... Phylis NjungeSimon Gule Head of FreshBakery Manager 6.2.3 Bakery weekly cleaning checklist. CLEANING AREA MON TUE   WED   THU   FRI   SAT   SUN   GENERAL CLEANING   S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 S1 S2 DONE NOT DONE FLOOR Mixing area Slicing area oven/proofer area Storage area Sink area WALLS Behind the mixers Entire bakery wall Sinks Under the sink EQUIPMENT work tops/tables Cake mixer Bread mixer Bread slicer Sales display proofer/oven surface Oven inside walls, canopy, Trolleys, Tins and Trays GENERAL CLEANING The entire bakery, walls, floor, equipment, Sales display, (S1- shift 1, S2- shift) Every shift must tick to confirm that the working environment was left clean. This check list must be handed over to the second shift 7 Bakery Production and Stock Take Process description Project objectives Process owner a) This is a process flow chart for Bakery Supplies receiving, production and stock take in fresh department for the fresh store. b) Gives the daily guideline on the operations within the bakery department. i. Stipulate the procedures and processes to be adhered to. ii. Documentation of the processes done iii. Proper maintenance of equipment, surface and personal hygiene. Baker Baker assistant Branch manager Admin 1. Baker: Start the day with a production plan, as guided by the Production targets and Templates Stocks status advises the need for additional supplies purchase to add to the current stock. 2. IDTs and DC orders are done in accordance with the processes in place. 3. Receiving point requires so many conforming platforms. Receiving Clerk. Confirm deliveries against the accompanying documentation. Bakery Assistant. Confirm quantities received. 4. Storage and Stock take. Once supplies are received should be stored as per storage instructions, the received items are recorded in stock worksheet as added stock for the records. Opening stocks, added stock and closing stock have provision to record. All other products in storage should be tallied and recorded 5. Production and usage sheet records production, ingredient usage and damages. 6. Ingredients Stock sheet is a tool for the inventory controller to feed the data as extracted from the stock and production sheet Table 18 Bakery production and processes chart flow Process Flow Documentation records to keep Start KEY: ProcessDecision Terminator ocumentation 7.1 Processes controls 7.1.1 Stocktake Table 19 Stock take Process System Controls Manual Controls Process owners A Final product stock take Ingredient stock take 1. The baker starts the day by counting the stock at the section. Each of the products available at time of opening shall be recorded in the products Stock sheet. 2. Double checker will be present to confirm that stock taking has been accurately done. 3. The baker will give the Inventory Controller a duly filled Stock Taking Worksheet 4. Previous day’s BDSR will be reconciled and deviations addressed at this point 1. Stock taking Worksheet 2. Product Stock worksheet to record previous day’s closing stock and current day’s opening stock Bakery staff Manager/admin 7.1.2 Development of production plans Table 20 Development of production plans Process System Controls Manual Controls Process owners A Production planning 1. Production plan is guided by the stocks available. 2. Production plans are assigned Reference numbers on approval in the system 3. If production plans are declined by Manager/admin the system cancels them off 4. Approval of production plans is done online by branch manager/ administrator 5. Digital signature applied to production plan on approval 6. Data base of approved production plans maintained in for future references and analysis 1. The production plan will be drawn based on products stocks and guided by the production targets. 2. Products with zero stocks and low stocks will be prioritized 3. Production will be done in accordance with the laid down formulations and methodologies. 4. The production quantities and ingredient usage will be entered into the production and ingredient usage sheet, indicating the quantities produced in every batch. 5. The service team will then do the sorting and packaging and record the damages and the good products This is done for every batch 6. The production figures are fed in the system after every shift. 