PARLE BISCUITS

INTRODUCTION Bakery industry in India is the largest of the food

industries with annual turnover of about Rs.3000 crores. The biscuits are becoming quite popular in rural areas as well. Nearly 55% of the biscuits are consumed by rural sectors.

The biscuit industry in India comprises of organized and unorganized sectors. The FBMI represents the organized biscuit industry consisting of small scale, medium and large biscuit manufacturers located in all zones and all states of the country.

Major brands of biscuits are:- Britannia, Parle, Priya Gold, Elite, Cremica, Dukes, Anupam, Horlicks, Craze, Nezone, besides various regional/ State brands.

COMPANY OVERVIEW Parle Biscuits Limited is a subsidiary of the Parle

Products Limited, Mumbai, which is a closely held company run by the Chauhans. Today Parle enjoys a 40% share of the total biscuit market and 15% share of the total confectionery market in India.

Plants of Parle Biscuits Pvt Ltd are at:1) Bahadurgarh (Haryana)2) Neemrana (Rajasthan)3) Rudrapur (Uttranchal)4) Nasik

The production capacity of Bahadurgarh unit per month is-

Parle-G 3300 Metric Tones

Krackjack 1500 Metric Tones

Monaco 1200 Metric Tones

The plant also has a Auditorium and viewing gallery, which is used during the visits of the school children. A retail shop at the plant provides Parle products at MRP rates. The total turnover of Parle Biscuits Pvt Ltd is around 4000 crores.

PARLE-G :THE EVOLUTION

“QUALITY, HEALTH AND GREAT TASTE”

PARLE QUALITY SYSTEM

Hygiene is the precursor of every process at Parle. From husking the wheat and melting, the sugar to delivering the final products to the super market and store shelves nation wide care is taken at every step to ensure the best product with long lasting freshness. Every batch of biscuits and confectionery are thoroughly checked by the expert staff, using the most modern equipments hence ensuring the same perfect quality across the nation and abroad

QUALITY COMMITMENT

Parle Product has one factory at Mumbai that

manufactures biscuits and confectionaries while another factory at Bahadurgad in Haryana manufactures biscuits.

Apart from this parle has manufacturing facility at Nirvana in Rajasthan and at Banglore in Karnataka.

The factory at Bahadurgad and Nirvana are the largest such manufacturing facilities in India.

PARLE PRODUCTS – ‘AN EPITOME OF QUALITY’

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.

All these factories are located at strategic locations, to ensure a constant output & easy distribution. Each factory has state-of-the-art machinery with automatic printing & packaging facilities.

HACCP Hazard Analysis and Critical Control Point is

systematic preventive approach to food safety and pharmaceutical safety that addresses physical, chemical, and biological hazards as a means of prevention rather than finished product inspection. HACCP is used in the food industry to identify potential food safety hazards.

The seven HACCP principles are included in the inetrnational system ISO 22000. this standard is a complete food safety management system incorporating the elements of prerequisite programmers for food safety, HACCP and quality management system which together form an organization's Total Quality Management

PROCESS OF MANUFACTURING PARLE-G BISCUIT

RAW MATERIALS RAW MATERIAL TESTING MIXING MOULDING BAKING COOLING PACKING

RAW MATERIAL Name of the Raw Materials & why this Raw Materials

can be use in Biscuit Manufacturing   Wheat Process Quality made of contents process of Growth.   Vanspati For Carbohydrate.   Salt Mineral & Vitamin for

Development.   Milk For calcium build teeth and

bones.

How to check Raw Materials

Checking quality of raw materials in their own laboratory.

Checking raw materials and various packing as per

standards laid down. Setting standards for various raw materials and

packing materials per PFA (Products and Foods Act) and other food related legal Acts.

MIXING PROCESS

The quantity of manufacturing biscuit in proportionate in that ratio Raw Materials mixed in mixer machine.

Mixing of Raw Materials process continuous for 3 minutes

20 seconds.

The mixing process continue automatically and it is

operated by two person.if one person went for lunch or any reason that time his partner can handle all machinery.

MOLDING PROCESS

After completed mixing process all the mixed materials go on cutting machine.

The cutting machine cut the biscuit and are rolled by machine and the company logo of Parle –G is being printed on biscuits.

The company molding 10,000 biscuits per minute.

  Here all biscuits got a particular shape which is attracted

to customers.   After molding process, moving belt is carrying all biscuits

for baking process.

BAKING PROCESS 

In oven there are three processes.

Removing Moisture

Cook the biscuits

Coloring the biscuits

  COOLING PROCESS

After baking process completed the backing biscuits are taken to cool in cooling machine.

