Project on Parle

8/2/2019 Project on Parle

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PRODUCTIONLAYOUT

Project on: Parle Glucose(parle G)

Parle products

Submitted by: Mona DharmendraVyasEmail :[email protected]

Class: T.Y.BA

Division: B

Roll. no.: 139

Submitted to: Prof.Page | 1


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ACKNOWLEDGEMENT

TO GANESHA

At the very outstrip, fail to find adequate words, with limited vocabulary, at my

command, to express my emotions, to dear god, whos eternal blessing, divine presences and

masterial guidance help me to fulfill my project.

I will always will obliged and grateful to my teacher for their inspiration andencouragement, which gave succor, and strength to my thought and mapped my way to find

modus operandi for myself.

Sometimes it is not easy to express our emotions in words to say thanks to our

parents, for there constant un-demanding love scarifies and inspiration guidance and never

ending enthugiagam.

And ostentation use of words will not be sufficient to my institution patkar

collage for their valuable and critical suggestion, constant inspiration and encouragement and

sentimental support throughout my work.

I extent my sincear thanks to my friends whos inestimable has help me a lot to

complete the project.

We hope that anyone with idea and suggestion or criticism regarding this project

will feel free to contact me. Such comments are always welcome and I solicit additional

correction and criticism which may be address to me at [email protected] .

Mona D. Vyas.

T.Y.Ba.

Roll No-139.

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INDEX

INTRODUCTION

PARLE BISCUIT STORY

THE STRENGHT OF BRAND

THE QUALITY COMMITENT

THE MARKETING STRENGTH

THE CUSTOMER CONFIDENCE

PARLE G - THE EVOLUTION!!! IMPORT - EXPORT

VARIOUS UNIT OF COMPANY

IMPORTANT PEOPLES OF THE COMPANY

HIERARCHY OF PARLE PRODUCTS

MANUFACTURING PROCESS FLOW CHART

PROCESS LAYOUT ( FLOW )

PROCESS LAYOUT ( DESCRIPTION )

RAW MATERIAL

INVENTORY

SHIFTS WASTAGES

LOOSE BOSCUITS

STEPHEN MIXER

ROTARY MOULD

COOLING CONVYER

LAMINATOR

BISCUIT BAKING OVEN

ROTARY CUTTER

COUNTING UNIT

SUGAR GRINDER MULTIPACK WRAPPING MACHINE

POLYBAG

TAPPING MACHINE

PACKING MACHINE

MACHINERY USED IN MAINTANCE OF MAJOR MACHINERY

USE OF COST CUTTING MEASURES

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ParleGlucose

Biscuits

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Company Profile

Basic Information

Company Name: PARLE PRODUCTS PVT. LTD.Business Type: ManufacturerProduct/Service

(We Sell):BISCUITS,CONFACTIONERIES

Address: V. S. KHANDEKAR MAR, VILE PARLE EAST

Ownership & Capital

Year Established: 1929

Trade & Market

Main Markets:

North America

South America

Southeast Asia

Africa

Mid East

Eastern Asia

Factory Information

Management Certification: HACCP

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1. INTRODUCTION

A long time ago, when the British ruled India, a small factory was set up in the suburbs of

Mumbai city, to manufacture sweets and toffees. The year was 1929 and the market was

dominated by famous international brands that were imported freely. Despite the odds and

unequal competition, this company called Parle Products, survived and succeeded, by

adhering to high quality and improvising from time to time.

A decade later, in 1939, Parle Products began manufacturing biscuits, in addition to sweets

and toffees. Having already established a reputation for quality, the Parle brand name grew

in strength with this diversification. Parle Glucose and Parle Monaco were the first brands ofbiscuits to be introduced, which later went on to become leading names for great taste and

quality.

2.HISTORYBiscuits were very much a luxury food in India, when Parle began production in 1939. Apart

from Glucose and Monaco biscuits, Parle did offer a wide variety of brands.

However, during the Second World War, all domestic biscuit production was diverted to

assist the Indian soldiers in India and the Far East. Apart from this, the shortage of wheat inthose days, made Parle decide to concentrate on the more popular brands, so that people

could enjoy the price benefits.

The incredible demand led Parle to introduce the brand in special branded packs and in larger

festive tin packs. By the year 1949, Parle Gluco biscuits were available not just in Mumbai

but also across the state. It was also sold in parts of North India. By the early 50s, over 150

tonnes of biscuits were produced in the Mumbai factory. Looking at the success of Parle-G, a

lot of other me-too brands were introduced in the market. And these brands had names that

were similar to Parle Gluco Biscuits so that if not by anything else, the consumer would err

in picking the brand. This forced Parle to change the name from Parle Gluco Biscuits to

Parle-G.

Parle-G was the only biscuit brand that was always in short supply. It was heading towards

becoming an all-time great brand of biscuit. Parle-G started being advertised in the 80's. It

was advertised mainly through press ads. The communication spoke about the basic benefits

of energy and nutrition. In 1989, Parle-G released its Dadaji commercial, which went on to

become one of the most popular commercials for Parle-G. The commercial was run for a

period of 6 years.

Parle-G grew bigger by the minute. Be it the packs sold, the areas covered or the number of

consumers. It became a part of the daily lives of many Indians. It wasn't a biscuit any more.It had become an icon. The next level of communication associated the brand with the

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positive values of life like honesty, sharing and caring.