7. All the quantities produced must be feed in the system on that particular day. Bakery assistants Manager/ Admin 7.1.3 Product reprocess guide Table 21 Product reprocess guide Process System Controls Manual Controls Process owners A Inline reprocess Damages product reprocess N/A 1. Products that doesn’t conform before baking can be reprocessed by addition of the missing ingredients 2. All the damaged products will be reprocessed into bread crumbs and bread crusts and recorded in the rejects provisions worksheet 3. The two items are recorded in the ingredients and production worksheet as new stock. Bakery assistants. 7.1.4 Ingredients requisition Table 22 Ingredients requisition Process System Controls Manual Controls Process owners A Interdepartmental transfers Orders from warehouse Direct orders from the suppliers 1. Approved Production plans derive the ingredients needed for production. 2. The baker raises Internal ingredients requisition 3. The Ingredients requisition order is assigned a reference number derived from production plan reference no 4. Ingredients Received Note is generated by baker, based on actual inventory received. The received items are automatically deducted from fresh inventory database in the system. 1. The baker raises Ingredients requisition based on stock levels. 2. The requisition is approved by the manager/admin. 3. For IDT the baker will proceed to pick the items as stated in the requisition form. 4. The requisition form is handed to the back office where the ingredients are posted and a consumption worksheet generated. 5. The printed work sheet together with the IDT requisition is handed over to the omega for confirmation of the goods and cancelation by affixing the sticker. 6. Double checkers use Ingredients requisition Order to receive physical inventory from the fresh store. Double checkers sign and stamp 7. Ingredients Received Note is printed out and filed against the Respective Internal Requisition Order Baker, Branch manager/administrator Double checkers NOTE: As for QUALITY, PRODUCTION, HYGIENE, PERSONAL HYGIENE and CLEANING CHECK LIST are similar to CPU. 7.2 Bakery SOP worksheets BAKERY PRODUCTION AND INGRIDIENT USAGE – PROOFED PRODUCTS This template captures all ingredients utilisation for our bakery proofed products as our recipes states hence guide records are done as facet to assure good quality products measures are achieved. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTION AND INGRIDIENT USAGE – PROOFED PRODUCTS. BRANCH……………………………………… DATE…………………………………………..  No. ITEM DESCRIPTION CODE B/ FLOUR W/MEAL FAT SUGAR SALT YEAST IMPROVER YIELD DAMAGE GOOD QUALITY.  1 2 3 4 5 TOTAL USAGE Completed By. Reviewed By. Approved By. ……………………… ……………………. ………………….. Bakery Attendant. Administrator Branch Manager BAKERY PRODUCTION AND INGRIDIENT USAGE - PASTRIES. This template captures all ingredients utilisation for pastries products as our recipes states hence guide records are done as facet to assure quality measures are achieved. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTION AND INGRIDIENT USAGE - PASTRIES. BRANCH……………………………………… DATE…………………………………………..  No. ITEM DESCRIPTION CODE B/ FLOUR VANILA MIX CHOC MIX SUGAR OIL MARGARINE V/ESSENCE MILK EGGS TOTAL YIELD PRODUCED. DAMAGE GOOD QTY. 1 2 3 4 5 TOTAL USAGE BAKERY PRODUCTS REPROCESS WORKSHEET TEMPLATE. The template records rejected products tally at the end of production, packing and sorting processes, so as to keep track on their reproduction to output produced and record in batches as rejects tally. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTS REPROCESS WORKSHEET. BRANCH……………………………………… DATE………………………………………….. No.  REJECTS QUANTIES REJECTED BREADCRUMBS (230954) BREAD CRUSTS - BROWN BREAD 2 WHITE BREAD 3 BROWN BUNS 4 SCONES 5 GALLET BROWN 8 TEA SCONES 9 QUEEN CAKES 10 MUFFINS 11 MARBLE 12 BLOCK CAKES Completed By. Reviewed By. Approved By. ……………………… ……………………….. ………………….. Bakery Attendant. Administrator Branch Manager BAKERY PRODUCTS AND INGREDIENTS STOCK TAKE WORKSHEET The template takes tally of both ingredients and final products on daily basis, this compliments the production worksheet recording. TUSKER MATTRESSES LIMITED. BAKERY PRODUCTS AND INGRIDIENTS STOCKTAKE WORKSHEET. BRANCH……………………………………… DATE…………………………………………..  No. ITEM CODE ITEM DESCRIPTION OPENING STOCK. ADDED(ORDRES /IDTS) CLOSING STOCK. 