PART-A

Corporate profile UNIBIC India was incorporated in August 2004 to produce world class biscuits in a niche, unique and premium segment.

UNIBIC Australia is a niche player in the Australian biscuit market and has been in business for over 40 years. UNIBIC Australia markets under a licensing arrangement with RSL (Returned Service Men League). Brands like ANZAC have iconic status as well as significant equity and historical association in Australia and New Zealand.

UNIBIC Australia has a range of over 40 products including specialty Australian and European cookies, centre filled products and niche products like Weight Watchers (under a joint venture agreement with Weight Watchers of USA).

UNIBIC in Australia does things which are different from the main line manufacturers and does not compete on price. Its reason for being is to produce niche, unique and premium products. It also works under licensing arrangements in order to leverage existing brand equity.

UNIBIC India has its factory and infrastructure in Bangalore with state of the art machines from Italy. It is the first biscuit company to have put up a wire cutting technology which provides superior quality products and is the only method available to make real cookie. This has been done to create quality products as well as to build in a structural competitive advantage. The Company has also installed equipment and packaging machinery for exports, which are both captive as well as strategic partners, will require world approved standards.

HACCP (Hazard Analysis and Critical Control Point) certification has been done and recently they have obtained BRC (British Retailers Consortium) certification.

The Company has a threefold strategy to provide World class product at affordable prices to keep our customers delighted.
1. To manufacture and market the best quality products in the Indian consumer market with emphasis on major towns and organized trade. The company has launched Chocolate Chip cookies (Bradman), Oatmeal Cookies (ANZAC), Butter, Butter Cashew, Choconut and Jamz Cookies. The company has focused on its distribution and sales effort Pan India across Modern Retail, Traditional Trade and Institution. We are present in more than 1,00,000 outlets and have extensive coverage across all channels all over India. Unibic proposes to launch speciality health products (Sugar free) and milk cookies. 2. To build strategic alliances by building specialized products with competitive advantages. Unibic India has entered into an exclusive agreement with Caf Coffee Day to produce coffee accompaniment cookies. The company is also considering such offers from other Branded Chain stores. 3. Exports: Exports are a major plan for the Company. UNIBIC India has relationships in major markets particularly Australia, New Zealand, UK and US. They are already marketing their products in those countries through their super market chains. This has provided an excellent platform for UNIBIC India to get market access for a range of products to be produced from India. These include assortment packs as well as potion packs. UNIBIC India is also exporting to Middle East and South East Asia. UNIBIC India has an complete range of gifting packs which will be packed in tins for festivals such as Diwali, Christmas etc. People are looking for affordable good quality, healthy and long shelf life products. The Company intends using celebration packs to promote the corporate gift segment in Industries like Pharmaceuticals and those who gift both to their employees and business associate.

Cookies and biscuit

Most people confuse cookies with biscuits. The truth is when it comes to Cookies and biscuits, there really isnt much to compare. Cookies are softer and tastier than traditional biscuits. Cookies use wire cut technology that allow them to have a soft and chewy texture. Biscuits on the other hand, due the high compression of the dough piece in between the rubber roller and the die roll cavity, give a denser texture. When it comes to chocolate chips and fruit ingredients, cookies allows the inclusions to embed themselves in the midst of the rich dough, to give fantastic flavor and taste. Biscuits on the other hand, run a risk of burning the inclusions while baking, which is why most ingredients end up on the bottom of the biscuit. No matter how you look at it nothing comes close to enjoying a perfect cookie.

Unibic and society

Australian and New Zealand soldiers during World War 1 displayed courage & determination which earned them the highest respect. A spirit existed which bound them, built around the desire to look after each other. This became known as the Anzac spirit. Meanwhile at homes, mothers and wifes of the soldiers were busy making cookies to send to the war front to raise the morale of their men. The Anzac Cookies- as they became known proved very popular among the soldiers as well as at home where they were sold to raise money for the Red Cross in support of the war veterans. These cookies became an institution and in conjunction with Unibic are sold in Australia, NZ , UK and USA. So Unibic are proud to bring Australias favorite cookies to India in support of Indias Jawans. Each time you buy a packet of Unibic ANZAC cookies, money is being raised to provide support to Indias war widows, as well as the Indian JAWANS who risk their lives for us every day. UNIBIC donates 3% of sales for the support of Indian veterans.