Thankfully today, there's no dearth of ingredients and the demand for more premium brands

is on the rise. That's why, we now have a wide range of biscuits and mouthwatering

confectionaries to offer.

3.PARLE G - THE EVOLUTION !!!

Parle-Ghas been a strong household name across India. The great taste, high nutrition, and

the international quality, makes Parle-G a winner. No wonder, it's the undisputed leader in

the biscuit category for decades. Parle-G is consumed by people of all ages, from the rich to

the poor, living in cities & in villages. While some have it for breakfast, for others it is a

complete wholesome meal. For some it's the best accompaniment for chai, while for some it's

a way of getting charged whenever they are low on energy. Because of this,Parle-G is the

world's largest selling brand of biscuits.

Launched in the year 1939, it was one of the first brands of Parle Products. It was calledParle Gluco Biscuits mainly to cue that it was a glucose biscuit. It was manufactured at the

Mumbai factory, Vile Parle and sold in units of half and quarter pound packs.

The incredible demand led Parle to introduce the brand in special branded packs and in larger

festive tin packs. By the year 1949, Parle Gluco biscuits were available not just in Mumbai

but also across the state. It was also sold in parts of North India. By the early 50s, over 150

tones of biscuits were produced in the Mumbai factory. Looking at the success of Parle-G, a

lot of other me-too brands were introduced inthe market. And these brands had names that

were similar to Parle Gluco Biscuits so that if not by anything else, the consumer would err

in picking thebrand. This forced Parle to change the name from Parle Gluco Biscuits to

Parle-G.

Originally packed in the wax paper pack, today it is available in a contemporary, premium

BOPP packwith attractive side fins. The new airtight pack helps to keep the biscuits fresh

and tastier for a longer period.

Parle-G was the only biscuit brand that was always in short supply. It was heading towards

becoming an all-time great brand of biscuit. Parle-G started being advertised in the 80's. It

was advertised mainly through press ads. The communication spoke about the basic benefitsof energy and nutrition. In 1989, Parle-G released its Dadaji commercial, which went on to

become one of the most popular commercials for Parle-G. The commercial was run for a

period of 6 years.

Parle-G grew bigger by the minute. Be it the packs sold, the areas covered or the number of

consumers. It became a part of the daily lives of many Indians. It wasn't a biscuit any more.

It had become an icon. The next level of communication associated the brand with the

positive values of life like honesty, sharing and caring.

In the year 1997, Parle-G sponsored the tele-serial of the Indian superhero, Shaktimaan that

went on to become a huge success. The personality of the superhero matched the overallPage | 8
http://newwindow1%28%27parle-gspecial.html%27%2C%27name%27%2C%27365%27%2C%27455%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gadd.html%27%2C%27name%27%2C%27610%27%2C%27500%27%2C%27yes%27%2C0%29/http://xopenwindow%28%27parleg-premium1.html%27%29/http://xopenwindow%28%27parleg-premium1.html%27%29/http://www.parleproducts.com/images/PARLE-GDADAJI.rmhttp://newwindow1%28%27parle-gpositive.html%27%2C%27name%27%2C%27681%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/images/SHAKTIMAAN.rmhttp://newwindow1%28%27parle-gspecial.html%27%2C%27name%27%2C%27365%27%2C%27455%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gadd.html%27%2C%27name%27%2C%27610%27%2C%27500%27%2C%27yes%27%2C0%29/http://xopenwindow%28%27parleg-premium1.html%27%29/http://xopenwindow%28%27parleg-premium1.html%27%29/http://www.parleproducts.com/images/PARLE-GDADAJI.rmhttp://newwindow1%28%27parle-gpositive.html%27%2C%27name%27%2C%27681%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/images/SHAKTIMAAN.rm


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superb benefits of the brand. Parle extended this association with Shaktimaan and gave away

a lot of merchandise of Shaktimaan, which was supported by POS and press communication.

The children just could not get enough of Parle-G and Shaktimaan.

In the year 2002, it was decided to bring the brand closer to the child who is a major

consumer. A national level promo - `Parle-G Mera Sapna Sach Hoga' was run for a period of

6 months. The promo was all about fulfilling the dreams of children. There were over 5 lakh

responses and of that, over 300 dreams were fulfilled.

Dreams that were fulfilled ranged from trips to Disneyland atParis & Singapore; free ride

on a chartered plane; 20 scholarships worth Rs 50,000; a special cricket coaching etc.

The year 2002 will go down as a special year in Parle-G's advertising history. A year that

saw the birth ofG-Man - a new ambassador for Parle-G. Not just a hero but also a super-hero

that saves the entire world, especially children from all the evil forces. A campaign that is

not just new to the audiences but one that involves a completely new way of execution that is

loved by children all over the world Animation

To make the brand much more interesting and exciting with children, it was decided to

launch a premium version of Parle-G called Parle-G Magix in the year 2002. Parle-GMagix

is available in two exciting tastes - Cocoh and Cashew. The year 2002 also witnessed the

launch of Parle-G Milk Shakti, which has the nourishing combination of milk and honey,

especially launched for the southern market.

Parle-G continues to climb the stairs of success. Take a look at the global market where it is

being exported. First came the Middle East then USA followed by Africa and then Australia.

An Indian brand, that's exported to almost all parts of the world. After all that's what youwould expect from the Parle-G World's Largest Selling Biscuit.

