DEFECT REDUCTION IN THE PUFF PASTRY FORMING PROCESS A CASE STUDY OF BAKERY PRODUCTION FACTORY

Abstract

The purpose of this research is to reduce defect in the puff pastry forming process in a case study of bakery production factory. Over a period of three months, data was gathered on defects occurring during the production of puff pastries. Out of a total production of 15,275,198 pieces, there were 180,262 defects, resulting in a defect rate of 1.2%. Upon categorizing these defects, it was found that the primary issue was filling spilling over the sides of the puff pastries, accounting for 0.346% of all defects. Therefore, this issue was analyzed using Fishbone diagrams and the Why - Why technique, identifying the main cause as the improper placement of filling too close to the edge of the dough sheet due to the lack of specified filling positions. This research resolved by designing and implementing equipment to define the filling positions, along with creating work manuals and training working methods for both employees and supervisors. The result from improvement shows that the defect from the puff pastry filling spilled over the sides has been decrease from 0.346% or 1,994,138 baht per year to 0.067% or 383,733 baht per year, reduced by 1,610,405 baht per year or 80.6%.