Industry Profile
Unibic Biscuits India, in which Unibic Australia has a majority stake, is not quite averse to another takeover deal after an earlier bid by Marico was aborted because of valuation issues.

FOCUS ON NICHE SEGMENT

The takeover would have accelerated Unibic's growth trajectory, but for now the company does not want to be distracted by the takeover experience'. Instead, it wants to focus on building the brand in a niche segment that is high on both the price and wellness factors. There is a vacant space here as there are no Indian players in this slot, Mr Nikhil Sen, Unibic's Managing Director told Business Line. The company was launched in 2004 and has brands such as Chocolate Chip cookies (Bradman), Oatmeal Cookies (Anzac), Butter, Butter Cashew, Choconut and Jamz Cookies.

Unibic Australia holds about 65 per cent stake in the Indian company and the rest is held by Mr Sen and private equity investors. Marico's takeover attempt was to acquire an estimated 51 per cent stake in Unibic. The company is also considering a foray into other segments such as breakfast offerings on the health' platform. Having strengthened the brand in the southern and western regions, the company will now focus on the northern and eastern markets. Mr Sen, We'll never be a rural brand, and plan to be a national brand in 12-18 months and be present in 21 markets across the country. In June 2012 Early this year, Unibic launched its sugar-free range of cookies and is now ready to bring out a range of sugar-free cream biscuits for diabetics.

COOKIE-DRIVEN
Retail sales of the Unibic brand of cookies make up about 80 per cent of the company's revenues. About 10 per cent of the revenues come from manufacturing cookies for the HORECA (hotels, restaurants and catering) segment and for Food Bazaar ( under the brand Tasty Treat) and the rest is from exports.

DETAILS OF COMPANY 1 Location

51/1A, Heggadadevanapua Village, Huskur Road, Bangalore 562 123.

2 Telephone no.

+91 -80-23712008

3 Employees 4 Certificates 5 Franchise

180
HACCP (Hazard Analysis and Critical Control Point) & BRC (British Retailers Consortium) certification.

Entire industry is set up in Bangalore only.

INFRASTRUCTURAL FACILITIES
Unibic India Pvt Ltd has its corporate office at # 1134, Shreram Nivas, 5th Floor, 100 Feet Road, H.A.L. 2nd Stage, Indiranagar, Bangalore 560 038.

Its manufacturing unit is located at 51/1A, Heggadadevanapua Village, Huskur Road, Bangalore. The manufacturing plant is made of different divisions viz., Mixing division Oven Quality Cold storage warehousing Packaging Section Canteen.

Mckinseys 7S frame work

1. STRATEGY: The following are the strategies adopted by Unibic in accordance with the company principles: Launch all products under Unibic master brand Operate only in value added Foods market. Set up industry standards for Hygiene and food safety. Operate only in categories in a niche market.

2. STYLE: Style is one of the seven levers which top managers can use to bring about Company change. The style of the company becomes evident through the patterns of actions taken by member of top management team over a period of time. The Company is following the participative and social type of leadership in which all the level of managers interact with each other for achievement towards the goals and report to each other for achievement towards the goals and report to the higher officials. Managers work together as team to solve todays and tomorrows problems in a significant manner. The Organizations style of management can be described as to be participative in nature. The reasons to support this are as follows: Whenever important decision are to be made, the whole staff is allowed to participate in the decision making where by suggestions are sought and if found appropriate are accepted and implemented. Top management communications with each and every one in the most modest way being casuals at certain times. The response from the entire staff is also the same, when everyone gets to know and every happening then and there and this proves to be good relation with the top management. The top management always encourages changes in the Organization provided they happen to be always ready to cope with different situation.

Each and every person is involved in the success of the Company and not just key person, as Unibic Biscuits acclaims the efforts of the entire staff.

3. STRUCTURE: Sub structure detailing with each functional discipline Detailed study of various departments & their functions:

PRODUCTION DEPARTMENT Production and Operations The manufacturing process involves various subsidiary operations like the processing of raw materials, mixing, cooling and packaging. This process is carried out under the strict supervision of Production head. Procurement of Raw Material The quality control starts from the purchase of quality raw materials. These raw materials are directly purchased from the growers and original manufacturers. The packing materials and other requirements are dealt directly with manufacturers to maintain the standard of quality and to curtail the overhead costs. Functions of Production Department To produce required quantity of products as per the order placed. To ensure that there is orderly flow of materials during the process of manufacturing. Scheduling and machine loading to ensure coordinated manufacturing and completion as per production plan. Before the purchase of required material the production department should inform the stores manager. The production manager should ensure that break down in any particular Machine should not affect the whole process of production.

