OPERATIONS MANAGEMENT

TQM REVIEWER FINALE

“Commit to the Lord whatever you do, and your plans will succeed”
-Proverbs 16:3-
 Chapter 6
MANAGEMENT OF QUALITY

“Study as if you know nothing”

Concepts
The Plan-Do-Check-Act Cycle
6.1 as a circle to stress that continuous improvement is a never-
ending process.

Figure 6.2 shows an overview of the acceptance

sampling and process control in the production process.

Evolution of QM
During the middle ages, the skilled craftsperson all stages of production. Quality assurance was
informal;one person or a small group of people were responding to the final product they produced.
These themes were lost in the advent of the Industrial Revolution where each worker was then
responsible for only a small portion of each product.
In the early 1900s, the “Father of Scientific Management”, Frederick W. Taylor led to a new
philosophy of production and inspection as primary means of quality control. G.S Radford improved
Taylor’s method by considering quality early in the product design stage.
In 1924, Bell Telephone Laboratories introduced Statistical process control charts, which became
a popular means of identifying quality problems in production processes and ensuring consistency of
output. H.F. Dodge and H.G. Romig developed the sampling inspection tables in the early 1930s. During
the 1950’s, quality control evolved to quality assurance with emphasis on problem avoidance rather than
problem detection and involvement of upper management in quality. In the 1960’s, Philip Crosby
introduced the philosophy of Zero-defect management which focused on employee motivation and
awareness and the expectation of perfection form each employee. During the 1970’s, quality assurance
methods gained to focus on services. Japanese products had a significant global impact on the market as
they integrated quality in their organizations and developed a culture of continuous improvement.

Gurus in field of QM (Notes are very important)

Walter Shewhart was an American statistician and known as the “father of statistical quality control”.
Shewhart’s work focused on how the manufacturing process could be monitored in such a way as to
reduce variations and determine when corrective action was necessary.

W. Edwards Deming, an American professor and statistician, who helped in Japan's recovery after World
War II through his statistical knowledge and methods in improving quality and productivity. Dr. Deming’s
famous 14 points that he believed were the prescription needed to achieve quality in an organization.

Joseph M. Juran was a Romanian-born American engineer and management consultant and known as
the "father of modern-day quality management". Like Deming, he was also invited and assist Japanese
manufacturers on how to improve the quality of their products, he too, can be regarded as a major force
in Japan's success in quality. It is his view that quality begins by considering what customers want. A key
element of his philosophy is the commitment of the organization to continuous improvement.

Armand Feigenbaum was an American quality control expert who recognized that quality was not
simply a collection of tools and techniques, but a “total field” that integrated the process of the
organization. According to Feigenbaum, it is the customer who defines quality.

Philip B. Crosby was a legend in the discipline of quality. He is widely recognized in his concept of “zero
defects” and he believed that there is absolutely no reason for having errors or defects in any products or
services.

Kaoru Ishikawa is considered the Father of Japanese Quality. He developed the fishbone or the cause-
and-effect diagram where users can see all possible causes of a result which can help for problem-solving
and the implementation of quality circles, which involve workers in quality improvement.

Genichi Taguchi made a significant contribution to his methodology in improving the quality and
reducing the cost. Taguchi loss function involves a formula for determining the cost of the poor quality.

Taiichi Ohno and Shigeo Shingo both developed the philosophy and methods of kaizen or rapid
improvement process which focuses on eliminating waste, improving productivity, and achieving
sustained continual improvement.

The Dimensions of Quality in Product The Dimensions of Quality – Service

Performance - primary operating Convenience - the availability and accessibility
characteristics of the product. of the service
Aesthetics - appearance, feel, smell, taste or Reliability - the ability to perform what was
sounds of a product promised of a service, dependably, consistently,
Special Features - extra characteristics. and
Conformance – the degree to which a product accurately.
corresponds to design specifications. Responsiveness - the willingness of service
Reliability - dependable performance. providers to help customers to deal with
Durability - ability to perform over time. problems.
Perceived Quality - indirect evaluation of the Time - the speed with which service is delivered.
quality Assurance - the knowledge and courtesy by
Serviceability – speed, courtesy, and personnel who come into contact with a
competence in the handling of complaints or customer and their
repairs. ability to convey trust and confidence
Courtesy - the way customers are treated by
employees who come into contact with them
Tangibles - the physical appearance of facilities,
equipment, and personnel

Analysis on Dimensions of Quality (Tricky— tama lahat ng sagot pero select the best)

Definitions and Terminologies

Quality
is a measure of the company's excellence. refers to the ability of a product or service to
consistently meet or exceed stated requirements or expectations of the customers (Stevenson, 2015).