3.1 HOW PARLE FOUGHT TO MAKE BISCUIT AFFORDABLETO ALL

Biscuits were very much a luxury food in India, when Parle began production in 1939. Apart

from Glucose and Monaco biscuits, Parle did offer a wide variety of brands.However, during the Second World War, all domestic biscuit production was diverted to

assist the Indian soldiers in India and the Far East. Apart from this, the shortage of wheat in

those days, made Parle decide to concentrate on the more popular brands, so that people

could enjoy the price benefits.

Thankfully today, there's no dearth of ingredients and the demand for more premium brands

is on the rise. That's why; they now have a wide range of biscuits and mouthwatering

confectionaries to offer.

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http://newwindow1%28%27parle-gshaktiman.html%27%2C%27name%27%2C%27736%27%2C%27500%27%2C%27yes%27%2C0%29/http://newwindow1%28%27parle-gsapna.html%27%2C%27name%27%2C%27737%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/images/G-man.rmhttp://newwindow1%28%27parle-gmagix.html%27%2C%27name%27%2C%27726%27%2C%27500%27%2C%27yes%27%2C0%29/http://newwindow1%28%27parle-gchoco.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gchoco.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gchoco.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gcashew.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gcashew.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gcashew.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gmilk.html%27%2C%27name%27%2C%27641%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/importexport.htmlhttp://newwindow1%28%27parle-gshaktiman.html%27%2C%27name%27%2C%27736%27%2C%27500%27%2C%27yes%27%2C0%29/http://newwindow1%28%27parle-gsapna.html%27%2C%27name%27%2C%27737%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/images/G-man.rmhttp://newwindow1%28%27parle-gmagix.html%27%2C%27name%27%2C%27726%27%2C%27500%27%2C%27yes%27%2C0%29/http://newwindow1%28%27parle-gchoco.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gcashew.html%27%2C%27name%27%2C%27360%27%2C%27265%27%2C%27no%27%2C0%29/http://newwindow1%28%27parle-gmilk.html%27%2C%27name%27%2C%27641%27%2C%27500%27%2C%27yes%27%2C0%29/http://www.parleproducts.com/importexport.html


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4.THE STRENGTH OF THE BRAND

Over the years, Parle has grown to become a multi-million US Dollar company. Many of the

Parle products - biscuits or confectionaries, are market leaders in their category and have

won acclaim at the Monde Selection, since 1971.

Today, Parle enjoys a 40% share of the total biscuit market and a 15% share of the total

confectionary market, in India. The Parle Biscuit brands, such as, Parle-G, Monaco and

Krackjack and confectionery brands, such as, Melody, Poppins, Mangobite and Kismi, enjoy

a strong imagery and appeal amongst consumers.

Be it a big city or a remote village of India, the Parle name symbolizes quality, health and

great taste! And yet, we know that this reputation has been built, by constantly innovatingand catering to new tastes. This can be seen by the success of new brands, such as, Hide &

Seek, or the single twist wrapping of Mango bite.

In this way, by concentrating on consumer tastes and preferences and emphasizing Research

& Development, the Parle brand grows from strength to strength.

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5.THE QUALITY COMMITMENT

Parle Products has one factory at Mumbai that manufactures biscuits & confectioneries while

another factory at Bahadurgarh, in Haryana manufactures biscuits. Apart from this, Parle hasmanufacturing facilities at Neemrana, in Rajasthan and at Bangalore in Karnataka. The

factories at Bahadurgarh and Neemrana are the largest such manufacturing facilites in India.

Parle Products also has 14 manufacturing units for biscuits & 5 manufacturing units for

confectioneries, on contract.

All these factories are located at strategic locations, so as to ensure a constant output & easy

distribution. Each factory has state-of-the-art machinery with automatic printing &

packaging facilities.

All Parle products are manufactured under the most hygienic conditions. Great care is

exercised in the selection & quality control of raw materials, packaging materials & rigid

quality standards are ensured at every stage of the manufacturing process. Every batch of

biscuits & confectioneries are thoroughly checked by expert staff, using the most modern

equipment.

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6.THE MARKETING STRENGTH

The extensive distribution network, built over the years, is a major strength for Parle

Products. Parle biscuits & sweets are available to consumers, even in the most remote places

and in the smallest of villages with a population of just 500.

Parle has nearly 1,500 wholesalers, catering to 4,25,000 retail outlets directly or indirectly. A

two hundred strong dedicated field force services these wholesalers & retailers. Additionally,there are 31 depots and C&F agents supplying goods to the wide distribution network.

The Parle marketing philosophy emphasizes catering to the masses. They constantly

endeavour at designing products that provide nutrition & fun to the common man. Most

Parle offerings are in the low & mid-range price segments. This is based on their

understanding of the Indian consumer psyche. The value-for-money positioning helps

generate large sales volumes for the products.

However, Parle Products also manufactures a variety of premium products for the up-market,

urban consumers. And in this way, caters a range of products to a variety of consumers.

7.THE CUSTOMER CONFIDENCE

The Parle name conjures up fond memories across the length and breadth of the country.

After all, since 1929, the people of India have been growing up on Parle biscuits & sweets.

Today, the Parle brands have found their way into the hearts and homes of people all over

India & abroad. Parle Biscuits and confectioneries, continue to spread happiness & joyamong people of all ages.

The consumer is the focus of all activities at Parle. Maximizing value to consumers and

forging enduring customer relationships are the core endeavours at Parle.

Their efforts are driven towards maximizing customer satisfaction and this is in synergy with

their quality pledge. " Parle Products Limited will strive to provideconsistently nutritious & quality food products to meet

consumers' satisfaction by using quality materials and byadopting appropriate processes. To facilitate the above we willstrive to continuously train our employees and to provide them anopen and participative environment."