MARKETING DEPARTMENT Concept of Marketing Marketing is more than a company department; it is an orderly and insightful process for thinking about and planning for markets. Marketing department functions with the coordination of other departments namely production, finance and research and development. A marketer can rarely satisfy everyone in the market therefore before marketing his products he has to start with market segmentation. Salient Features of Marketing It is a creative function It promotes trade and employment wants There is an emphasis on what consumer wants The aim of marketing is to make selling superfluous There is an emphasis on what consumer wants

A Simple Marketing System Communication Goods / Services Money Information

Modern economics abound in markets. Sellers and buyers are connected by four flows. The sellers send goods and services and communication to market in return they receive money and information. The inner loop shows an exchange of money for goods and services the outer loop shows an exchange of information

ADVERTISEMENT DEPARTMENT: This unit is mainly focused on the activity of advertisements through media TV channels, pamphlets etc.

PERSONNEL DEPARTMENT Responsibilities: To add in recruitment and selection of men for the appropriate job. To discuss and decide upon the grades of employee and to fix their wages. To have discussions with the unions of the company in and out of the court. To receive quarterly /monthly report from the departmental heads regarding performance working under them. To finalise holidays after discussions with the unions.

DISPATCH DEPARTMENT Dispatch department comes under marketing department and consists of one supervisor whose function is as under: As per order, job card is prepared and then the production process is carried out is carried out and the product is ready. They are checked by the quality control and packed in the cartoon, which contains all details and then printed on the box of each. All these are then packed in a master cartoon and sealed with appropriate addresses. All consignments are transported to their main office and from there are distributed to main cities in India and abroad. Transport of products is through road and courier.

FINANCE DEPARTMENT There exits an inseparable relationship between finance on the one hand and production, marketing and other. Almost all kinds of business activities, directly or indirectly involve the use of funds. FUNCTIONS: They look after the overall financial requirement of the company. They see that a proper inflow and outflow of income and expenditure is maintained.

Funds are allocated on priority bases and keeping in mind future long term plans. It decides on the dividend or profit allocation decision. It has to decide the dividend or equity and debt. Liquidity is yet another important financial function.

4. SYSTEMS: ERP software is being used in UNIBIC Pvt. ltd.

5. SKILLS: RESPONSIBILITY AND AUTHORITY-The responsibilities of key personnel who manage, perform and verify quality and food safety related activities are indicated clearly keeping in view the main activity of each department. Their authorities are commensurate with the responsibilities defined. Training schedules happen time to time for updating the employees which are generally conducted by Knowledge and Talent management department.

6. STAFF: Present personnel strength at Unibic is above 150 people. Unibics aggressive growth strategy suitably entails its people to succeed.

7. SHARED VALUES: Excellence, Passion, Innovation, Inclusiveness and Openness.

Company SWOT Analysis

Strengths Good margin to Distributors and retailers. Best quality product in its range. Product Differentiation (Through better Ingredients contain). Wide Flavors in Unibic Cookies. Doing Corporate Social Responsibility (product like Bradman, oatmeal good example of CSR).

Opportunities India as potential Market for cookies. Wide scope of product penetration Brand Promotion (e.g.,-promotion of CSR activities)

Threats Parle, Britannia and Sunfeast. Lack of awareness.

PART-B

a. General Introduction b. Analysis / Design, Interpretation of results, findings, observations and suggestions properly divided into chapters. c. Conclusions and Recommendations. d. Bibliography

Statement of the problem/Project Title:

TO IMPROVE THE EFFICIENCY OF PACKAGING MACHINE & REDUCE THE EXCESS WEIGHT Unibic Biscuit is widely known for its Cookies. Types of Cookies Anzac Oatmeal Cookies Ericas Kitchen Choco Chip Cookies Ericas Oatmeal & Honey Cookies Ginger Crunch Cookies Black Current Jam Tart Almond Biscotti Brandy Baskets Savoury Oats Savoury Tarts Honey & Oatmeal Cookies Choconut Cookies Fruit Mince pies Double Chocochip Cookies Unibic Butter Cookies Tasty treat Premium Butter Cookies Cashew Butter Cookies Bradman Chocolate Chip Cookies Tasty Treat Premium Chocochip Cookies Tasty Treat Premium Oatmeal Cookies