SERVQUAL
is a multi-dimensional research instrument designed to obtain feedback on an organization’s
ability to provide quality service to customers. focuses on consumer expectations and perceptions of a
service along the five dimensions: tangibles, reliability, responsiveness, assurance, and empathy.

Quality of design
refers to the intention of the producer or supplier to include or exclude certain features in a
product or service.
Quality of conformance
refers to the level to which goods and services meet their design specifications Implications of
Quality

Company Reputation
quality will show up in the perception of the firm's products, employment practices, and network
relations.

Product liability
the organization must pay special attention to damages or injuries resulting in the use of their
faulty products or poor workmanship.

Global implications
inferior products harm a firm's profitability, a nation's balance of payments, and may become a
major issue nationwide.

QUALITY CERTIFICATIONS
As quality became a major focus of many firms that do business internationally, various
organizations
developed standards and guidelines.

International Organization for Standardization (ISO)

The International Organization for Standardization promotes worldwide standards to achieve,
maintain,
and seek to continuously improve product quality through a series of standards and guidelines. Two of
the most well-known are ISO 9000 and ISO 14000 which both relate to an organization's processes and
stressing continual improvement.

ISO 9000
is a set of standards that pertains to quality management that helps what an organization does to
ensure that its products or services meet its customers and stakeholder’s needs. Its standards include the
following categories:
• System requirements
• Management requirements
• Resource requirements
• Realization requirements
• Remedial requirements
ISO 14000
concerns the standards related to environmental management to help the organizations minimize
the negative effects of its operations on the environment.

Eight quality management principles form the basis of the latest version of ISO 9000:
• A customer focus
• Leadership
• Involvement of people
• A process approach
• A system approach to management
• Continual improvement
• Use of a factual approach to decision making
• Mutually beneficial supplier relationships

TOTAL QUALITY MANAGEMENT

The use of quality management has become widespread in every organization’s daily operations.
The aims of the businesses may differ, but the importance of customers is a matter of common interest
and the ability of organizations to adapt to new customer requirements on a global market is of vital
importance for long-term success. Thus, quality has become an important factor to achieve the goals of
the businesses.

Total
made up of the whole and every aspect of its business
Quality
degree of excellence a product or service provides
Management
act, art or manner of planning, controlling, directing and organizing

Therefore, TQM is the art of managing the whole to achieve excellence.

Total quality management

is an approach that organizations use continuously to quest for quality and improve their internal
processes and increase customer satisfaction. Stevenson (2014) pointed out that, “there are three key
philosophies in this approach: continuous improvement, the involvement of everyone in the organization,
and the goal of customer satisfaction”.

Six Sigma
is a set of management techniques that focuses on improving quality, reducing cost, and increasing
customer satisfaction by minimizing the occurrence of defects and errors. can be integrated with design,
service, production, inventory management, and delivery. provides a blueprint for the implementation of
a total quality system.

PROBLEM SOLVING AND PROCESS IMPROVEMENT

Problem-solving
is the act of defining a problem and finding solutions in an orderly manner using appropriate tools
and techniques. one of the basic procedures of TQM where the users of this approach eliminate the cause
so that the problem does not recur. an important factor for users to think of problems as "opportunities
for improvement" to be successful.

Process Improvement
 is a proactive task of improving the process. It involves documentation, measurement, and
analysis to improve the functioning of a process. Typical goals of process improvement include increasing
customer satisfaction, achieving higher quality, reducing waste, reducing cost, increasing productivity,
and reducing processing time.

QUALITY TOOLS (seven basic quality tools.)

Flowcharts
are a graphical representation of a process or step. These are best developed by having all
levels involved in the process.

Check sheets
are simple tools frequently used for organizing and collecting data.

The histogram
is a basic statistical tool that graphically shows an empirical frequency distribution.

Pareto Diagrams,
named after an Italian economist Vilfredo Pareto, often used to analyze data collected in check
sheets by classifying problem areas according to the degree of importance.