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8.GLOBAL ENVIRONMENT

Going international is yet another trend followed by modern business houses.

Internationalization and globalization is fast becoming imperative for modern business due

to technological innovations, crumbling trade barriers, global flow of capital and technology,

information explosion, intensity of market competition, changing life styles and the demand

for new products. Production facilities are being set up in different countries and products are

being sold through a global network. Gradually, business houses are exposed to global

competition which augurs well for consumers. Internationalization of business is a means of

sustaining a strong domestic base in terms of technology, product, market and the capital

over a longer period.

At the company level, globalization means two things:

(a) The company commits itself heavily with several manufacturing locations around the

world and offers products in several diversified industries.

(b) It also means the ability to complete in domestic markets with foreign competitors. In thepopular sense, globalization refers mainly to multi-plant operations.

RELATING PARLE-G WITH THE GLOBAL ENVIRONMENT

According to Parle-G, the term GLOBALISATION does not merely mean imports and

exports, but letting your presence felt all over the world. Expansion and recognition are the

main factors of going global. The immense popularity of Parle products in India was always

a challenge to their production capacity. Now, using more modern techniques for capacity

expansion, they have begun spreading their wings and are going global.

Parle biscuits and confectionaries are fast gaining acceptance in international markets, such

as, Abu Dhabi, Africa, Dubai, South America and Sri Lanka. Even the more sophisticated

markets like USA & Australia, now relish Parle products.

Parle-G continues to climb the stairs of success. Take a look at the global market where it is

being exported. First came the Middle East then USA followed by Africa and then Australia.

An Indian brand, that's exported to almost all parts of the world. After all that's what you

would expect from the Parle-G World's Largest Selling Biscuit.

Other international companies choose India as a global market because labour in other

countries is costly as compared to in India. In India things are quite easier. Government has

become more liberal for MNCs to enter Indian market which results in high competition

with the in-house companies. For example: China has a huge impact on the Indian market.

Cameras from Japan and China are of hi-tech technologies which are available at the

cheapest rates. There is a huge gap between the prices of Indian products and such other

imported products. Another example is of Intel-II.

They have now started manufacturing chips in India which further resulted as a toughcompetition to other Indian companies. Another international biscuit making company is ITC

which winded up its business within a year due to tough competition laid by Parle-G.

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Parle-G has a strong base in India since 1939. it has now become the largest biscuit selling

company in entire India and is also proved to be three times more then the US based biscuit

manufacturing companies. Parle-G has 40 factories working all over the country including 6

mother units. These mother units are located at Mumbai, Rajasthan, Haryana, Bangladesh,

Bhuj and Uttaranchal.

Raymond Vernon had introduced a product-cycle theory in late 1960s, but this theory is still

relevant till today. This theory explains that how companies go global. Initially, small scale

companies produce attractive products and sell them in their home markets. Sooner or later,

foreigners come to know about these products. As the popularity of these products increases

they start exporting them abroad. As the foreign demand grows, the economies of foreign

production changes. Eventually, the company starts setting up their own plants globally. In

this manner various companies go global.

But Parle-G doesnt agree with this theory laid by Vernon. According to them there are four

stages that the company should follow for going global. They are: infancy, growth, maturity

and decline. Parle-G is yet at the growth stage of the theory for going global.

Going global for any company involves risk. Hence, Parle-G recruits a special team for

market surveys called a market research team. This team keenly studies the culture, market

situation, fashions, preferences, habits and taste of the consumers of the country they are

going to enter. As Parle-G is meant for poor class of population, other variety in biscuits

made by Parle-G are for middle and upper class people, they need to study all levels of

society to launch the product similar to their conclusions. Supplying or launching a new

product requires sample testing before the same. According to Parle-G, company should

behave in the same manner and culture as of its host country. They need to follow their laid

rules and regulations and their local laws.

Parle-G will continue in its host countries the same performance appraisal methods as in its

home country. Because they follow the norm which says that the employees are of same

capabilities and talents everywhere even though the working conditions are not the same.

Hence, they would appraise the performance of their employees based on caliber and not

based on the impression of the host countries.

8.1Imports-exports

The immense popularity of Parle products in India was always a challenge to their

production capacity. Now, using more modern techniques for capacity expansion, we have

begun spreading their wings and are going global.

Parle bisuits and confectionaries are fast gaining acceptance in international markets, such

as, Abu Dhabi, Africa, Dubai, South America and Sri Lanka.

Even the more sophisticated markets like USA & Australia, now relish Parle products.

As part of the efforts towards a larger share of the global market, Parle has initiated the

process of getting ISO 9000 certification. Many Parle Products have also won Gold, silverand bronze medals at the Monde Selection.

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9.VARIOUS UNIT OF COMPANY

There are five mother units and thirty one contact manufacturing units in India. The main

difference between mother units and contact units is that mother units produce more than one

product that is PARLE G, MONACO, KRACK JACK, SIXER, HIDE AND SEEK etc. while

contact unit manufacture only PARLE G.

Mother units are as follows.

