User Guide Muffin Authors: Annika Crynen Marie Fakesch Celina Fastenrath Christoph Karstens Christian Regulski
Table of Contents Table of Contents... I 1 Introduction... 1 2 Installation/ Setup... 2 2.1 Configuration... 2 3 Recipe... 3 4 Job Execution... 4 5 Learning Curve... 6 6 Time & Cost Study... 7 6.1 Time Study... 7 6.2 Cost Study... 7 7 Troubleshooting... 8 7.1 Common Issue #1... 8 I
1 Introduction The instruction manual at hand is developed in order to ensure an accurate process description. To start, it involves a user-friendly recipe where all tasks are explained in an appropriate way. To avoid failures in the production process, pictures will show the consecutive sequences in detail. Furthermore, the learning curve will show the improvement of the labor forces skills regarding the production. In addition to this, the cost & time study gives detailed information about the spending of these resources. Summarizing, the following data will provide: - User-friendly Recipe - Visualization of the Tasks - Learning Curve - Time & Cost Study 1
2 Installation/ Setup To guarantee a healthy and esculent product, the production place has to fulfill different requirements. The field of work has to be clean regarding hygiene. This means, that dirt and other foreign matters have to be removed before starting the production. In addition to this, the equipment has to be as clean as the field of work. To complete the hygienic standards, all students, which are involved in the production, have to wash their hands and arms at the beginning. 2.1 Configuration If all of the above mentioned requirements are fulfilled, the main production begins with the placement of the needed ingredients. It is important to place the belonging ingredients on the same workplace, in order to avoid the possibility of mixing the wrong fixings, which would lead to a false production. Finally, the oven has to be preheated to 180 C with the setting top- / bottom heat. 2
3 Recipe Amount of ingredients for 12 muffins: 220g flour (type 405) 125g sugar 200ml buttermilk 150ml sunflower oil 2 eggs (medium size) 3 tsp. baking powder 1 package vanilla sugar 1/2 tsp. natron 2 tsp. cocoa 120g baking chocolate Further you need: 1 bowl 1 mixer 2 tablespoons 1 teaspoon 1 scale 1 measuring pitcher 12 paper forms 2 metal baking forms for muffins 1 egg timer 3
4 Job Execution First step: Preheat the oven to 180 C (upper lower heat). Second step: Put flour, baking powder, sugar, vanilla sugar, natron and cocoa into a bowl. Mix these ingredients with a mixer for 30 seconds. Third step: Chop the baking chocolate into small pieces. Fourth step: Put milk, sunflower oil and eggs into the measuring pitcher. Mix also the wet ingredients for one minute with the mixer. Then, stir the chocolate pieces in the pitcher as well. Fifth step: Put the liquid ingredients including the chocolate pieces to the dry ingredients into the big bowl. Again, mix all ingredients for four minutes with the mixer at the highest level. Sixth step: Finally, put the paper forms into the metal baking form and fill them up with the dough until a certain level (see picture). Put the forms on a baking tray and put this on the middle rack and bake them for 22 minutes. To test whether the muffins are ready, put a wooden stick into the middle of one muffin and check if there is dough remaining on it. If not, take the muffins out of the oven. If yes, follow the steps of 7.1. 4
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5 Learning Curve The arithmetic approach is used. A 90% learning curve Unit Man hours 1 st 0.3333 (20 min) 2 nd 0.9 * 0.3333 0.2997 (18 min) 4 th 0.9 * 0.2997 0.2697 (16 min) 8 th 0.9 * 0.2697 0.2427 (15.min) One unit of muffins includes the preparation of 12 single muffins excluding the baking time. 6
6 Time & Cost Study 6.1 Time Study The cycle time (CT) to produce one baking sheet of muffins is 15 minutes. This is under the condition that the qualified employee works eight hours a day and 90% of the time. According to the learning curve, it is possible to produce 30 backing sheets per day. This was calculated as follows: 7.5*60 = 450 (Working time less the break times minutes per hour) 450/15 = 30 (Total working minutes divided by expected time according to learning curve) The employee is expected to work on a performance rating of 100, therefore it can be said: Normal time = 15*1 = 15 minutes per baking sheet (excluding baking time) According to the company policy, an allowance of 10% on the total job time is given. Therefore, the standard time (ST) per baking sheet is: ST = 15*1.1 = 16.5 In conclusion, a fully skilled worker is allowed to need round about 17 minutes for one baking sheet at a performance rate of 100. When taking this study into consideration, one qualified worker is able to produce 26 baking sheets of muffins on a 7.5 hours working day. This amounts to 312 single muffins a day, under the assumption that one oven per person is available. The possible monthly production is 520 baking sheets, therefore 6240 single muffins. 6.2 Cost Study The cost study include the variable costs of flour, sugar, buttermilk, vegetable oil, eggs, baking powder, vanilla sugar, natron, cocoa and chocolate. All of the calculated prices last for 12 muffins. First, 220g flour cost 0.099. Secondly, 125g sugar amount 0.11. Thirdly, 200ml of buttermilk charge 0.12. In addition to this, 150 ml of vegetable oil cost 0.51. Moreover, the expense for two eggs is 0.28. Furthermore, one package of vanilla sugar costs 0.17. To go on, ½ teaspoon of natron amounts 0.12. Then, two teaspoons of cocoa cost 0.73. Finally, 0.95 is needed for the chocolate. In total, the costs for 12 muffins are 3.089, therefore one single muffin amounts about 0.26. 7
7 Troubleshooting In this chapter, several common problems which may occur during the whole process will be explained. To be able to solve these problems, following steps have to be taken. 7.1 Common Issue #1 The first common issue describes the situation, if the muffin dough has to be filled in the paper forms. The dough often droppes besides the forms on the baking tray. Therefore, one has to use a small amount of dough putting on the spoon and being very concentrated during the whole process. 7.2 Common Issue #2 Second, another problem will occur meaning that it is often difficult to measure the perfect time of baking. For this reason, the muffin has to be checked with a wooden stick. First, the stick has to be put in the middle of the muffin and check if there is still unbaked dough on it or not. If yes, another minute of baking is needed. If not, the muffins and therefore the process is finished. 8