Cause-and-Effect Diagrams
offer a structured approach to assist the generation of ideas for causes of the problem and serve
as the basis for finding the solution.

Scatter Diagrams
are useful in deciding if there are important relationships between two variables
Control Charts
are a statistical process control tool used to monitor how a process changes over time.

QUALITY CONTROL
Quality control
is a process that evaluates the quality of factors involved in production to ensure that theoutput
adheres to a standard of quality or meets the requirements of the customers. It is similar to, but not
identical with quality assurance.

Quality assurance
can be defined as the systematic activities implemented to provide a confident confirmation that
the product or service fulfilled the specified requirements.

INSPECTION
involves measuring, examining, and testing of products or services and comparing them to the
standard. This separates good and It can occur before, during, and after the production. Inspection
performed either before (raw materials inspection) and after production (pre-shipment inspection) often
involves acceptance sampling procedures; inspection during the production process is referred to as
process control.

Cent Percent Inspection or 100 percent inspection

involves inspecting every item produced and incoming material to ensure that no defective
product would go to market.
STATISTICAL PROCESS CONTROL
Statistical process control (SPC)
is a statistical technique applied to the control of the processes with a certain degree of variability
to ensure that processes meet the standard.

Control chart
developed by Walter Shewhart, is a simple but powerful tool; it is a time-ordered plot of process
data over time used to determine if a manufacturing process is within the range of acceptable or out of
control.

6.12 PROCESS CAPABILITY

Process capability
is the ability of the resources and process to produce a product which consistently meets the
design specifications set by the customer requirements and expectation (Kale, 2013). It is the range of
the performance level in which the natural variations of the process must be stable under statistical
control.

QUALITY AWARDS
The philosophies of Deming, Juran, Crosby, and others serve much help in the form of "best
practices" to managers around the world, leading to the development and a lot of awards and
certifications for the effective application of Total Quality principles.

The Malcolm Baldrige National Quality Award

The Baldrige Award annually administered by the National Institute of Standards and Technology.
The award’s Criteria for Performance Excellence is designed to encourage companies to enhance their
competitiveness and recognize quality achievements of integrating total quality principles and practices
in any organization.

The European Quality Award

Europe's most prestigious award was designed to increase awareness of the growing importance
of quality to the competitiveness of the business in the increasingly global market and the standards of
life.

The International Asia Pacific Quality Award

This award is given to organizations in countries bordering the Pacific Ocean and the Indian Ocean,
dedicated to achieving continuous quality improvement of goods and services and life for people around
the world.

The Deming Prize

This award is Japan’s highly coveted award recognizing successful quality efforts. It is given
annually to all companies that meet the prescribed standard. The major focus of the criteria is on
statistical quality control which also reflects the involvement of senior management and employees,
customer satisfaction, and training.

Not included: Computations

 Chapter 8
SUPPLY CHAIN ANALYSIS

“Study as if you know nothing”

Supply Chain Management

can be defined as the management of flow of products and services, which begins from the origin
of products and ends at the product's consumption. It also comprises movement and storage of raw
materials that are involved in work in progress, inventory and fully furnished goods

supply chain
is the system of organizations, people, activities, information and resources involved in moving a
product or service from supplier to customer. Supply chain activities transform raw materials and
components into a finished product that is delivered to the end customer.

Supply Chain Management

is the design and management of processes across organizational boundariesn with the goal of
matching supply and demand in the most cost-effective way.
- A set of processes and sub-processes which attempt to implement and optimize the functions,
connected entities, and interacting elements of a supply chain.
Involves: – Organizations, procedures, people. – Activities: Purchasing, delivery, packaging,
checking, warehousing, etc. – Establishment of long-term relationships with suppliers (supply alliances)
and

Three Flows in Supply Chain

material, information, capital.

Downstream – Material: Products, Parts – Information: Capacity, Delivery Schedules – Finance: Invoices,
Pricing, Credit Terms

Upstream – Material: Returns, Repairs, After-sales Services – Information: Orders, Point-of-sale Data –
Finance: Payments

Push vs. Pull in supply chains

Push or Building-to-stock (BTS):
Producing stock on the basis of anticipated demand. Demand forecasting can be done via a variety
of sophisticated techniques (some from the Operations Research area and some using Data Mining).

