A
REPORT
ON
PARLE PRODUCTS
IN
OPERATIONS MANGEMENT
MASTER OF MANAGEMENT STUDIES
University of Mumbai
(2009-2010)
SUBMITTED BY
GROUP IV
UNDER THE GUIDANCE OF
PROF. SURBHI AGARAWAL
SUMAN EDUCATION TRUST
“DILKAP RESEARCH CENTER AND INSTITUTE
OF MANAGEMENT STUDIES”
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PARLE PRODUCTS
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TEAM MEMBERS
Mr. Akshay Sononi……………..22
Mr. Krishnahari Shriramula…..23
Mr. Chetan Mhatre…………….24
Miss. Nilam Mali………………..25
Mr. Jayesh Parmar……………..26
Miss Janavi Pitale……………….27
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ACKNOWLEDGEMENT
It is our immense pleasure to submit this project on
PARLE PRODUCTS. This project is a result of the effort taken
by us to collect as possible information on the topic and it
highlights on the soil erosion on farmland, which is of high
importance with reference to our environment.
We are taking this opportunity to thanks our project
guide Prof. Surbhi Agarawal for giving this opportunity to
work on this project and for the guidance provided without
which this project would have been an unsuccessful attempt.
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INTRODUCTION ABOUT COMPANY
Parle Products has been India's largest manufacturer of biscuits and
confectionery, for almost 80 years. Makers of the world's largest selling
biscuit, Parle-G, and a host of other very popular brands, the Parle name
symbolizes quality, nutrition and great taste. With a reach spanning even
the remotest villages of India.
Many of the Parle products i.e. biscuits or confectioneries, are
market leaders in their category. With a 40% share of the total biscuit
market and a 15% share of the total confectionary market in India, Parle
has grown to become a multi-million dollar company. While to
consumers it's a beacon of faith and trust, competitors look upon Parle as
an example of marketing brilliance.
History: In 1929 a small company by the name of Parle products
emerged in British dominated India. The intent was to spread joy and
cheer to children and adults alike, all over the country with its sweets
and candies. A small factory was set up in the suburbs of Mumbai, to
manufacture sweets and toffees. A decade later it was upgraded to
manufacture biscuits as well. Since then, the Parle name has grown in all
directions, won international fame and has been sweetening people's
lives all over India and abroad.
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Apart from the factories in Mumbai and Bangalore Parle also have
factories in Bahadurgarh in Haryana and Neemrana in Rajasthan, which
are the largest biscuit and confectionery plants in the country.
Additionally, Parle Products also has 7 manufacturing units and 51
manufacturing units on contract.
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INTRODUCTION ABOUT PARLE’S PRODUCT
Krack-jack deserves points for having the sense to dispense with
the annoying Krack and Jack.
Parle a name known for its original products. Parle is always the one to
introduce a type of biscuits while the other follow suit. Parle started as a
small scale industry in 1929. It started production of biscuits, which we
still enjoy as ‘Parle-G’.
‘Hide n Seek’ everyone has played this game for sure. Here my tongue
plays this game with the chocolate chips each time I take a bite of Hide n
Seek.
‘Hide n’ Seek’ comes from the house of Parle. What distract me are the
chocolate chips hidden in the biscuits. Hide n’ Seek are square shaped
biscuits with diagonal ridges and small grooves filled with chocolate
chips.
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MANUFACTURING LINE PROCESSING LAYOUT FLOW CHART:
RAW MATERIAL TESTING
MIXING
MOULDING
BAKING
COOLING
PACKING
PROCESS LAYOUT
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LINE PROCESSING LAYOUT OF PARLE PRODUCTS LTD.
PRODUCT DESIGN:-
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After visiting plant at Khopoli and after doing analysis we can say
approach used for product design is design for quality.
Designing for quality:-
2 aspects for design for quality product design are included in the
product design are included in production plant at Khopoli.
Design for robustness:-
Robustness can be designed into product by assuming less than desirable
field condition in terms of heat, cold, humidity and nature of use.
Designing for reliability:-
Reliability has been improved by improving production techniques and
by using improved testing methods.