  Baked biscuits contain steam so without removing steam that

biscuits can not lasting for long periods or up to its expiry period.   Parle Company cooled biscuits by natural way. Moving belt

moved the biscuits from baking machine to packing machine within 5 minutes.

  After removing the steam that biscuits made so hard for packing This is also 4 to 5 minutes in cooling process before starting

cooling process all raw wastage removed by automatically in the wastage machine.

  PACKING After cooling process completed biscuits goes out in packing

department for packing.   The remaining wastage biscuits removed by automatically.

  At one minute 1000-1500 biscuits packed by automatically.

  Parle-G packing department have 10 multipack machine.

  Per multipack machine packed 140 biscuit’s packet per minute.

  Parle-G company have own printing press and printing

department to fulfill all packing materials for biscuits and chocolates.

  They buy whit paper for printing packing papers from other

company.

ADDITIONAL INFORMATION

Every day 100 tones biscuits are manufactured by company.   They are keeping 7 days finished good’s stock due to reason of

any problem arises in the production process.   There is having separate maintainence department which is

working for 24 hours. This department includes Engineers, Fitters, Tuners, Electricians and any other professionals for maintaining Machineries properly and regularly.

  10,000 workers are working in all Parle-G factories in India.   750 workers are working in Parle-G Product Ltd. in Vile-Parle at

Mumbai. Out of that 450 workers are working in Production Department. 

Parle-G are having 34 factories in all over India. That are maintaining under Zonal and Divisional area.

Product Life-Cycle Strategies

• PLC StagesPLC Stages Product development Introduction Growth Maturity Decline

Introduction Phase - Parle

Founded in 1929 as a Confectionary Company.

Decade later Introduced Biscuits Imported Biscuits shipped by British Introduced butter glucose biscuits Initially sold only in Suburbs of

Mumbai Wax wrappers for packaging

Growth Phase PARLE

Total Market – 4000 Crores

Total Market Growth 10 to 12 % per annum

Parle holds 40% Market share

Large unorganized sector

Indians eat 0.48 KG and Americans 4kg Biscuits

Growth phase

% Market Share

40

37

7

16

ParleBritaniaITCOthers

Total Market(Crores)

1600

1420

280

640

ParleBritaniaITCOthers

Growth Phase - Parle Cont

Parle-G Largest brand in world

65 % of Glucose Market

50 % to Turnover Large

consumption in rural market

12 to 15 % Growth Low Margin High Volume

Glucose Market

65

28

7Parle

Britania

others

Turn over %

50%

35%

15%

Parle G

Other Bis.

Confec.

Growth Phase - Parle Cont

0

500000

1000000

1500000

2001 2007

Increase In Retailoutlets

RetailOutlet

Product S %

Parle G, Milk Shakti

H H

Marie, Monaco , Krack Jack

M M

Hide n Seek ,Cheeslings

H L

High Penetration in Marketlow price ,low margin and high volume gameBrand Repositioning Addition of taste Variants (Magix ,Milk shakti) Addition of weight variants (25 gm to 1kg)

Conclusion

PLC analysis – very IMP tool in the hands of marketer.

Better understanding in managing profitable products & eliminating unprofitable one.

As products moves from one stage to another in PLC- Marketer evaluate and adjust strategies for promoting ,pricing & distribution of the product.

TECHNIQUES ADOPTED AT PARLE

5S KAIZENS SQC TQM POKA-YOKE

5S

1S:- SEIRI

2S:- SEITION

3S:- SEISO

4S:- SEIKETSU

5S:- SHITSUKE

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

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.

SUMMARY The company has effectively implemented the HR

techniques in the plant.

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

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.

Suggestions

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

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

costs least wastage. 3) The company may also use the other HR techniques so

as to make more effective production like Andon, Six

thinking Hats, etc 4) The power cuts that affect a lot to the production and

results in wastage must be controlled. Since one power cut of 3-5 seconds wastes at least 10-15 packs of biscuits.

5) Another cause of wastage is machinery breakdown. So

regular checks on the machines must be adopted.

6) 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 ½ 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.

Acknowledgement

  We would like to Thank our Professor Mrs. Fatema

Modi for giving us this wonderful opportunity to make this project. This project would not have been possible without her help and guidance.

BIbliography

Information taken from:

www.google.com   www.ask.com   www.parleproducts.com   www.managementparadise.com

Project presented by: S.Y. BMS DIV:A

ALIFIYA HAJI 34  AMMAR DHOONDIA 14  MURTAZA KAPADIA 30

MOHAMMED BHANPUR 22   HATIM KOTHARI 45  MANSUR MEHTA 33