Pull or Building-to-order (BTO):

Producing stock in response to actual demand (firm orders). The Push-Pull Point: In many supply
chains, upstream units employ BTS, while downstream units employ BTO strategies. The point in the
supply chain where the switch-over (from BTS to BTO) occurs is called the Push-Pull point. Optimally
locating the Push-Pull point is a key determinant of supply chain performance.

Not included: Supply Chain Stories Computation of Inv and COGS

 Chapter 9
MATERIALS, INVENTORY AND MANAGEMENT

“Study as if you know nothing”

Materials Management’
is a term used to connote “controlling the kind, amount, location, movement and timing of various
commodities used in production by industrial enterprises”.
is the planning, directing, controlling and coordinating those activities which are concerned with
materials and inventory requirements, from the point of their inception to their introduction into the
manufacturing process.

Purchasing:
Purchasing plays a crucial role in the materials management because it is concerned from input
stage up to the consumption in manufacturing. Purchasing functions as a monitor, clearing house and a
pipeline to supply materials needed for production.

Dr. Walters defines scientific purchasing as:

“Procurement by purchase of the proper materials, machinery and equipment and supplies of
nstores used in manufacturing of the product, adopted to marketing in the proper quantity and quality at
the proper time and at the lowest price consistent with quality desired.”

Source Selection (Vendor Selection):

The selection of right source of supply is an important aspect in materials management. The
nvendor is to be examined with respect to his capability and competency to supply right quality of
material at right time and at a competitive price.

Just In Time (JIT) Purchasing:

Just in time purchasing is a major component of JIT manufacturing system. The basic concept
materials/parts just in time for production. This approach is quite contrast to traditional approach of bulk
buying.
 HME REVIEWER FINALE

“Commit to the Lord whatever you do, and your plans will succeed”
-Proverbs 16:3-

Chapter 5
 BAKING PROCESS

“Study as if you know nothing”

The baking process is the same process from baking cakes to breads and cookies. This change
happens in order, or at the same time, or not one after the other. Knowing each stage would help you
know how to control them.
● Melting of fats ● Coagulation of proteins
● Formation and expansion of gasses ● Gelatinization of starches
● Killing of yeast and other microorganism ● Escape of water and other gasses
● Crust formation and browning

Stage 1. Melting of Fats

There is a reason why melted fats and even room temperature butter is done in the mixing process
or while preparing the batter. As the fat melts, they release trapped gasses and surround the air cell at
different temperatures. These gas bubbles from the melted fats make the baked goods more tender/soft,
having a melt-in-the-mouth texture, dividing the batter into delicate sheets.
Stage 2. Formation and Expansion of Gases
Some gasses are present, some expand as they are heated. Gasses formed from yeast and baking
powder as it expands if they are heated. This expansion causes the cake to rise and transform, making the
cell wall thinner as they are stretched. This expansion causes the product to become soft and tender.
Aside from glasses, steam is also formed as the moisture of the batter is heated.
Stage 3. Killing of Yeast and Other Microorganism
The batter may also contain other microorganisms, such as bacteria and mold, in addition to the
yeast. These microorganisms die when the temperature of the batter in the oven reaches about 140
degrees Fahrenheit or 60 degrees Celsius. Fermentation stops and no more gas are released when the
yeast dies.
Stage 4. Coagulation of Proteins
When the temperature is high enough, proteins such as gluten and egg proteins solidify or
coagulate. This gives structure to the baked goods. That is why baking temperature is crucial in cake
making. If the coagulation starts soon caused by too high temperature, the solidification will start too
soon before the expansion of gasses completes. This will result in baked goods that have poor volume or
split gas. If the temperature is too low, the product may not solidify or not set enough, making the product
collapse.
Stage 5. Gelatinization of Starches
The starches will then absorb the moisture, enabling it to expand and become firm.
Stage 6. Escape of Water and Other Gasses
As you bake the cake, water and gases are released due to its rise in temperature, but this happens
fastest in the last stages of baking. Note that water evaporation decreases the weight of the baked good, as
it enables crust formation.
Stage 7. Crust Formation and Browning
As water evaporates or escapes as explained in stage 6, it enables the formation of crust and
browning. Browning is due to the caramelization or browning of sugar, while the starches and proteins
undergo Maillard browning that contributes to its flavor. Another factor that increases the browning is
the inclusion of milk, sugar and egg in the recipe.