Mumbai (Maharashtra)

Bhadurdgarh (Haryana)

Neemrana (Rajasthan)

Banglore and Kolkata

10.IMPORTANT PEOPLE OF THE COMPANY

CHAIRPERSON: MR. VIJAY CHAUVAN

DIRECTOR: MR. ANUP CHAUVAN

EXECUTIVE DIRECTOR: MR. AJAY CHAUVAN

COMMERCIAL MANAGER: MR. AMOL

FACTORY MANAGER: MR. NIVATIA

PRODUCTION MANAGER: MR. RAJESH RAUL

STORE MANAGER: MR. DIXIT

10.1 HIERARCHY OF PARLE PRODUCTS

CHAIRPERSON

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EXECUTIVE DIRECTOR

PRODUCTION MANAGER PRODUCTIONMANAGER

BISCUIT CONFECTIONERY

CHIEF ENGINEER ENGINEER OFFICER

HRD

BISCUIT CONFECTIONERY PRINTING

MANAGER

PERSONEL SUPERVISORS

ADMINISTRATOR CHARGE HAND

EMPLOYES EMPLOYEE

10.2 MANUFACTURING PROCESS FLOW CHART

RAW MATERIAL TESTING

MIXING

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MOULDING

BAKING

COOLING

PACKING

11. PROCESS LAYOUT

STEPHAN STEPHAN

MIXER MIXER

MOULDING OVEN CURVE

PLATE

COOLING CONVYER

CURVE PLATE

STALKING TABLE MULTIPACK

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MACHINE

BOX SEALING MACHINE

TAPPING

DEVIRSIONBELT

CONVEYORBELT CONVEYOR BELT

DISPATCH SECTOIN

11.1 PROCESS LAYOUT OF PARLE PRODUCTS LTD.

PARLE G are madeat parle products ltd. at vile parle .

First of all the parle products buys RAW MATERIAL from the various suppliers and stored

into the store room. This raw material is then sent to laboratory for testing and after testing

only it is used for manufacturing. The raw material consist of Wheat flour, Sugar, Partially

hydrogenated edible vegetable oils, Invert syrup, Leavening agents (503 Baking powder)

Milk, solids Salt Emulsifiers (E 322 or E 471 or E 481) and Dough conditioners (E 223).

Such a mixture of raw material is taken and mixed into STEPHAN MIXTURE, which is

high power mixture machine. Specially made for mixture of dough, from which the mixture

is passed to molder called ROTARY MOULDER. Through that moulder approximately

10,000 come out in a minute. Moulder had 260 cups fitted in it which gives shape to thebiscuits and an impression embossed on it of parle-g.

From rotary moulder the dough is passed through a 260 feet long OVEN which is

approximately 340* c. In oven there are three stages to be followed

Removal of moisture.

Building the structure of biscuits.

Colourings of biscuits take place.

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From oven the hot biscuits are placed on the COOLING CONVYOR, which is 260 feet

long and the biscuits continues to run on it for 5 to 7 minutes so that the biscuits become cool

and all the moisture that biscuits contain gets evaporated. And because of the above reason

the factory has S FLOW LAYOUT in the factory.

The conveyor continues to move to COUNTING UNIT where biscuits are counted and

seen that it is going on properly or not.

The conveyor continues till the biscuits reach the STALKING TABLE at which thebiscuits

are packed in very orderly manner.

From cooling conveyor sum biscuits are diverted through AUTO FEEDING MACHINE to

another stalking machine where packing is done.

From stalking table the biscuits are moved on conveyor to MULTI PACK WRAPPING

MACHINE were 16 biscuits are packed into a regular parle g wrapper so that the weight of

16 biscuits comes up to 100 grams.

Then 24 packets of parle g biscuits are packed into a POLY BAG

And after packing it into poly bag it is sent to SEALING MACHINE where it is sealed,

Then it is sent to CORRUGATE BOX SECTION in which 6 poly bags are placed and

Then the boxes are kept on conveyor and sent to DISPATCH SECTION from were the

biscuits are sent to various places in India and all over the world.

11.2 RAW MATERIAL

Wheat flour

Sugar

Partially hydrogenated edible vegetable oils

Invert syrup

Leavening agents (503 Baking powder)

Milk solids

Salt

Emulsifiers (E 322 or E 471 or E 481) and

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Dough conditioners (E 223) and contains added flavours.

The raw material is mixed in certain proportion, to get the best quality of biscuits. All the

ingredients are tested in laboratory so that no low quality of raw material is used in

manufacturing process. The raw material is tested for their acidic value, moisture it contains,

and quality of milk powder.

11.3 INVENTORY

The inventory of the company that is the raw material is of a week. They store such

inventory in store room and then is sent for testing in laboratory and after testing it is sent for

production.

11.4 SHIFTS

There is nearly 10,000 employees working in the company and are working in three

shifts.35,000 tones of biscuits are manufactured in a day of one particular product, and there

are such nine product manufactured in the factory.

11.5 WASTAGES

There are two type of wastage in factory. First is the waste materials fallen on ground. Such

waste material is of 1% which is marginal and acceptable which goes into total waste.

Second types of waste are the biscuit collected in tray of the multi-pack wrapping machine,

since these biscuit are broken they are notpacked and sold to the customer but collected in

other tray and sold as broken pieces and sold for less price for cattle feeding.

11.6 LOOSE BISCUIT

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On the stalking table one to two rows of baked biscuits are kept aside for selling it as loose

biscuits. They are normally assumed to be damaged biscuits but they are not damaged or

broken but company keep such loose packets of biscuits to sell it to the local people for

marginal rate of 33 Rs / kg.

