Turning process control into consistent texture, every single day
90% of texture is determined by three processes
MIXING
AGING
ROLLING
In other words, if these three are stabilized, the texture will also be stable. If they are handled ambiguously, quality will not stabilize no matter how much experience you have
Days when reproducibility tends to break down
In real-life operations, there are always days like the following:
- Busy days
- Days with high humidity
- Days when the flour changes
- Days when new staff join
On such days, noodle making procedures tend to fluctuate without anyone noticing.
The accumulation of these small deviations results in texture that differs from the usual.
The foundation of reproducibility is adhering to “standard parameters” in each process
The foundation of reproducibility is very simple:
Follow standard procedures and parameters for each process. To do this, the first step is to create a Standard Procedures Sheet.
The only items you need to define first in a Standard Procedures Sheet
MIXING
- Rotation speed
- Time
- Dough temperature
AGING
- Time
- Temperature
ROLLING
- Roller gap
- Number of passes
- Final Thickness
Even defining just these items numerically will greatly improve reproducibility.
Relying only on numbers is dangerous
However, there is an important point to note:
Operating based on numbers alone is risky. This is because raw materials and environmental conditions change every day.
- Flour condition
- Water temperature
- Humidity
Additionally:
- A person in charge of noodle may have their own ways of doing things and they may also small mistakes
- Machine trouble
These factors inevitably create conditions that differ from the usual.
What reproducibility requires is both “numbers” and “trained observation”
What is needed, therefore, is trained observation.
- Numbers: the ability to recognize standard operating conditions
- Observation: the ability to detect abnormalities
Numbers indicate what is normal, while observation identifies what is abnormal.
Reproducibility is achieved through the combination of
“numbers × observation”
Only when both are present can reproducibility truly be achieved.
Reproducibility is something that is built through design and systems, and maintained in the production settings.
The moment this is properly established, operations become significantly stronger.
Fujii ‘Rocky’ Kaoru