STALING
The main concern of the baker is to make the cake fresh and flavourful, while keeping its
structure intact. Staling refers to the change of texture and aroma of the baked goods. This is due
to the loss of moisture made by the starch granules and the structure changes of the baked cake.
Having the cakes stale makes it firmer, drier and more crumbly.
Techniques to Slow Down Staling
1. Protecting the product from air. To protect the product, wrap the cake bases with or without
icing in a cling wrap or plastic.
2. Adding moisture retainers to the formula. Ingredients that can retain moisture are fats and
sugars. Products that are high in these have less chance of being stale. For longer keeping, small
amount of fat or sugar can be added to the formula. The moisture retained will also increase the
holding capacity of the baked cake.
3. Freezing.
Cakes that are frozen before they become stale can maintain its quality for a longer period of time.
These cake bases should be served after thawing or losing its stiffness by being warmed.
4. Refrigerating, on the other hand, can increase the speed of staling. Refrigerating can only be done
in storing cream fillings.

CAKE PRODUCTION METHODS

There are five (5) main cake production methods to be discussed in this lesson, namely: sugar
batter method, flour batter method, blending method, all-in method
and boiling method.
Sugar Batter Method
It is a method where fat, such as egg, and sugar are creamed together until the batter is light and
fluffy. Adding the egg per piece ensures that each fat mixture is fully incorporated, well creamed and not
separated before adding another. Another important factor in This method is the temperature of the eggs.
The curdling or the thickening, solidifying and separating of mixture into lumps is due to too cold egg
used in the batter. Curdling forms as the fat separates out from the liquid.
If the egg is too cold, the fat hardens, air escapes, and the mix curdles or forms into lumps. If the
egg is too warm, the fat becomes oil, air escapes and the mix curdles. If the egg is added too fast, it will
make the mix saturated, that will make the air escape, making the mix curdle. Note that after adding all
the eggs, the batter should have a soft, smooth and thick texture. Over mixed batter will make the cake
tough.
Flour Batter Method
It is a method where fat is mixed with one-third (1/3) of the sifted flour for around 8 minutes
until it is fully creamed. This is done to ensure that the batter is fully incorporated and aerated (introduce
air into the batter). Note that the egg and sugar are whisked in a different or separate bowl. Both
ingredients must be at the same temperature before they are combined. To adjust consistency, some of
the egg mixture can be mixed into the fat. Then the remainder of the eggs, together with the sifted flour,
baking powder and liquid (must be in order) can be carefully folded into the fat mixture. Each ingredient
must be added fully and must be in sequence to avoid any lumps.
Blending Method
This method does not require creaming or aeration of fat with sugar or flour as the first step like
sugar or flour batter method, but is done as the last step in the mixing cycle. The reason behind the
creaming done in the end is because the formula or recipe container has high level of liquid, in the form of
milk that replaces some of the Egg. Using this method relies solely on the fat, egg white and small amount
of gluten to hold the air, but are not very strong to form a structure. Remember that the trapped air
tenderizes and softens the protein found in fat, egg, and flour. Less amount of the egg will lower its
aerating capacity that is why adding baking powder to the formula will compensate and will give off extra
gas (CO2) to increase lift during baking. Adding glycerine to the batter will also increase the moisture
retention or holding capacity of the cake and will act as an emulsifier that will help hold and combine
extra liquids with fat.
The two variations in this method include the two stage method and three stage method. These
methods are used to produce ‘high ratio cakes’. These cakes are sweeter and moisture because of its
capability to take more liquid and sugar.
Two Stage Method
Done by mixing all the ingredients except for the eggs and any liquid. The remaining ingredients,
such as eggs and liquid, are added in intervals into the flour mix, cream it for 3 to 5 minutes until the
batter is light.
Three Stage Method
This method is done by adding half of the flour into the mix after initial creaming, for 3 minutes
using a beater set on low speed, then adding the remainder of the flour and creaming it on low speed.
All in Method
This is used in making cheaper types of cake. It is when eggs are replaced with baking powder and
liquid. This method is commonly used with high speed mixers, for 6 to 7 minutes.
Boiled Method
This method is used in making Genoese sponges and Madeira cakes. It is also considered to be the
safest because of its small list of troubleshooting, but is rarely
used in the manufacturing. To do this method, heat the fat to 50 degree Celsius and stir well until
completely cleared. Eggs and sugar are whisked until stiff peak and are added into the flour
mixture in 4 to 5 additions (or parts divided equally).