12. FOLLWING ARE THE MACHINERY USED INMANUFACTURING

12.1 STEPHEN MIXER

The Stephan TK Mixer is an ideal component to fully automatically feed the down-stream

make-up equipment for biscuits, bread, rolls, buns, cake, sweet goods, cookies and crackers.

12.1.1The advantages are compelling:

High volume output results from the short kneading time and fast ingredient charging:

1000 kg/h to 6000 kg/h depending on the model.

Totally unassisted automatic discharge combines with predividing of the dough into

approximately 15 kg. Pieces, is the basis for a fully automatic operation without the need

for any full-time operator.

Dosing of flour, water, yeast, salt, shortening and other nutrients.

In a few seconds, all ingredients are homogeneously mixed. Then, as the dough begins

to develop, the Stephan energy meter control will ensure each dough is finished to the

same development

The Stephan Mixer is most economical with:

No-time dough formula Straight dough Liquid broth (yeast slurry) system

Flour fermented liquid sponge system.Page | 22


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Stephan Mixers are powerful and versatile.Automatic make-up equipment is fed totally automatically by the Stephan Mixer. Quality

improvement and automatic batching are the main advantages of the Stephan Mixer.

Biscuits and rolls will have bigger volumes, more uniform texture and a more tender and

delicate crumb.

The Stephan Mixer is also used efficiently in the cookie andcracker industry for products such as:

Biscuits

Bread sticks

Soda crackers

Rotary cookies

Wire-cut cookies

With only two different mixing and kneading tools, all of the above described products canbe produced.

12.2 STEPHAN MIXER

ROTARY MOULD COOLING CONVEYOR

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12.3ROTARY MOULD

structure in corrosion-proof; anodised aluminum

and Aisi 304 stainless steel satin stainless steel panelling

swivel wheels and

support feet

trays loader with automatic chain feed

feeder roller anodised aluminium

presser roller in White rubber

bronze moulder roller with quick change system

scraper blade in stainless steel

pressure adjustment of rubber roller on moulderroller

scraper blade adjustment

closed ring outlet belt with tension and centering

adjustment

belt cleaner blade with extractable drawer

product outlet with power driven roller

1.00 kW speed variator

12.4 COOLING CONVEYOR

The biscuit coming from stripping conveyor is directed on to the cooling conveyor to

transfer the heat in the biscuit to atmospheric air as it is passing on it. The total travel of the

cooling conveyor is 1.5 times the oven length. As per need specifications it need the travel of

150 ft. for effecting cooling. Cooling conveyor is made in a modular construction of 2.5

Meters. long and connected together to form the required length. The supporting side

channels are fabricated from 3mm thick M.S. sheet.

Idle rollers are spaced at 750mm apart on conveying direction and 1700mm on the return

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direction. All the idle rollers are of 48mm dia, mounted on 6004 ZZ deep groove ball

bearings with grinding finish and hard chrome plated for hygienic conditions.

During the production practically about the droppings of oil from the cloth due to rubbing of

cloth against tie angles when producing high fat biscuits. To minimise this is replaced the all

tie angles also with idle rollers. This might costs little extra, but you can maintain hygienic

conditions at working area.

Drive drums are two no's. of 220mm dia and projections are made on the surface of drums to

minimize slip or covered with friction grip rubber tape. Manual tensioning and tracking are

provided.

You can rely only on feeder table to stack the oil sprayed biscuits which does not require

more travel after oil spraying.

12.5 LAMINATOR

Laminators are generally used for production of all kinds of hard biscuits, crackers and

cocktail snacks. With laminator it is possible to create a puffy pastry-like structure, which is

of decisive importance for the quality level and consequently for the sales success.

Laminating of Dough band improves the weight/volume ratio considerably i.e., quantity

increase at same weight.

In this superior functioning machine the dough band received from sheeter of 838mm width

is passed through two shuttles. The dough sheet is cut into pieces by a knife for a length of

1000mm (39") and these pieces are laid on bottom shuttle by top shuttle. This bottom shuttle

layers the pieces on first conveyor unit of 1000mm (39") wide production line very carefully.

The first conveyor unit feeds to the first gauge roll unit. No. of layers can be controlled by

the speed of first conveyor unit or increasing the speed of sheeting unit and laminator by

A.C. variable frequency drive.

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12.6 BISCUIT BAKING OVEN

Construction: The oven body consists of steel steam tight tunnel with equally divided zones

of the radiators. Stainless steel expansion joints are provided between these zones in order to

eliminate the expansion of the oven section. The inspection doors are provided for inspection

of the baking goods during the process. And it is 260 feet long.

Firing Chambers:

The complete chamber are insulated with minerwoll filled from outside to conserve heat and

increase efficiency. The fully automatic imported burner shall be fitted to the chamber and

the temperature shall be controlled by automatic temperature controller on the control panel.

Insulation:

The complete oven will be covered with 10" thick mineral wool insulation from top, bottom

and the sides. The bottom portion of the oven at the sides will be covered with CRC sheets

for the conveyor protection and to avoid heat loss.

Baking System:

The baking in the heating chamber takes place by radiators located under and above the wire

mesh band which distribute heat for uniform baking. The recirculation heating gases of these

radiators can be controlled for each zone separately. The closed recirculation system is

having slight vacuum so that combustion gases can not enter into the baking chamber. The

ventilating fan is for circulation of the heating gases through the recirculation system and

thermostatically controlled burners provide the set temperature of the heating gases.