Flow Diagram for Manufacture of Cookies

Raw materials (Depends on product) 1st stage-Addition of sugar, Butter, SMP, Water 50%

2nd stage- Addition of wheat flour, chemical and water

3rd stage Addition of chocolate chip/ oats / nuts (as per requirement)

Dough making

Collecting to trolley

Putting to passing conveyor

Wire cut hopper

Weight setting

Baking

Cooling on conveyor

Metal detection

Putting in tray

Packing with metalized wrapper

Bulk packing in cartoon or Box

Storage & Distribution

Materials & Ingredients Wheat Flour Rolled Oats Sugar and Syrups (Sucrose , Brown Sugar, Honey , Liquid Glucose) Fats & Oils (Butter , Margarine) Emulsifiers (Lecithin , Egg Powder) Dairy Product (SMP, Butter) Dried Fruit & Nuts (Black Current, Cashew, Almond) Flavor and Flavor enhancer (Vanillin, Caramel, Cocoa Powder) Non-nutrient Additives a. Water b. Common Salt c. Sodium Bicarbonate d. Ammonium Bicarbonate e. Colorant (Annatto) Chocolate & Cocoa (Chocolate chips and Cocoa Powder)

Production Process and Equipment

Bulk Handling Bulk Handling contributes to improved efficiency, labor saving and maintaining the hygiene in the cookies factories. Flour is conveyed pneumatically. When drown from the silo the flour is sieved to separate lumps and to remove any foreign particle. It is normal to have a return circuit arrangement to return the excess of flour back to silo. Sugar may be stored as a granular or fine powder. It is also pneumatically conveyed. Excess of sugar is not returned to silo thus to avoid cracking and lumping. Metering of Ingredients to Mixers Various metering system with programmable logic controller (PLC) and electronic weighing allows a much more scientific approach to mixing control and investigation of process difficulties. It is metered automatically for bulk handling and manually for small ingredients.

Mixing Mixing is a process of blending together of ingredients to form a uniform mass. Mixing Method The method generally used is the Three stage method Shortening (Butter, margarine), Milk powder (SMP), Sugars (Sucrose crystals), Syrups (Liquid glucose), coconut powder, Biscuit powder, Brown Sugar, Emulsifier (Lecithin). Sodium Bicarbonate, Ammonium Bicarbonate, salt with water. Flour, Other cereals (oat) or chocolate chip or cashew.

What happens During Mixing? Agitation or mechanical mixing facilitates the overcoming of surface tension developed at film interface of flour and water. Thus resulting in greater surface area for absorption of water by the flour. It also facilitates gluten complex formation result in unique property of dough

formation. This protein complex is a continuous three dimensional network of very fine threads and distributed throughout the dough mass thus imparting elasticity, resilience and mouldability to the dough. The amount of water used determines the amount of gluten formed. The sorting added during mixing controls the gluten formation and structure. Mixing time and development of temperature must have an influence on the leavening agents. Remove the dough from the mixer after completion of the mix.

Mixer Horizontal type of mixer is used, which contains agitator for proper mixing. Extruding and Depositing Depositing is a form of extrusion so these two means of dough pieces forming are not distinct from one another. Wire cutting method is used to form pieces from more sticky dough and dough containing coarse particle such as nuts or oat flakes, that cannot be successfully rotary moulded.

Extruding and Depositing Machines These machines basically consist of a hopper over a system of two rolls, which force the dough into a pressure/balancing chamber, the rolls run continuously. Dough is extruded through a row of dies and then a frame bearing a wire strikes across the base of the die holes cutting off the extruded dough at intervals. These pieces then fall onto the conveyor.

Baking It is a process of heating the moulded dough to a particular time and temperature combination resulting in evolution of gases (CO, NH) and evaporation of water to give the product its required body and texture.