SPONGE PRODUCTION METHOD

Sponge Production Methods

Note that the weighing and mixing equipment to be used in a recipe that follows the sponge
production method must be free from grease for this may greatly affect the batter.
Traditional Method (Orthodox Sponge)
This egg sponge has the ratio of 2 parts egg : 1 part sugar : 1 part flour. Its light texture is due to
whisking together of eggs and sugar on high speed, followed by folding of flour. Nowadays, formula may
also contain some baking powder and butter. For better result, mixture is whisked on medium speed for
short time and the batter must fill into the baking sheets and baked immediately. Sifted flour is also folded
carefully into the butter so as not to lose the trapped air.
Enriched Method (Genoese Sponge)
This method is the same as the traditional sponge but it contains fat that is up to 80% of the sugar
weight. Sifted flour must be incorporated in the mixture, followed by the folding of melted butter in cool
temperature. If the butter is too hot, the egg will curdle (or form lumps).
Emulsified or Stabilized Sponges
This method is most widely produced using the all-in method with a stabiliser or emulsifier. This
emulsifier often contains lecithin and lacto albumen that binds incompatible substances like water and fat
to form an emulsion. This can be stored longer because of the established emulsion that retains the
condition of the cake. This usually contains water and a proportion of baking powder.

Delayed Soda Method

After the sponge is aerated, the baking powder will be added. This is not added at the same time to
gain better aeration. To do this method, liquids are placed in a mixing bowl. In another bowl, dry
ingredients including the cream of tartar are sifted. Dry ingredients will then be added into the liquids.
Followed by the mixture of the batter until it is aerated. Cream of tartar is used to increase the stability of
proteins in eggs. Bicarbonate of soda is mixed with cold water, and then must be added slowly to the
batter. Mixing it first with cold water will retain its ability to aerate the sponge. The batter should be
baked immediately in a preheated oven.

Separated Sponges
This method as the name implies has a separated mixture. This is when the egg yolks and whites
are whisked separately with some sugar. It will then be combined and the sifted flour will be folded in.
Whisking egg yolk needs some water for better aeration. Egg whites must not be overbeaten to prevent
lumps in the batter.

THE CORRECT BAKING TECHNIQUES

The start of a good result is in the mixing bowl. These baking techniques are skills that must be
learned because it greatly affects the texture of the prepared batter. Listed are the correct techniques that
can be used in cake making:
Sifting.
This is done by passing the dry ingredients through a strainer to aerate it (e.g. sifting of flour).
Beating.
It is a technique where ingredients are moved strenuously in a back and forth, and up and down
motion until the correct consistency is achieved (e.g. beating of eggs).
Whisking or Whipping.
It is done by mixing the ingredients vigorously until it adheres together (e.g. whisking or whipping
the heavy cream and egg whites). Airy and foamy like texture of angel food, sponge and chiffon cake are
formed when whole eggs or white eggs are whipped until voluminous, then folded into the batter. The air
incorporated by whipping the eggs gives the cake volume, making it springy and elastic.
Folding.
It is a technique of gently adding one ingredient into another using a large spoon or spatula (e.g.
folding whipped cream and melted chocolate to make mousse).

Creaming.
This is done by blending several ingredients together until the consistency is smooth, lighter and
fluffier (e.g. creaming the sugar and butter).The soft, fine texture and moistness of butter cakes like
pound cake and moist cakes are from the crumble, or first creaming together the fat and sugar, adding
eggs, and slowly incorporating dry ingredients while alternating it with a liquid such as milk or
buttermilk.
Piping.
This technique is used to decorate cakes. To do this, squeeze the piping bag from the top using
your dominant hand, and let the tip of the bag rest on your other hand.

