LEAN MANUFACTURING AT LINGARAJ BISUITS PVT. LTD. – A PARLE FRANCHISE

Submitted By: Group 3Arupananda Rout UM16193

R Priyanka UM16207Amlan Lenka UM16210Sourav Pattanaik UM16233Suman Panigrahi UM16233S Seemanchal Mohanty UM16238

Aprameya Bhol MG16002

COMPANY PROFILE

LINGARAJ BISCUITS:• Lingaraj Biscuits Private Limited is a CMU of Parle Biscuits Private Limited. • It was incorporated on 23rd August 2004• Its authorized share capital is Rs. 30,000,000 and its paid up capital is Rs. 14,750,000.

PARLE: • Parle was started in India in 1928 by Shri Mohanlal Dayal for making confectionaries. • Parle enjoys 40% market share of the total biscuit market in India. • Parle-G biscuit brand is the largest selling biscuit brand in the world with 80% market share in the

glucose biscuit category in India and has a huge global presence.• It 12 manufacturing units for biscuits and 75 manufacturing units for confectioneries. It also

operates plants based on a franchise model.

QUALITY CONTROL• Testing of raw

materials that are going to be used.

• This would come under Preventive costs.

• Ingredients addition• Sugar solution• Milk solution• Preparation of flour• Fat• Ammonia• Additives• Flour sifters sugar

grinders

PRE MIXING MIXING FORMING

BAKINGCOOLINGPACKAGING

• Mixers• Mixing time• Water• Creaming• Dough Consistency• Biscuit grinders

• Laminators• Gauge rolls• Sheet Reduction• Cutter• Moulders• Shape and size of

dough piece

• PPM• Metal detection• Stackers• Feeding Chute• Horizontal flow

form wrap • Vertical filling• Cream

sandwiching

• Cooling time• Cooling conveyer

• Baking ovens• Baking time • Temperatures• Burners• Steam Extraction• Oven Output

FLOWCHART OF THE MANUFACTURING PROCESS OF PARLE

MANUFACTURING EQUIPMENT IN LINGARAJ BISCUITS

STEPHAN MIXERBISCUIT BAKING OVEN

ROTARTY MOULDER

Profit

Satisfy customer demand• Best Quality

Lowest cost• Best prices

Shortest lead time• Supply on time

OBJECTIVES OF LEAN MANAGEMENT

ANDON It’s a term referring to a system to notify the management, maintenance and

other workers of a quality or process problem. In Lingaraj Biscuits, the concept of Andon has been implemented by installing

three buttons in every unit i.e. the six steps from mixing to packaging. The three buttons red, yellow and green send the below message to the shift in-

charge and supervisor:

Process needs attention but need not stop.

A defect in the product is detected and the process stops. Every other units also stop till the defect is solved.

This indicates the process is running fine. It is also pressed once the identified defect is resolved.

UTILITY OF LEAN TECHNIQUES

LEAN TECHNIQUES USED

• Check of the entire process and incorporate minor changes which has cumulative effects

KAIZEN

• Immediate identification of problems in an automated process

JIDOKA

LEAN TECHNIQUES NOT USED

• Aimed at reducing flow times within production system as well as response times from suppliers and to customers

JIT

• It is an inventory-control system to control the supply chain

KANBAN

• There are two types of biscuits manufactured here – Parle G and Happy Happy.• A forecast of the demand is given by Parle to the factory every month and that exact amount is

supplied.Over Production

• If Parle Company does not collect the order, they do not send further demand data for production.

• A safety stock of 3 tones is maintained constantly. Unnecessary Inventory

• Biscuits are immediately transported to a warehouse located in Bihar.• The trucks return with stock for the Odisha warehouse for distribution of biscuits in Odisha.• The movement of the trucks is monitored online through real-time GPS.

Transportation

• Though the process is automated there is still a risk of over processing at the baking stage.• Such defective products are sold as fodder for poultry or for use in the farms.Over Processing

• Human intervention occurs only in the mixing and cooling stages. • Due to this there are high chances of incurring waiting costs due to delay.Waiting

• The process is entirely automated • The use of conveyor belts, mixers, molders, coolers, etc. ensure that the process is not

wasteful in nature. Unnecessary Motion

WASTE MANAGEMENT

After the end of third shift, the Production Manager and Shift-in-Charge along with a representative of Parle perform an end to end check on machines and

maintenance is carried out for 2 hours every day.

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38.5

39

39.5

40

40.5

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CONTROL CHART (FROM 12:00 pm TO 4:00 pm)

UCL LCL CL SAMPLE AVG

TIME

SAM

PLE

AVER

AGE

WEI

GHT

QUALITY CONTROL & PREVENTIVE MAINTENANCE

The company organizes health check up camps for its workers on a monthly basis

PEOPLE PRACTICES AND SAFETY ASPECTS

The workers are provided accommodation inside the company in case of emergency situations

The company has a separate training and orientation department for onboarding of new workers

The company has a separate safety officer who is responsible for all safety aspects inside the plant premise

The company is certified in ISO 22000-Food Safety Management and ISO 9001- Quality Management Systems

KEY LEARNINGS

Lean Techniques applied: Andon, Kaizen and JidokaNot Implemented: JIT and Kanban

A safety stock of 3 tonnes is maintained, which are sent to Parle the very next day.

Over Production,Unnecessary Inventory and motion, Product Defects and Waiting Time Avoided

Transportation Costs Minimized by a two way transport between the Bihar and Odisha facilities.

Regular feedbacks taken from employees and working conditions assessed for safety standards.

Quality checks and Preventive maintenance done on a regular basis daily.

THANK YOU !!