Internal changes during Baking Heating of starch and protein resulting in selling, gelatinization and denaturation. Liberation of gases from leavening chemicals. Expansion of gas bubbles due to increase in temperature. Rapture and coalescence of some of this bubbles. Loss of water vapor from product surface followed by migration of moisture of the surface. Increase of temperature with increase of sugar solution concentration. Reduction in consistency of sugar solution and fat with temperature.

Baking in oven The product is supported on a band which is usually a sheet of steel. The oven mainly consists of three heating zones that produce following changes in dough. 1) First zone: Fat melts water gains temperature through conduction. 2) Second zone: Baking reaction, starch gelatinization, protein coagulation and gaseous evolution. 3) Third zone: Maillard reaction.

Heating of cookies occur by all the three methods of conduction, convection and radiation. The best heat transfer is through convection in the gases moved in the oven. As moisture evaporates from the product and as cool air enters in the oven there is a rise in pressure in oven. To relieve this pressure flues are there. At the entrance if dough pieces and oven band are below the dew point of oven atmosphere then condensation occurs. Due to condensation liberation of latent heat of evaporation occurs and results in wet surface of the product. Heating by this is a beneficial to avoid crust hardening. After dough has risen and structure has set heat is transferred rapidly to promote moisture removal. Strong turbulence around the dough pieces is required to avoid premature coloration.

Oven atmosphere conditions are kept even across the width of the oven otherwise there may be production of cookies with different thickness, shape and color. Cooling: After coming out from oven the cookies are conveyed to the packaging table. The conveying time is the time allowed for cooling. The cookies are allowed to cool naturally so that they not only take up the particular size but also to protect it from moisture uptake from atmosphere. There is appreciable loss of moisture during cooling and this is beneficial for cookies quality and shelf life.

Packaging and Storage Packaging is not only the contaminant of products but also maintaining its proper quality and shelf life.

Functions of Package To protect the content against mechanical damage. To protect contents against gain or loss of moisture and foreign odor contamination. To prevent against rancidity. To protect against attack by insects, bacteria and other air borne contamination. To protect against U-V light causing color fading and flavor deterioration. The printing on packages specify legal requirements of the country in which it is sold. The package attracts potential buyers.

Primary and Secondary Packages The primary pack is the moisture proof unit which is to be offered for sale to the consumer. Secondary packaging into groups of 10, 20 or more in boxes or cases is for ease of storage and transportation.

Printed or unprinted wrapping material for primary packing is usually fed from reels and the action of the wrapping machine may be intermittent or continuous. For packing HORIZONTAL FLOW WRAP MACHINE is used.

Pack Weight The average weight system states that over a given period the average net weight of the pack must be as stated on the wrappers. Records must be kept to show how the weights varied throughout the run but only samples need be checked not every packet.

Seal Qualities Less protective wrapper is produced due to imperfect seals and perforations of the film by sharp edges such as sugar crystals. Quick checks can be made of the seal performance by observations, blowing through the folds to see if the pack inflates. Pack Appearance The customer is much influenced by the pack appearance. Any fault printing should not be allowed to pass for sale as it suggests a casual approach to quality of the contents also.

Storage Conditions of temperature and humidity are very important in cookies. Temperature fluctuation causes fat migration, fat bloom, and rancidity problem. High humidity reduces strength of cardboard cases and increases rate of moisture transmission. Thus all parts of biscuit stores should be dry and cool.

Recycling, Handling and Disposal of waste materials During cookies manufacture it is inevitable that there will be losses and wastages at all stage. It is important that these factors are recognized, quantified and reduced as much as possible in the interest of factory efficiency and costing.

Sources of Waste Materials Faulty mixing of dough which cannot be used. Cutter scrap from the end of run or that which is in excess of the quantity incorporated with the fresh dough. Baked biscuit which are unsuitable quality due to over or under baking or misshapen. Broken biscuits. Good biscuits which have been imperfectly wrapped or from packs too light for sale. Wrapping material from damaged packs and bad printing. Various spillages on the floor or in accessible parts of the machine. Cleaning from the plant at the end of production run. Substances or contaminated ingredient stocks, dough and deteriorated biscuit.

Recycling Incorporation of scrap dough is the biggest problem in the recycling programme. By every means possible the amount of scrap dough to be recycled should be kept as low as possible and where it is used it should be used as evenly as possible through mixes. Unwrapped biscuits attract insects and pests causing serious infestation. If these brought into mixing room, may lead to infestation of other ingredient also. The rescue of over baked and burnt cookies is avoided in all except strongly flavored dough (e.g. Ginger cookies).