THE CORRECT OVEN SETTING

Oven Settings for Cakes

Oven should be in ‘solid heat’, with temperature set to 150 to 180 degrees Celsius. Solid heat
means that the oven should have stabilized within this temperature for 15 to 20 minutes before placing
the cake.
To prevent premature coloring of the cake surface, a baking pan can be covered with sheets of
clean paper for approximately 50% of baking time.
To test the internal temperature and test whether the cake is baked, use an oven thermometer.
The baking process is considered complete when the center of the cake reached gelatinization, having 87
to 90 degrees Celsius in temperature.
Skewers can also be used to test if the cake is already baked. It should be inserted into the cake and
must come out clean.

OVEN SETTING FOR SPONGES

Oven Settings for Sponges

 Sponge cake and Genoise cake will cook quicker in an oven temperature of 180 to 200 degrees
Celsius, because of its lighter density. Gelatinization and coagulation happens quickly, having less drying
out of the product. Sponge sheets can be baked at 220 to 230 degrees Celsius for about 7 minutes.

Tips in Using the Oven

It is important to know the oven that you will use, as you bake any type of cake. Get oven
thermometers to make sure that the oven is
calibrated correctly. Placing the oven thermometer inside the oven will assure that the cake will not be
underdone or overdone.
Place the cake in the middle of the oven because placing it too close to the top or bottom can cause
overbrowning. Gently close the
oven afterwards.
Rotate the pans during baking. Do this until two -thirds of the way through baking time to prevent
collapse. If using more than one
rack, it is time to swipe the pans.
Do not remove the cake from the tin pan until it is cold to avoid damage. Cold cake bases must be
wrapped immediately to prevent staling.

Chapter 6 AND 7
CAKES, FEELING AND FROSTINGS

“Study as if you know nothing”

Cakes
Are created from liquid batters with high fat and sugar contents.
Ingredients are classified by function:
● Tougheners
● Tenderizers
● Moisteners
● Driers
● Leaveners
● Flavorings

Ingredients

Tougheners – flour, milk and eggs contain protein. Protein provides structure and strengthens the cake
once it is baked. Too little protein and the cake may collapse; too much protein and the cake maybe tough
and coarse

Tenderizers Sugar, fat and egg yolks interfere with the development of the gluten structure when cakes
are mixed. They shorten the gluten strands, making the cake tender and soft.
These ingredients also improve the cake’s keeping qualities.

Moisteners Liquids such as water, milk, juice and eggs bring moisture to the mixture. Moisture is
necessary for gluten formation and starch gelatinization, as well as improving a cake’s keeping qualities.

Driers Flour, starches and milk solids absorb moisture, giving body and structure to the cake

Leaveners Cakes rise because gasses in the batter expand when heated. Cakes are leavened by the air
trapped when fat and sugar are creamed together, by carbon dioxide released from baking powder and
baking soda and by air trapped in beaten eggs. All cakes rely on natural leaveners-steam and air-to create
the proper texture and rise.

Flavorings Flavorings such as extracts, cocoa, chocolate, spices, salt, sugar and butter provide cakes with
the desired flavors. Acidic flavoring ingredients such as sour cream, chocolate and fruit also provide the
acid necessary to activate baking soda.

Types of Cakes
● Shortened Cakes- contain fat such as butter, margarine, or shortening. Also called butter cakes.
Most are leavened with baking powder or baking soda.
● Pound cakes are a type of shortened cake that do not contain a chemical leavener.
● Unshortened Cakes- sometimes called foam cakes, contain no fat. They are leavened by air, which
is beaten into eggs, and by steam, which forms during baking.
● Examples are angel food cake and sponge cake. The difference between these two is the egg
content. Angel food cake contains just egg white. Sponge cakes contain the whole egg.
● Sponge cakes are made with an egg foam that contains yolks.
● Chiffon Cakes- are a cross between shortened and unshortened cakes. They contain fat like
shortened cakes and beaten egg whites like unshortened cakes.