1 2 3 4 5 6 7 Completed By. Reviewed By. Approved By. ……………………… ……………………….. …………………… Bakery Attendant. Administrator Branch Manager 8 DELI PRODUCTION AND STOCK TAKE GUIDELINES Process description Project objectives Process owner a) This is a process flow chart for Deli for receiving, production and stock take in fresh department for the fresh store. b) Gives the daily guideline on the operations within the deli department. i. Stipulate the procedures and processes to be adhered to. ii. Documentation of the processes done iii. Proper maintenance of equipment, surface and personal hygiene. Deli assistants Team leaders. Branch manager Admin 1. Chef Starts the day with a production plan, as guided by the Weekly Production plans and Templates It guides you to pre-plan for the next day production. Putting misen- plus in place this includes, marination of chicken, condiments preparation E.g. carrots, French beans, garlic etc. Production plans status advises the need for additional supplies purchase or shop transfer to add to the current stock 2. IDTs and Direct orders are done in accordance with the processes in place. 3. Deli Supplies receiving point requires both the receiving clerk and deli assistant present during receiving process. 4. Receiving Clerk. Confirm deliveries against the accompanying documentation. Deli Assistant. Confirm quality and quantities received. Storage and Stock take. 5. Once supplies are received they should be stored as per storage instructions, the received items are recorded in stock worksheet as added stock for their cords. Opening stocks, added stock and closing stock have provision to record. All other products in storage should be tallied and recorded. 6. Daily Production process is whereyield and any variance is recorded for accountability…Production yield, transfer for reprocess and wastage if any. 7. Transfer reprocess products-these are products which are produced in pieces and sold as budget packs and combos. Also records of products which can’t be counted such as reprocessed products and fit to be used the following day’s misen plus production is prepared Table 23 Deli Production and processes chart flow Process Flow Documentation records to keep Start KEY: ProcessDecision Terminator Document 8.1 Process controls Table 24 Process controls Process System Controls Manual Controls Process owners A Stock taking. 1. The chef starts the day by counting the stock at the section. Each of the products available at time of opening shall be recorded in the products Stock sheet. 2. Double checker will be present to confirm that stock taking has been accurately done. 3. The Chef will give the Inventory Controller/store admin a duly filled Stock Taking Worksheet. 4. Previous day’s BDSR will be reconciled and deviations addressed at this point 1. The Deli will take stocks of all the products and record in the Stock taking Worksheet 2. Stock worksheet to record previous day’s closing stock and current day’s opening stock. 3. stock take guides you on stock control and enables you to maintain the fifo rule first in first out and also enables you to know additional supply if any Chef Deli assistants Branch Manager/ Administrator B Production plans and Production processes 1. Availability of production plan templates in the system for weekly and daily production 2. Production plans are assigned Reference numbers on approval in the system 3. If production plans are declined by Manager/admin the system cancels them off 4. Approval of production plans is done online by branch manager/ administrator 5. Digital signature applied to production plan on approval 6. Data base of approved production plans maintained in for future references and analysis 1. The Deli will start the daily production guided by the production plan which should be done prior to cover a weeks’ time. 2. The production plan will be drawn based on branch menu and previous sales of menu products projections and set monthly targets. 3. Production plan guides you to plan for the next day production. 4. Putting misen- plus in place this includes, marination of chicken, condiments preparation e.g. carrots, French beans, garlic etc. 5. Follow production sequence, simply meal planning .starter – breakfast, main course and desert and priotise on urgency. 6. Adhere to assigned Menu scheduled recipe follow standard recipe to maintain consistency. 7. Production will be done in accordance with the laid down recipes and formulations procedures stipulated. 8. The production meal quantities and ingredient usage will be entered into the production and ingredient usage sheet, indicating the quantities produced in every batch. 9. The service team will then do pre-prep need for serving the meal and Plano the display with produced meals and advise on the additional flow sequence. 10. The production data shall be submitted and captured after every after every shift. 11. All the quantities produced, consumed and wasted must be feed in the system on that particular day. Chef Deli assistants Branch Manager/ Administrator C Product processes 1. All products produced and are to be used to give a combo or budget pack or reprocessed as ingredients to produce another meal as recipe outlined, should be recorded in the transfer to reprocess tab provisions worksheet. 