Disposal and Management of Waste It is done by supplying the waste to poultry feed, cattle feed and remaining amount is burnt.

Objective of the study:

To be a value addition factor in the process of standardization of the plant Performance evaluation Finding out the down time resulting in less productivity To reduce the excess weight in production line

Analysis/ Design, Interpretation of results, findings, observations and suggestions

For Measuring the %moisture loss

i.

For Fruit & Nut cookies: (Weight of 5 Cookies)

Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Wt. of cookies (Before baking) Wt. of cookies (After baking) % loss 48.5 40.5 45.5 38 45.5 38.5 44.5 38 44.5 38.5 45 38.5 44.5 38.5 45 38.5 45 37.5 44.5 38 45 38.5 44 38 43.5 38.5 44.5 38 45 38 43.5 38 44.5 38.5 47 40.5 Average loss in %= 14.4

16.5 16.5 15.4 14.6 13.5 14.4 13.5 14.4 16.7 14.6 14.4 13.6 11.5 14.6 15.6 12.6 13.5 13.8

Fruit & nut

60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Wt. of cookies (After baking) Wt. of cookies (Before baking)

% loss
18.0 16.0 14.0 12.0 Axis Title 10.0 8.0 6.0 4.0 2.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Series1

ii.

For Oatmeal Digestive (Weight of 5 Cookies)

Time Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

At 10:30 am Wt. of cookies (Before baking) 59.5 59.5 61 60.5 60.5 61 61.5 61 61.5 61 62.5 62 60 61 62.5 60.5

Wt. of cookies (After baking) 50 50 52 50.5 50 50.5 51.5 51 51.5 50 51 52 51 50.5 51 50

% loss 16.0 16.0 14.8 16.5 17.4 17.2 16.3 16.4 16.3 18.0 18.4 16.1 15.0 17.2 18.4 17.4

Average loss= 16.61%

Oatmeal
70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Wt. of cookies (Before baking) Wt. of cookies (After baking)

% loss
20.0 18.0 16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

% loss

Time Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

At 11:30 am Wt. of cookies (Before baking) 56.5 57.5 58.5 58 58 59.5 60 60.5 60 59.5 60 61.5 61 61 59 59.5

Wt. of cookies (After baking) 50 50.5 51 50.5 50.5 50 50.5 50 51 51 50.5 51 51 51 50.5 48

%loss 11.50 12.17 12.82 12.93 12.93 15.97 15.83 17.36 15.00 14.29 15.83 17.07 16.39 16.39 14.41 19.33

Average loss = 14.64%

Oatmeal
70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Wt. of cookies (Before baking) Wt. of cookies (After baking)

%loss
25.00 20.00 15.00 10.00 5.00 0.00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 %loss

iii.
Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Milk Cookies
Wt. of cookies (Before baking) Wt. of cookies (After baking) % loss 46.5 42 46.5 40 46 41 46.5 41 46.5 40 45 39.5 46 39.5 45 39.5 44.5 39.5 44.5 39.5 45 40 45.5 40.5 45.5 40.5 45.5 40.5 46.5 40.5 45.5 40 46.5 40 47.5 41 Average %loss = 12.6

9.7 14.0 10.9 11.8 14.0 12.2 14.1 12.2 11.2 11.2 11.1 11.0 11.0 11.0 12.9 12.1 14.0 13.7

Milk Cookies
50 45 40 35 30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Wt. of cookies (Before baking) Wt. of cookies (After baking)

% loss
16.0 14.0 12.0 Axis Title 10.0 8.0 6.0 4.0 2.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 % loss

Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Wt. of cookies (Before baking) 47 46 45 44.5 44.5 44 45 44.5 44 43.5 44 43.5 44 44 44.5 45.5 45 46 Average %loss = 12.75

Wt. of cookies (After baking) 40 39 39.5 39 39 38.5 38 39 38 38 39 39.5 39 39 38.5 39 39.5 40

% loss 14.9 15.2 12.2 12.4 12.4 12.5 15.6 12.4 13.6 12.6 11.4 9.2 11.4 11.4 13.5 14.3 12.2 13.0

Milk Cookies
50 45 40 35 30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Wt. of cookies (Before baking)2 Wt. of cookies (After baking)3