Panning and Scaling Cakes

Baking pans are usually coated with fat and flour or lined with parchment paper.
Commercial pan preparations are also available.
Pans should be filled one-half to two-thirds full.
Spread the batter evenly with an offset spatula.
When making multiple cakes or multi-layer cakes, fill the pans to the same level.
Have the pans prepared before mixing the batter. Pans should be filled as soon as possible after
mixing is complete so that air cells in the batter will not collapse.
Shortened Cakes
In order to get cakes consistent size, the batter is scaled before it is panned.
Place pans in the oven so the heat circulates freely around the cake.
The pans should not touch each other or any part of the oven—this creates hot spots and the cake
will bake unevenly.
To test a cake for doneness-lightly touch the center with your fingertip. If the cake springs back, it
is done.
You can also insert a toothpick in the center of the cake, if it comes out clean, the cake is done.
Look to see if the cake has pulled away from the sides of the pan.
Allow the cakes to cool in the pan for about 10 minutes.
To remove the cake from a pan, run the tip of a spatula around the sides of the cake to loosen.
Invert the cooling rack over the top of the pan, and gently flip the cooling rack and the pan.
Carefully remove the pan and place a second cooling rack on top of the cake. Turn the cake so that
it is right side up. Let the cake layers cool before frosting.
Angel Food Cakes
1. Beat the egg whites with some of the sugar
2. Carefully fold the flour and remaining sugar into the beaten egg whites.
3. Usually baked in an ungreased tube pan.
4. The ingredients should be at room temperature. Egg whites that are cold will not achieve
maximum volume when beaten.
5. After removing an angel food cake from the oven, immediately suspend the pan upside down over
the neck of a bottle. This prevents the loss of volume during cooling. Cool completely before
removing from the pan.
Angel Food Cakes
A high quality unshortened cake has a large volume, spongy interior. It is tender and moist but
not gummy.

Sponge Cakes
1. Beat the egg yolks until thick and lemon colored.
2. Add the liquid, sugar and salt to the yolks. Continue
beating until thickened.
3. Gently fold the flour into the yolk mixture.
4. Fold the beaten egg whites into the egg yolk mixture.
Chiffon Cakes
1. Combine the egg yolks, oil, liquid and flavoring with the dry ingredients.
2. Beat the mixture until smooth.
3. Beat the egg whites with the sugar and cream of tartar.
4. Fold the egg white mixture into the other mixture.
Fillings and Frostings
● Fluffy whipped cream, creamy puddings, and sweet fruits are popular fillings for cakes.
● Spread the fillings between layers of cake or roll them into the center of a jelly roll. You can also
spoon them into a cavity dug into the middle of the cake.

Frosting a Cake
1. Brush crumbs from the surface of the layers.
2. Arrange strips of waxed paper on a cake plate. Cover only the edges of the plate.
3. Frost the top of the bottom Layer.
4. Put the top layer on top of the frosting or filling. Frost the sides of the cake. Then frost the top of
the cake.
5. Gently and slowly remove each piece of waxed paper from under the cake.

Frostings
● Cooked frostings-use the principles of candy making. They include ingredients that interfere with
the formation of crystals in a heated sugar syrup. Then you beat them until fluffy.
● Uncooked frostings-are made by beating the ingredients together until they reach a smooth,
spreadable consistency.

Buttercream Frostings
Simple buttercream-made by combining butter, shortening, confectioner’s sugar, egg whites and
vanilla.
French buttercream-made with beaten egg yolks and butter.
Beat a boiling syrup into beaten egg yolks and whipping to a light foam.
Soft butter is then whipped in.This is a very rich, light icing.
Italian buttercream-made with Italian meringue and butter.
Italian meringue is made by beating a hot sugar syrup into the egg whites. Makes a very stable
meringue.
Making Italian Buttercream
● Place the egg whites and water in the bowl of a stand mixer. Whip until they begin to foam.
Gradually add the sugar and continue whipping until the whites form stiff peaks.
● Place the sugar in a medium sized saucepan. Slowly add the water and place the pan over medium
high heat.
● Cook the syrup until a thermometer reads 248º-250ºF.
 ● Turn the mixer to low speed and carefully pour the syrup between the whisk and the side of the
bowl.
● Leave the mixer running and cool the meringue to 80ºF.
● Add the butter- 2 Tablespoons at a time.
● Add your favorite flavoring.

Buttercream Frostings

German buttercream-made with butter, emulsified shortening and fondant-a sugar syrup. Simply
cream together equal parts fondant and butter.
Fondant is a cooked mixture of sugar, water and glucose or corn syrup added to encourage sugar
crystallization.
Swiss Buttercream-made with Swiss meringue and butter.
A Swiss meringue is made from egg whites and sugar that are warmed over a hot water bath
while they are beaten. This warming gives the meringue better volume and stability.