Fans:All the circulating fans are fabricated from M.S. & S.S. and will be well balanced to avoid

vibration and will give noise free operation in high speeds

12.7 ROTARY CUTTER

The single head rotary cutter prints fine design on a continuously fed dough sheet and also

cuts out the individual dough piece.

The unit powered by 1.5KW helical geared motor and speed controlled by AC frequencycontroller. Drive is given to cutting roller only to accommodate different sizes of die's in this

machine.

Rubber lined anvil roller is adjustable in height so that pressure can be controlled at both

sides in parallel or independently. The anvil roll is being driven by friction of the cutting

web, which is independently powered by its own separate drive. For safety reasons the

cutting roll is provided with guard, removal of which stops the motor.

12.8 COUNTING UNIT

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The counting unit counts and see that the biscuit making process is going fine or not, i.e. as

per the program set in the machine, program is set as per the grams required. Generally 16

biscuits are taken by the counting unit so that it leads to 100 grams.

12.9 SUGAR GRINDER

Turbulence System and Steam Extraction:APPLICATION: The machine is used to granule (crystal) sugar to make it in powder form

for using in biscuit recipe.

DESIGN: Hammer Mill type, body of the machine is fitted on a sheet metal

box/container/receiver with one air exhaust balloon. The driving motor is fitted on the top of

the box. In case of auto feeding a bucket elevator is fitted at one end of the box.

OUTPUT: 10 Kg/min. (icing sugar)

FEEDING: Automatic

POWER LOAD: 5 HP for grinder, 1 HP for auto feeder with built-in control panel

12.10 MULTIPACK WRAPPING MACHINE

This machine helps in wrapping the biscuits on the particular wrapper fixed on the roller of

the machine. The wrapper is feed into the machine and the sealing of the wrapper is done by

four heater roller, which is fitted on the machine. This heater roller heat up the plastic and

seals the packet. And at the same time the jaw cutter cut the packet on the cutting edge

marked i.e. as per the grams of the packet which is feed in the automatic machine (100 120,120 150, 150 -170, 170 - 190). The packets coming out from the wrapping machine in a

minute is programmed in computer and can be changed as per the need.

12.11 POLY BAGS

Poly bags contain 24 packets of parle g biscuits in one poly bag. There are 4 workers

employed on this section who take care of the work by putting 24 packets of biscuits in the

bag and forwarding it to sealing machine section.

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12.12 SEALING MACHINE

The sealing machine has heater rod for sealing the poly bag in which 24 packet of biscuit are

placed, and it have a conveyer belt on other side so that when the poly bag passes through the

heater and get sealed then it is passed to the tapping machine.

12.13 TAPPING MACHINE

Six such poly bags are placed in one such corrugated box and the box is passed through the

tapping machine where are tapped and then sent through a long diversion conveyer belt. This

belt helps to transfer the box to the dispatch section directly. 36 boxes are arranged on pallet

in the dispatch section, from where they are transferred to the various dealers all over the

India and world wide.

13. MACHINERY USED IN MAINTENANCE OF MAJORMACHINERY

Laphe

Drilling machine

Shaper

Miller

Pantograph and many more.

14. USE OF COST CUTTING MEASURES.

For example:

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3S :-SEISO

4S :-SEIKETSU

5S :-SHITSUKE

Japanese TermEnglish Equivalent

Meaning in Japanese Context

Seiri :-Tidiness Throw away all rubbish and unrelated materials in the workplace

Seiton:- Orderliness Set everything in proper place for quick retrieval and storage

Seiso:- Cleanliness Clean the workplace; everyone should be a janitor

Seiketsu :-Standardization. Standardize the way of maintaining cleanliness

Shitsuke :-Discipline Practice 'Five S' daily - make it a way of life; this also means 'commitment'

1S:- SEIRI

Seiri

The first step of the "5S" process, seiri, refers to the act of throwing away all unwanted,

unnecessary, and unrelated materials in the workplace. People involved in Seiri must not

feel sorry about having to throw away things. The idea is to ensure that everything left inthe workplace is related to work. Even the number of necessary items in the workplace

must be kept to its absolute minimum. Because of seiri, simplification of tasks, effective

use of space, and careful purchase of items follow.

2S:- SEITION

Seiton

Seiton, or orderliness, is all about efficiency. This step consists of putting everything in

an assigned place so that it can be accessed or retrieved quickly, as well as returned in that

same place quickly. If everyone has quick access to an item or materials, work flow

becomes efficient, and the worker becomes productive. The correct place, position, or

holder for every tool, item, or material must be chosen carefully in relation to how the

work will be performed and who will use them. Every single item must be allocated itsown place for safekeeping, and each location must be labeled for easy identification of

what it's for.

3S:- SEISO

Seiso

Seiso, the third step in "5S", says that 'everyone is a janitor.' Seiso consists of cleaning up

the workplace and giving it a 'shine'. Cleaning must be done by everyone in the

organization, from operators to managers. It would be a good idea to have every area of

the workplace assigned to a person or group of persons for cleaning. No area should be

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left uncleaned. Everyone should see the 'workplace' through the eyes of a visitor - always

thinking if it is clean enough to make a good impression.

4S:- SEIKETSU

Seiketsu

The fourth step of "5S", or seiketsu, more or less translates to 'standardized clean-up'. It

consists of defining the standards by which personnel must measure and maintain

'cleanliness'. Seiketsu encompasses both personal and environmental cleanliness.