% loss
18.0 16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 % loss4

iv.
Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Milk Coffee
Wt. of cookies Wt. of cookies (After (Before baking) baking) % loss 64.5 53.5 63 52 64 53.5 64 54 63.5 54 63 53.5 63.5 53.5 62.5 52.5 62 52.5 62 52 62.5 52 63 53 63 50 62 51.5 62 51.5 Average %loss = 16.43

17.1 17.5 16.4 15.6 15.0 15.1 15.7 16.0 15.3 16.1 16.8 15.9 20.6 16.9 16.9

Milk Coffee
70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Wt. of cookies (Before baking) Wt. of cookies (After baking)

% loss
25.0 20.0 15.0 10.0 5.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 % loss

v.
Line 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Oatmeal Digestive
Wt. of cookies Wt. of cookies (After (Before baking) baking) % loss 43 37.5 43.5 38 44 39 44.5 38 44 38.5 44.5 39 44 39.5 44 39 44 39 44.5 38.5 44.5 38.5 44.5 39 45.5 39.5 45 39 44.5 39 42.5 37.5 43 39 43 38.5 43.5 39 Average %loss = 12.01

12.8 12.6 11.4 14.6 12.5 12.4 10.2 11.4 11.4 13.5 13.5 12.4 13.2 13.3 12.4 11.8 9.3 10.5 10.3

Oatmeal Digestive
50 45 40 35 30 25 20 15 10 5 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Wt. of cookies (Before baking) Wt. of cookies (After baking)

% loss
16.0 14.0 12.0 10.0 8.0 6.0 4.0 2.0 0.0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 % loss

 Average Moisture loss%

Variety Fruit & Nut Oatmeal Oatmeal Milk Cookies Milk Cookies Milk Coffee Oatmeal %loss 14.4 16.61 14.64 12.6 12.75 16.43 12.01

Average=14.20%

%loss
18 16 14 Axis Title 12 10 8 6 4 2 0 Fruit & Nut Oatmeal Oatmeal Milk Cookies Milk Cookies Milk Coffee Oatmeal Series1

Packaging line:

Observation of Two Multi packs machinery: Machine 1(Multi pack 1): 4 workers and 1 helper Speed of machine 70 cuts in one minute For one hour 4200 cuts In one CFB box total number of packets are 72 Total CFB boxes packed in one hour -53 Total number of packets 3816 Total weight in CFB box 286.2 During this packaging line total number of wastage of biscuit wrapper is 78 in one hour. Total weight of wrapper 1.984 gm %age of wastage - 1.3% Efficiency of Machine [( 53*72/60)/70]- 90.4 %

Problem Faced During packaging: Problem of raw material and packaging material for that reason stoppage for three times was done for several minutes. Lack of pallets availability. Labor absentee for several minutes.

Machine 2(Multi pack 2): 4 workers and 1 helper Speed of machine 70 cuts in one minute For one hour 4200 cuts In one CFB box total number of packets are 72 Total CFB boxes packed in one hour -52 Total number of packets 3744 Total weight in CFB box 280.8 During this packaging line total number of wastage of biscuit wrapper is 42 in one hour. Total weight of wrapper 1.81 gm %age of wastage - 1 % Efficiency of Machine {( 52*72/60)/70]- 89.1 %

Problem Faced During packaging: Problem of raw material and packaging material for that reason stoppage for four times was done for several minutes. Lack of pallets availability. Labor absentee for several minutes.

Observation on Sincropack packaging machine: Machine 3: 6 workers and 1 helper Cutting speed 110 / minute For one hour 6600 cuts In one CFB box total number of packets are 72 Total CFB boxes packed in one hour -71 Total number of packets 3744 During this packaging line total number of wastage of biscuit wrapper is 24 packets in one hour. Total weight of wrapper 1.004 gm %age of wastage - 0.3 % Efficiency of Machine [( 71*72/60)/110]- 77.45 %

Problem Faced During packaging: Problem of packaging material for that reason stoppage for four times was done for several minutes. Lack of pallets availability. Labor absentee for several minutes. Power cut

Efficiency Of packaging machinery:

Sincropack:

Overall efficiency of machine:

Date 30/10/2012 31/10/2012 31/10/2012 2/11/2012 % Efficiency % of wrapper waste %Downtime 76.03 1.3 73.3 76.02 85.1 5.05 6.05 1.655

12.2 17.5 19.1 4.1

90 80 70 60 50 40 30 20 10 0 30/10/2012 31/10/2012 31/10/2012 2/11/2012 % Efficiency % of wrapper waste %Downtime

 Excess weight in production line

Date 9/11/2012 10/11/2012 10/11/2012 12/11/2012 12/11/2012 12/11/2012 12/11/2012 15/11/2012 15/11/2012 15/11/2012 15/11/2012 15/11/2012 15/11/2012 15/11/2012 15/11/2012 18/11/2012 18/11/2013 18/11/2014 20/11/2012 20/11/2012 20/11/2012 Variety Ginger Nut Pista Badam Pista Badam Multigrain Multigrain Multigrain Multigrain Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies Butter Cookies Display Butter Cookies Display Cashew Butter Cookies Display Fruit & Nut Choco Nut Choco Nut Excess weight 7.98 8.28 6.29 3.87 4.1 2.28 1.07 1.19 4.5 0.11 2.18 5.56 5.47 5.002 2.38 6.3 6.5 2.007 2.55 3.39 2.24

Axis Title 9 8 7 6 5 4 3 2 1 0 Ginger Nut Pista Badam Pista Badam Multigrain Multigrain Multigrain Multigrain Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies Milk Cookies

Excess Weight

Milk Cookies
Milk Cookies Butter Cookies Butter Cookies Cashew Butter Fruit & Nut Choco Nut Choco Nut

Series1

SUGGESTIONS: Line balancing not proper in case of sincropack. The machine is of the capacity of 120 cuts/ minute, but the due to machine usage over years it reduces the efficiency on higher speed. As a result optimum utilization of the resources is not being done. MANPOWER SHORTAGE resulting in Line Balancing. The no. of workers required for the operations are as follows: Mixing =3, Feeding = 2, Packing (in trays) =6, Packaging=6-7, Helper = 1, Machine operator = 1. Less efficiency in production due to carelessness of the workers .Training modules should be designed for the Supervisors and workers. The workers should be trained to make them aware of the Machine consciousness.

The workers should be very careful in weight of wet dough in wire cutting. As soon as the weight start to increase beyond 9.0gm, gradual hammering or by some adjustment weight can be reduced and control the excess weight. Effective planning to maintain the Proper stock for the continuous production need to be ensured and informed to the workers. Batch ingredients should be counter checked after the batch weighing process to avoid the ambiguities.

CONCLUSION: Productivity is a measure of the efficiency of production. Productivity is a ratio of what is produced to what is required to produce it. Usually this ratio is in the form of an average, expressing the total output divided by the total input. Productivity is a measure of output from a production process, per unit of input.

Date

PRODUCTION(CFB'S)

12/11/2012 443 15/11/2012 478

Sum Average

921 460.5

From the production data, we can see that there is 7.13% increase in the production on 15thof November.

Reduced Excess weight: Pista Badam Pista Badam Multigrain Multigrain Multigrain Multigrain Milk Cookies Milk Cookies Milk Cookies Milk Cookies 8.28 6.29 3.87 4.1 2.28 1.07 1.19 4.5 0.11 2.18

From the data, it can be seen that there is 1.99% decrease in Pista Badam Excess weight as compared to earlier, 1.82% decrease in Excess weight of Multigrain cookies when compared to the other three batch of Multigrain and 2.43% decrease in excess weight of Milk Cookies when compared to earlier batch.

Efficiency: Date 30/10/2012 31/10/2012 31/10/2012 2/11/2012 %Efficiency 76.03 73.3 76.02 85.1 %Wrapper Waste 1.3 5.05 6.05 1.655

To increase the Efficiency Wastage need to be minimised .This can be done by giving the workers proper training at regular intervals to imbibe in them the habit of putting their conscious effort in increasing efficiency and reducing the wastage and also by maintain the proper maintenance of machinery.

References and Bibliography:

http://www.unibicindia.com/ http://www.vectorstudy.com/management_theories/7S_framework.htm

http://www.thebiscuitdoctor.com/manufacturing-processes/biscuit-making-processes/80resources/processing-extruding-etc/178-extruding-and-wire-cutting

http://www.wikipedia.com