2. Also the products that are fit for the following days misen-plus should be transferred and recorded. 3. The two items are recorded in the production yield, transfer. Chef Deli assistants. D Direct supplies purchase. 1. Based on the production plan, identify the quantity to be ordered, keeping in mind not to overstock or under stock 2. The butcher raises a requisition, which is approved by the branch admin/ manager. 3. The approved requisition is taken to back office where procurement procedures are followed as stipulated by the branch. 4. The butcher follows up with the supplier on the order placed. 5. For smooth operations, Direct supplies should be based on projected daily production plans 1. Approval of requisition note 2. Purchasing procedures adhered Chef Deli Assistants Branch administrator Branch manager E Receiving and Storage. 1. All meat products (including ingredients) will be assigned a batch number on entry at the butchery section. 2. Beef ,goat meat, lamb shall be stored in cold freezers and chillers where temperature will be maintained at range of 5ºC or lower, with daily monitoringand 3. documentation 4. No products meant for the cold rooms will be stored on the floor. 5. Non meat products should not be put inside the cold room. 1. Temperature monitoring and tare arrangements to avoid contamination and mishandling of the ingredients. 2. Meat product such as meat balls, marinated meats and biltong’s will be stored separately from raw meats, either in separate coolers/freezers/rooms, or on physically separate racks/shelves. 3. Poultry/ fish products will be packaged immediately and labelled, and stored separately in freezers and temperature maintained at -18ºC or lower, with daily monitoring and documentation. 4. Non meat products should not be put inside the chiller with meaty supplies. Chef Deli Assistants Branch administrator Branch manager F Ingredients requisitions (IDTs and supplies from DC) 1. Approved Production plans derive the ingredients needed for production. 2. The chef raises Internal ingredients requisition Order online to Fresh Store in the outlet 3. The Ingredients requisition order is assigned a reference number derived from production plan reference no 4. Ingredients Received Note is generated by chef, based on actual inventory received. The received items are automatically deducted from fresh inventory database in the system. 1. Order demand forecast;-order according to product demand and deli status to avoid overstocking. 2. Have production master planning schedule which will enable you to be equipped with the top selling product. 3. The Chef raises Ingredients requisition based on stock levels. 4. The requisition is approved by the manager/admin. 5. For IDT the Chef will proceed to pick the items as stated in the requisition form. 6. The requisition form is handed to the back office where the ingredients are posted and a consumption worksheet generated. 7. The printed work sheet together with the IDT requisition is handed over to the omega for confirmation of the goods and cancelation by affixing the sticker. 8. Double checkers use Ingredients requisition Order to receive physical inventory from the fresh store. Double checkers sign and stamp. 9. Ingredients Received Note is printed out and filed against the Respective Internal Requisition Order. Chef Deli assistants Branch Manager/administrator Double checkers G Cost recognition. 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note 1. Costs of production are guided by the shared recipes based on ingredients costs. 2. Production costs are recognized on actual ingredients used for production. This is guided by the actual ingredients received as posted in the system using ingredients received note. Chef Deli assistants Branch Manager/ administrator Deli production plan worksheet The weekly production, plan will help you plan for the week. This is an approximation what you will produce in the week. This will actually be done in sections, i.e. the cook on duty for starches, will have their own planning sheet. This will also help the team leader in purchasing or ordering for ingredients on time. TUSKER MATTRESSES LIMITED. DELI PRODUCTION PLAN WORKSHEET. BRANCH……………………………………… DATE………………………………………….. CODE DESCRIPTION MON TUE WED THUR FRI SAT SUN DELI CONSUMPTION STOCKSHEET TEMPLATE. The deli consumption stocktake template, is the template that will show the movement of all