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Family mart would like FFA improve taste of GW553
INTRODUCTION
FFA decide to improve taste GW553 for- More delicious ,Soy sauce flavor ,Spice taste
RD TAB & FFA Co-Operation test on Lab - Test
TAB & FFA Co-Operation Cp - Test
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Detail of Lab-Test
- 2 R/M size ( 15-19g ,18 -22g), 2 Typerecipe ,
- Up soy sauce in MR- Add Soy sauce powder MN in BA- Remove salt , sugar in BA
- Family mart can accept this lab sample
- Confirm quality by Cp- Test 1 st
- 2 R/M size : 15-19g ,20-24g
- Change recipe in MR- Change white pepper to Gaban White
pepper- Fry condition : From 165 C , 3.00 min- To 180 C ,2.00 min ,2.20 min
Lab Test1 st : 1/10/50
Lab Test2 nd :30/11/50
- 2 R/M size ( 15-19g ,18 -22g)- Change recipe in MR- Add Koji Aji in MR for delicious taste
Result of test
- All most are OK but weak soy sauce flavor- Taste not on target
- All most are OK but have to improve taste
- R/M 20 -24 is little big size of finishedproduct
Lab Test3 nd :8/1/51
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CP Test 1 st On5/02/51
Result of cp-test : - Family mart cant accept cp-test sample weak soy sauce flavor- FFA request Lab-Test again
- For confirm quality of lab-test 3 nd 8/01/51 - Confirm dropping test by New skewer Teppou skewer
Teppou skewer
Broken skewer
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Lab Test 5 th on 27/02/51
- Family mart can accept this labsample
- Confirm quality by Cp Test 2 nd
Result of test
CP Test 2 On 5/02/51
- For confirm quality of lab-test 27/02/51
- Confirm dropping test by current skewer
- Increase Soy sauce extra in MR
- Increase Soy sauce powder in BA
- FFA & Family mart can accept this cp test
- Result of dropping test is OK
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Conclusion of GW553 Rev. : GW568- GW553 (Karaage kushi) To GW568 (Karaage
kushi)- R/M size : Bl K 18 -22 g- Used Gaban white pepper (From Malaysia)- Current skewer ( Same GW553)
Schedule of GW568
- FFA & Family mart conclusion on Feb.- Prepare R/M , Ingredient & Package with in Mar.- Mass Production about on 1 April- Delivery to Japan on April
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Market detail Fried Roasted
Home maid 40 11Cooked in store 30 54
Frozen (retail) 10
Chilled (retail) 4
Total 84 69
4
* Billion baht
2007 forecast chicken market (retail product)
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Fried Chicken MarketFried Chicken Market
We have 30% in fried chicken market bymainly RWK1- W & ROK1. It means market leader .
Roasted Chicken MarketRoasted Chicken Market
We have no share in roasted chicken market.So we have to try to gain by SYC & New charcoalproduct (2008 autumn).
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Why they stopped using frozen food?Why they stopped using frozen food?
1. Not delicious 48 50
2. Anxiety for meat 17 30
3. Too small 30 18
4. Too expensive 35 19
5. Time for cooking 3 3
2005 2007 (%)
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Why they stopped using frozen food?Why they stopped using frozen food?
In 2007, the ratio of anxiety for meat increase twice as morethan 2005.So we can win in the market if we clearly informconsumers about the safety of Betagros chicken meat.
From 2008, FFA will say much louder about the safety of Thai chicken, promotion in store and message on our package.
1. Good taste
2. Safety raw material
3. TraceabilityR & D Department
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Preference of new product idea (n=80)Preference of new product idea (n=80)
Sumibi chicken 4P(yakitori sauce)
Vege in Tsukune4P (sumibiyaki)
Sumibi chicken 4P(oroshi sauce)
1. Absolutely buy 3 4 4
2. Want to buy 66 68 24
3. Cant decide 28 26 55
69 72 28
Tsukune need some another machines and to take moretime than sumibi chicken. So we decide to make Sumibi chicken
(yakitori sauce) for 2008 autumn.
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Image of the new productImage of the new product
1. Texture of chicken (soft & juicy)
2. Using safe chicken
3. Charcoal flavor
4. Taste of yakitori sauce
5. Other ingredients like vegetables( Healthy food product)
Same asSYC
We will try them on new product.
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Image of packageImage of package
Subdividable 4 hole tray + pillow film
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RBS Cp test1 st on 25/02/51
Detail of
Cp Test & Result of Cp -test
Result of sensory test
Confirmation point in next cp -test
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RM
PROCESS
BL-K 23 27 g
(New size)
SELECTION
TUMBLING(75 MIN CONTINUE )
- : 14.6%
- 9.62%
DRAIN
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PROCESS
IR 1, IR 2 OFF : X -Actual cp test use IR2 for solveskin attach CV.