Process design:-
Repetitive process (line process) is being used for process design. The
main concept of repetitive process, there is continuously raw material is
feed into machine. Machines are moderately flexible.
High volume standard product.
Low labour skills.
Material move in line flow from one operation to another.
Less work in progress inventory.
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Manufacture to stock strategy with standard products held in finished
goods inventory.
Availability of raw material:-
There are 2 kinds of biscuits which are produced in this production
plant Parle-G and Milano the raw material required for production of
both is easily available in ample amount.
Advantages:-
Reduced cost of transportation.
Regular and proper supply of material.
Saving in cost of transportation of material.
Availability of power:-
Although power is not continuously available but they have taken
sufficient majors to keep supply of electricity uninterrupted.
Availability of labour:
As plant is located in remote place. Process does not require skilled
labour.
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Laborers are available at low cost in sufficient number. In all there are
525 workers working in Khopoli plant of Parle.
Civic amenities’ are provided for labour that came to Khopoli from
different state. Along with this company implement number of scheme
for welfare of worker which motivates them to give their best for well
being of company. As plant is located at remote place their might be
exemption from taxes imposed.
The following civic amenities are provided by Parle and company:
Hospital facility
Hostel and transport facility
Birthday celebration of the individual employee,
Visit to worker’s home
Facility layout:-
The plant at khopoli satisfies following qualities of good layout:-
Provide enough production capacity.
Utilize labour efficiently .utilize space efficiently.
Provide ease of supervision.
Allow ease of maintenance.
Allow high machine utilization.
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Product layout:-
It involves arrangement of machine in one line, depending on sequence
of operation.
Two machine are kept horizontal to each other so that it save the space
and sufficient space between the packaging centre
In this material are fed into first machine and finished product come out
of last machine.
In between partly finished goods travel from machine to machine.
Where output of one machine becomes input to next machine.
The machines used are special purpose machines for product layout.
Scheduling approach:-
Scheduling approach used here is forward scheduling. Marketing
department set monthly production target for production department at
each plant there are 7 mother plants and in all 17 plants. Product demand
changes monthly and change is conveyed by marketing department.
Monthly target is divided in daily basis by engineering people as per
desired production they set speed of conveyer belt. Maximum capacity
of production plant is 225 metric tones on single day.
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Parle product layout is batch type of layout, Product choice is
continuous type because of raw material continuously feed into the
machine.
Observations :
Two machine are kept horizontal to each other so that it save the space
and sufficient space between the packaging centre
They take care of hygienic condition
Procedure:
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.
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 the biscuits 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 degree Celsius.
In oven there are three stages to be followed
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Removal of moisture.
Building the structure of biscuits.
Colorings of biscuits take place.
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 the biscuits 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
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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.
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
Dough conditioners (E 223) and contains added flavors.
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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.
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.
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.
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
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biscuit are broken they are not packed and sold to the customer but
collected in other tray and sold as broken pieces and sold for less price
for cattle feeding.
LOOSE BISCUIT
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. This is practiced in other plants of Parle Company.
FOLLWING ARE THE MACHINERY USED IN
MANUFACTURING
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.
The 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.
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Totally unassisted automatic discharge combines with pre dividing 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
From batch to batch, the dough will be consistently uniform "Process
Control"
Compact construction, no building preparation necessary, almost
service-free day to day operation.
The direct drive design allows the kneading element to be fastened
directly onto motor shaft. There is no coupling or power transmission.
Easy to clean.
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Only solid stainless steel construction.
Quiet operation, less vibration.
How the Stephan Mixer works.
The operation can be divided into four phases: loading, mixing,
kneading and discharging. After loading the mixer with all ingredients,
the mixing process starts.
The unique shape of the mixing/kneading tool, combined with the
mixing baffle, produces a very homogeneous mix. The combination of
the mixing tool allows for the optimum hydration of the flour. Due to
this intensive hydration, a higher yield is possible in the range of 1.5-3%
depending on the type of dough. Stephan Mixers are powerful and
versatile.
STEPHAN MIXER
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ROTARY MOULD COOLING CONVEYOR
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CONCLUSION
Parle G is known for the better quality and better price. It is the only
multinational company which is producing a better quality of biscuits at
very low price with good taste.
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