goods. It has been divided into two categories , that is of dry goods that includes items like the containers , soy sauce and the perishables this will include all the meats and vegetables. The Deli consumption worksheet objective is to track on the daily consumption of all deli products. All the goods purchased for the day should be recorded under added stock, at the close of business all items should be recorded under closing stock. In case of any damage of the any of the goods be it perishable or dry goods, it should be recorded under damaged, in cases where the supply is meant to return the product, note it down and communicate, when the product should be replaced, in order to have effective stock. TUSKER MATTRESSES LIMITED. DELI CONSUPMTION STOCKTAKE (EXPENSES, PURCHASES, IDT) WORKSHEET. BRANCH……………………………………… DATE………………………………………….. Dry goods EXPENSES DESCRIPTION OPENING STOCK ADDED STOCK DAMAGE /RETURNS CLOSING STOCK CONSUMPTION REMARKS 500ML CONT 1000PC 50 5   35 Perishable DESCRIPTION OPENING STOCK ADDED STOCK DAMAGE /RETURNS CLOSING STOCK CONSUMPTION REMARKS BEEF CUBES 10KG 5KG 2KG   13KG Completed By. Reviewed By. Approved By. ……………………… ……………………….. …………………… Deli Attendant. Administrator Branch Manager DELI PRODUCTION YIELD AND WASTAGE TEMPLATE. This template, has recording of all the days’ production. Once a particular item from the menu is produced, the sticker should be stuck on the book, and then recorded on this template. The essence of this template is to be able to see what has been produced on a daily basis, and compare it against wastage. This helps to know whether we are over producing or under producing. Before starting the day’s production the team leader has to look at this template, to guide him or her in the day’s production. TUSKER MATTRESSES LIMITED. DELI PRODUCTION YIELD, REPROCESS AND WASTAGE WORKSHEET. BRANCH……………………………………… DATE………………………………………….. PRODUCTION SHEET ITEM CODE DESCRIPTION PRODUCTION YIELD TRANSFER TO RE PROCCESS WASTAGE VARIANCE 370 Tuskys rice 10kg   800gms 572 Sausages 22pc 5pcs Completed By. Reviewed By. Approved By. ……………………… ……………………….. …………………… Deli Attendant. Administrator Branch Manager THE HOT DOG DELI STOCKTAKE TEMPLATE This is to track the daily movement of hotdogs. In this template the person in charge of doing hotdogs for the day is the one who is to record all necessary information. What has been added to the stock, all the damaged items should be recorded. The person handling the hotdogs is in charge of sodas whatever amount of soda that will be purchased from the IDT, should be recorded here. In case the sodas are used for the combos, the total amount of sodas, should be recorded under transfer. TUSKER MATTRESSES LIMITED. DELI HOTDOG STOCK TAKE WORKSHEET. BRANCH……………………………………… DATE………………………………………….. ITEM OPENING STOCK ADDED STOCK DAMAGE TRANSFER CLOSING STOCK HOTDOG ROLLS BOEREWORS TOMATOE SAUCE CHILLI SAUCE (ZESTA) MUSTARD MAYONNAISE. SODAS 8.2 Master cleaning schedule. 8.2.1 Deli hygiene All staff should practise ‘’CLEAN AS WE GO” policy. This is a cleaning strategy used to minimise risks to hygiene, health, and safety. The clean as you go method involves taking opportunities to clean continually throughout the working day and making cleaning part of your daily routine to ensure that surfaces, equipment, waste, and the premises are clean. Note: All the staff should always wash their hands before and after preparation of meals to avoid cross contamination. DELI CLEANING PROCESS. The Deli should be clean at all items. This includes all the working surfaces and the floors. PROCESS OWNERS All Deli staff Branch managers. CONTROL DOCUMENTS. Master Cleaning Schedule  SSOPs Routine Cleaning checklist and verification checklist  GENERAL CLEANING. This should be done on a weekly basis. The team leader should select a day, when less busy. CLEANING GUIDE. Daily, the following should be done in all stores. Wipe down the walls if necessary(has splashes) Sanitize the cleaning surfaces after finishing prepping of meals. Wipe the baine marie and the glasses of the display. Take out the trash and recycling Clean the interior and exterior of all the trash bins. Sweep and mop the floors. Taking out the trash frequently. The fridges or cold rooms should be arranged and wiped. The microwave should be wiped at the close of business. The gas cookers, should be cleaned at the close of business. All inserts should be cleaned and stored in back area at the close of business No dirty utensils should be left in the sink. The cling shrink wrapper should be wiped frequently after use. The weighing machine should