CR - ROASTER- Charcoal 4 kg/box, takt time 500
- Clearance 20 180 mm, time 500
2 nd STEAM
PUT IN TRAY
- Chicken 4 pcs/tray
- Skin side is upper
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PROCESS
FILLING SAUCE
FREEZING
Chicken 1 pcs/sauce 5 g
(spiral freezer)
Product A/F Frozen
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PROCESS
WEIGHT CHECKER
X RAY DETECTER
CARTONING- 12 bags/box, 2 boxes/case
COLD STORAGE
WRAPPING (By Machine)
METAL DETECTOR
X- Plan test machine on 22 26/03/51
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1. Difficult of put skin bottom when molding that effect to som
3. Have clearance during IR2 CV. & CR CV. Effect to product
4. Color of product some pieces are too dark next cp test mus.
CR conveyor
Product drop
5. Product A/F steam 2nd found huddle meat , not flat that effect to sauce
2. R/M is small size that easy to skin separate during process
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Appearance : All most nearly OK but cant accept should to improve dark color point
Taste & Flavor : That tend of CR are OK but not enough chacoal flavor
Texture : The edge of product little hard but can accept
OKNG NG
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- Test 2 type of Tray
Type 1 Type2
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Choice type 2
- Easy to put on tray
- Look good appearance
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1. Improve taste and appearance
2. Process speed (1 st CP-test 220 pcs/min, target 320 pcs/min)
3. Find easy method take off meat from mold
4. Wt./Pcs.
5. Test making sauce in line ( by Kneader)
6. Test wrapping machine
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1.DECREASE % LOSS OF BOILING BAG GW086
- Auto vacuum setting too difficult especially
sealing and sauce weight.
- Thickness of bag not appropriate for machine
- Size of bag not convenience for working
Cause of reject boiling bag GW086
From Start - Jan
IMPROVEMENT PROJECT
Characteristic of reject
- Shrink seal
- Dirty on seal
- Seal not complete
- Adjust wt. sauce etc.
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IMPROVEMENT PROJECT
% Boiling bag reject / shife
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.0040.00
45.00
50.00
55.00
1 2 3 4 5 6 7 8 9 10 11 12
No.of production
% reject
Dec. JanFeb
Avg. 28.81%
Avg. 14.67%
Avg. 22.51%
-1.914.306FebNew size
30329.611.7823.118Avg.
10601.671.7826.302Jan
50057.551.7819.934Dec.Old size
Dif (Bath)Cost /
pcs.(Bath)Total%Reject/
MonthMonthBag
Old bag- SIZE ( W * L ) : 140 *190 mm.
- Thickness : ( LLDPE ) 60
New bag- SIZE ( W * L ) : 150 *190 mm.
- Thickness : ( LLDPE ) 70
Conclusion
New boiling bag can decrease% loss of bag
% loss boiling bag New sizeis 14.306 % it still highshould to improve.
Profit of new bag
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Check process that how to reducesetting sauce and control wt. a/f put inbag on std.
- STD. : Wt. A/F put in bag 150g/Bag: Wt. Min. 145.5g/Bag
CP Test
Meat a/f steam 77 g up + Setting sauce
75 g Found problem some bag under wt.
Actual production
Meat a/f steam 77 g up + Setting sauce79 g
Found wt. some bag over wt. too much(150 175 g) Avg. 165 g
2.DECREASE WT. SETTING OF SYC SAUCE
Auto vacuum sauce packing
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Actual process
- To much meat a/f steam delay put in bag
- Delay time of meat b/f put in bag is over 20 min
- Wt. of put in bag 150 175 g ,Avg. 165 g
Effect of this process
- Weight meat a/f steam loss
- Charcoal flavor loss
- Wt. a/f put in bag risk to under wt.
- Quantity of sauce /bag is high
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- Delay time of meat b/f put in bag is less 10
min
- Meat delay b/f put in bag not over 3 box
Control process
- Good smell charcoal flavor
- Wt. a/f put in bag is over (160 170 ) Avg.165.0 g
Result of controlprocess
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Test reduce sauce
10 min150 - 172158.0375 - 9784.9475 g
Immediately154 - 177165.3173 - 9888.61
15 min149 - 171158.8374 - 9584.29
10 min160 - 169164.7477 - 9587.82
79 g
RangeAvg.RangeAvg.
Delay time a/f steam b/f fill sauce
Wt. a/f put in bagWt. a/f steamWt.setting
- Setting 75g/Bag
- Control delay time less 10 min
- Control meat delay b/f put in bag not over 3 box
Conclusion Reduce
settingsauce
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