Personnel must therefore practice 'seiketsu' starting with their personal tidiness. Visual

management is an important ingredient of seiketsu. Color-coding and standardized

coloration of surroundings are usedfor easier visual identification of anomalies in the surroundings. Personnel are trained to

detect abnormalities using their five senses and to correct such abnormalities immediately.

5S:- SHITSUKE

Shitsuke

The last step of "5S", Shitsuke, means 'Discipline.' It denotes commitment to maintain

orderliness and to practice the first 4 S as a way of life. The emphasis of shitsuke is

elimination of bad habits and constant practice of good ones. Once true shitsuke is

achieved, personnel voluntarily observe cleanliness and orderliness at all times, without

having to be reminded by management.

KAIZENS

Kaizen , a Japanese term that basically translates to 'continuous

improvement' or 'change to become good. Kaizen is aimed at producing

more and more value with less and less wastes (higher efficiency), attaining better

working environment, and developing stable processes by standardization.

TQM

Total Quality Management (TQM) is a business management strategy aimed at embedding

awareness of quality in all organizational processes.

Total: Involving the entire organization, supply chain, and/or product life cycle

Quality: With its usual definitions, with all its complexities

Management: The system of managing with steps like Plan, Organize, Control, Lead Staff,

provisioning and organizing.

POKA-YOKE

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Poke Yoke is a Japanese technique which means mistake proof system. Yokeru means to avoid

and Poka means inadvertent errors. Poka Yoke methods are simple concept for achieving this

goal.

DATA ANALYSIS

% of workers who strongly agree to the following statements

% of workers who think rejection can be fully eliminated

According to workers which among the following factors are main cause of wastage

% of workers who think rejection can be fully eliminated

%of workers who think Kaizens has reduced the wastage

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67%

33%

YES

NO

97%

3%0%0%

YES

NO


34/41

% of workers thinking Kaizens are important

Deptt wise result of PQS quiz

Also a PQS test was taken of workers and their average score was 75.86%

Page | 34

87%

13%0%0%

YES

NO

26%

17%

18%

18%

21%

PERSONNEL

ACCOUNTS

IT BRANCH

CHIP PLANT

ENG. DEPTT


35/41

16. Labor participation in management.

SHIFTS

There is nearly 10,000 employees working in the company and are working in three

shifts.35,000 tones of biscuits are manufactured in a day of one particular product, and there

are such nine product manufactured in the factory.

The total work strength of Parle-G in its Mumbai factory is 750 blue color workers out of

which 70 are female workers. Other than its labor staff there are 200 more administrative

staff.

For maintaining cordial relationships between management staff and labor staff there is one

labor union at present. Earlier there were two labor unions which divided the laborers into

two sections. This increased competition which gave good productivity initially but later

proved to be the cause of industrial dispute in Parle-G. The two unions started internaldisputes which forced the company to reunite both the unions into one union. This was the

last case of industrial dispute occurred in Parle-G. Since then there is no such case of

industrial dispute.

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.

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1.SUMMARY

There is a proper repo between the Workers, Management, and Trade Union.

The company has effectively implemented the HR techniques in the plant.

The workers and employees are well aware of the concepts of these techniques.

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All the workers have positive response towards the techniques and methods being adopted by the

plant.

Majority of workers are happy with the system of the factory.

They are satisfied with the policy of the factory.

Workers are given basic knowledge of the machines before setup of it.

Requirement of the workers are meet by the management the company.

There is place for the disable people in the company.

Proper incentives are provided for housing facilities.

There are medical facilities for the workers.

Loans facilities for the workers with minimum interest rates.

The HACCP applied in the plant is working in its most effective manner.

The wastage in the plant is least and the production team and the workers try their level best to

reduce it even more.

The wastage of the biscuits that fall on the floor is minimized by the use of trays under the

machines.

The use 5S in the plant has helped in keeping the plant well and tidy.

The under baked or over baked biscuits are reprocessed by sending them back to the chura store and

thus minimizing the wastage.

The Kaizens given regularly by the employee and the workers has also helped in reducing the

wastage and increase the effective production.

The total wastage of the plant is sent to the poultry farms and it is around 1 truck in 6 months.

All the workers have positive response towards the techniques and methods being adopted by the

plant.

1.Suggestions

The management should be more protective for the workers.

There is should be more interaction of the workers and the management.

Trade union should let have a interaction on the worker and management.

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Disable workers should be taken care by the trade union.

Bonus are not given on time and sometime not given at all.

Travelling facilities for the workers are not proper; the transport sometimes is cancelled at the last

moment.

Pick and drop of the buses are not frequent and are not on time, so buses should be increased.

Transport for the workers who stay far in central Mumbai, should also be provided with transport

facilities.

The condition of the canteen should be improved, more fans should be placed.

The company should focus more over the application of the Kaizens.

The drop down belt at the Krackjack biscuit must be replaced by the straight belt as used in Monaco

since it costs least wastage.

The company may also use the other HR techniques so as to make more effective production like

Andon, Six thinking Hats, etc

The power cuts that affect a lot to the production and results in wastage must be controlled. Sinceone power cut of 3-5 seconds wastes at least 10-15 packs of biscuits.

Another cause of wastage is machinery breakdown. So regular checks on the machines must be

adopted.

Some kaizen like cuts in the conveyor belt at Krackjack machine to assure the safety requirements

of the operator, a railing of nearly 1 and inches must be put along the sides of the conveyor belt

so as to minimize the falling of biscuits during the in line process of the manufacturing, that would

also minimize the use of trays under the machines.

Quesinior

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Bibliography

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