always be wiped. Weekly: Dust and wipe down the light fixtures Wash behind and beneath all the operating equipment’s Scrub the gas cooker in order to remove soot. Wiping of coke fridge and re-arranging the sodas. Remove of the glass display and wipe it from the inside. Check the ceiling for cobwebs. Wash the walls thoroughly with soap. The Deli cleaning checklist is useful because it helps the team leader stay organized, delegate tasks to your team, and keep on top of important sanitation regulations. Table 25 Deli cleaning process Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Floors Daily Kitchen Steward Suma Extend D3 Hard Broom Floor Mop Bucket Squeegee Rubber Gloves 1) Prepare mopping solution (1ltTiket in 20lt of hot water) 2) Apply solution using floor mop 3) Scrub the floor with a hard broom 4) Rinse with clean water 5) Squeeze excess water and allow to air dry. Surface – Food Contact Daily Chef Suma Bac Conc D10 Spray bottle Sponge cloth Scourer None required During Processing 1) Fill up the bottle with water. Insert bottle in the Diver mite dispenser and push once (10 ml / 750 ml). 2) Remove any excess soil from the surface. 3) Spray onto surface to be cleaned. 4) Leave for 5 minutes and wipe surface clean. 5) Rinse food contact surfaces thoroughly with clean water and allow to air dry. End of Shift Use at a concentration of 4 pushes (60 ml) in 6L of hand hot water 1) Remove excess soil from surface 2) Apply solution with cloth or brush 3) Clean via washing thoroughly the food contact surfaces and the non-food contact surfaces. 4) Brush in between the spaces where the cloth cannot reach. 5) Leave for 2 to 5 minutes and wipe surface clean 6) Rinse food contact surfaces thoroughly with clean water and allow to air dry. Main ovens Daily Kitchen steward Suma Grill D9 Spray Gun Scourer Bucket Rubber Gloves Avoid high temp before apply the product. 1) Warm the oven / grill (70°C - 80°C maximum) before commencing cleaning. 2) Attach foaming sprayer to the Suma Grill D9 – 2-litre bottle 3) Beginning at 4) the top and working downwards, spray the neat product onto the surfaces to be cleaned 5) The product will cling to the surface as a foam. Leave for 10-30 minutes then scrape with a scouring pad to remove stubborn Residues. 6) Rinse well with water and a clean cloth. Allow to air dry. Fridges Weekly Kitchen steward & 2nd Chef Suma Bac Conc D10 Spray bottle Sponge cloth Scourer None required 1) Remove all food to another refrigerator 2) Switch off the fridge. 3) Remove all movable parts of the fridge into water sink 4) Scrub the surfaces and other movable parts with Scourer soaked in Suma Bac D10 solution 5) Allow contact for 5 minutes 6) Rinse and allow to air dry Bins Daily Kitchen steward & 2nd Chef Nobla Multiclean Suma Sol D4.8 Scourer Bucket None required 1) Pre-clean 2) Scrub the bin thoroughly with Scourer soaked in Nobla Multiclean solution inside and outside -Rinse with clean hot water 3) Sanitize with Suma Sol solution (5gms in 1lt of water) 4) Allow to air dry and insert polythene paper ready for use Walls Weekly Kitchen steward & 2nd Chef Suma Extend D3 Scourer Sponge cloth Rubber Gloves 1) Scrub the walls with Scourer soaked in Suma Extend D3 solution starting from the top coming downwards 2) Rinse with clean water 3) Wipe off the water with clean cloth to dry. Windows/ Extern al Glass Display units Weekly Kitchen steward Sanctify glass Cleaner Scourer Sponge cloth None required 1) Spray a small quantity onto a soft, lint-free cloth/paper towel and wipe the surface clean. Buff with a dry cloth/paper towel for extra shine. Ceiling Monthly Kitchen steward Suma Extend D3/Nobla Multiclean Mop Bucket Soft Broom Gloves Eye Goggles Quadripod stand 1) The attendant to use the stand to reach the ceiling. Clean 2) Apply Suma Extend D3 or Nobla Multiclean solution using the floor mop. 3) Scrub the ceiling using the broom 4) Rinse with clean water 5) Air dry. Drains Daily Kitchen steward Suma Extend D3 Bucket Hand Brush Gloves 1) Lift the drain cover and turn over 2) Scrub the cover and drain channel with brush dipped in Tiket 3) solution (D 3 Ratio.1lt in 10lts of hot water) 4) Rinse the cover and drain channel with clean hot water 5) Replace the cover. Cold rooms Monthly Kitchen Steward + Deli Staff. Suma Bac D10 Scourer Hard broom Squeegee Bucket None required 1) Switch off the fan 2) Transfer all food to another cold room 3) Scrub with Scourer soaked in Suma Bac D10 solution starting from top coming downwards 4) Scrub the floor using the hard broom 5) Rinse with clean water 6) Sanitize the shelves and handle with Sponge cloth soaked in Suma solution 7) Wipe with clean cloth and leave to air dry 8.2.2 Equipment Table 26 Equipment Area/ Item of Frequency Responsibility Cleaning Materials H&S Precautions (Refer to product label) Method of Cleaning Tables and chairs Daily Kitchen Steward D10 spray bottle Sponge cloth None required 1) Spray D10 sanitizer on the table surfaces and the chairs 2) Wipe with Sponge cloth to dry 3) Buff the surfaces with a clean cloth to a shiny finish. Bain Marie Daily Kitchen steward Nobla Multiclean Suma Scale D5.2 Suma Conc D10 Scourer Bucket WhitexCloth Gloves 1) Switch off the heater and drain off the water 2) Scrub the food containers, top covers and the inside with Scourer soaked 3) in Nobla Multiclean solution 4) Descale with Suma scale when necessary (use 10% ) 5) Rinse with clean water 6) Disinfect with D10 and wipe with Sponge cloth 7) Allow to air dry. Micro wave Daily Kitchen steward Nobla Multiclean Scourer Bucket Sponge cloth None required 1) Unplug the micro wave from power supply 2) Apply detergent with Sponge cloth and scrub to remove stubborn dirt from the surface 3) Rinse with clean water 4) Air dry. Potato peeler Daily Kitchen Steward & Cooks Nobla Multiclean Suma Sol D4.8 Hand brush Bucket None required 1) Flush with water to remove excess soil 2) Scrub the inside and outside surface with Scourer/hand brush soaked in Nobla Multiclean solution. 3) Rinse with clean water 4) Disinfect with Suma Sol solution and allow to air dry. Potato Chipper Daily Kitchen steward Nobla Multiclean Suma Sol D4.8 Hand brush Bucket Sponge cloth None required 1) Flush with water to pre-clean 2) Scrub the equipment with the brush dipped in Nobla Multiclean solution 3) Rinse with clean water 4) Disinfect with Suma Sol solution and allow to air dry. Deep Fryer Daily Kitchen steward Suma Extend D3 Scourer Hand brush Bucket Gloves Flyers and Bratt Pans: 1) Isolate gas / electric supply 2) Drain and remove the oil 3) Spray directly on to surface ROUTINE CLEANING CHECKLIST BRANCH…………………………… WEEK STARTING……………………………… DATE………………… PLACE / ITEM CLEANED CLEANING AGENTS PROTECTIVE EQUIPMENT FREQ Cleaned by (signature) Confirmed Sign MON TUE WED THUR FRI SAT SUN Floors Nobla Multiclean Rubber Gloves After emptying Work Surface – Food Contact Suma Bac Conc D10 None required After each usage Microwave Nobla mutli clean None required COB Chopping boards Suma Bac D10 None required After each usage Utensils, knives Suma Bac D10 None required After each usage Trolleys/ Trays Nobla Multiclean &Suma Conc D10 None required DAILY Display units Suma Conc D10 (Inside) & Sactif glass Cleaner (Outside) None required DAILY/WKLY Cleaning equipment Nobla Multiclean None required DAILY Drains Suma Extend D3 Gloves DAILY Bins and buckets Nobla Multiclean None required DAILY Freezers / FRIDGES. Suma Bac Conc D10 None required WEEKLY Walls Nobla Multiclean Rubber Gloves WEEKLY/DAILY Bain marie Suma conc D10 None required Daily Cling shrinkage wrapper None required DAILY Oven Suma Bac D10 None required Daily Ceiling Nobla Multiclean Gloves Eye Goggles WEEKLY BRANCH MANAGER COMMENTS (Tick Applicable): Cleaned properly, Not cleaned properly, Not cleaned at all, Training on cleaning required SIGNATURE……………………………………… DATE…………………………………….. 8.2.3 Personal hygiene. The requirements for personal hygiene shall be documented, adequately communicated to all personnel and enforced at all time. Hair nets should be worn at all times, no hair should be out of the net. All staff should wash their hands before production, between preparations where necessary to avoid contamination. Gloves should be worn when necessary. Gentlemen should have a clean shave at all times. Do not sneeze, scratch or blow your noise in the working areas. Watches shall not be worn. Jewelry shall not be worn, with the exception of a plain wedding ring. In the event of such exception, the ring shall be completely covered Rings and studs in exposed parts of the body, such as ears, nose, tongues and eyebrows, shall not be worn. Fingernails shall be kept short, clean and no nail polish. False fingernails shall not be permitted. No makeup. Excessive perfume or aftershave shall not be worn. Hand cleaning shall be performed on entry to the production areas and at a frequency that is appropriate to minimize the risk of product contamination. Any staff in direct contact with food and/ or food products should be in possession of valid health certificate from a recognized government facility. All cuts, open wounds or lesions on exposed skin shall be covered by an appropriately. Required uniform shall be worn at all times.