marketing

Description
project for RMB...

INTRODUCTION OF THE PARLE COMPANY
Parle Products (Parle) is an Indian manufacturer of cookies and confectionery (including toffees, candies, savories, and mints). The company has a 40% share of the Indian biscuit and a 15% share of the confectionery market within the country. The company?s major biscuit brands include Parle-G, Monaco and Krackjack, with principle confectionery brands comprised of Melody, Poppins, Mangobite and Kismi. Parle?s production facilities include a flagship plant in Mumbai, producing biscuits and confectionary; while another factory at Bahadurgarh, Haryana manufactures biscuits. Apart from this, Parle has manufacturing facilities at Neemrana, Vile parle in Mumbai and at Bangalore, Karnataka. The factories at Bahadurgarh and Neemrana are amongst the largest biscuit and confectionary manufacturing facilities in India. In addition, to complement it?s wholly owned facilities, the company has a further 14 manufacturing units for biscuits; and five units for confectioneries operating under contract. The company?s distribution network is a major strength for Parle. Parle products are made available to consumers, even in the most remote places and in the smallest of villages. The company has around 1,500 wholesalers, serving in excess of 425,000 retail outlets. In addition, Parle maintains a 200 strong dedicated field sales force to service wholesalers and retailers. The company also has 31 depots and cost and freight (C&F) agents supplying goods to the distribution network. Parle?s marketing philosophy emphasizes catering to the masses. Consequently, most Parle offerings are in the low and mid-range price segments. However, the company also manufactures a variety of premium products for up-market, urban consumers. Parle?s international operations consist of serving markets in the Middle East, Africa, South America, Sri Lanka, Australia and North America. A concerted effort is made to target Indian expatriate communities in these countries. To further enhance its international reputation and open up new markets, the company is in the process of obtaining an ISO certification. Parle-G is one of the oldest and most popular brand name in India and is considered the largest selling brand of biscuits in the world. For decades, it was instantly recognised by its iconic white and yellow wax paper wrapper with the baby face on it. Everyone from every single corner of India, from any age, rich or poor is familiar with the brand. Parle-G is commended for its knack to reach the remotest of places in the huge landscape of the country of its origin. It also holds remarkable trust among its buyers for quality and taste. Due to this authority over generations of India consumers, it can be noted that Parle did little advertising for its flagship brand. It was though that Parle-G sells itself, without any publicity [1]

inputs, which was true until the late eighties when many multinational brands entered the market. Since 1989, Parle-G has seen significant marketing and an introduction of new flavours. Parle-G also sponsored the first superhero series to hit Indian television, Shaktimaan. Many competitors have tried to sell their lower quality products by copying the packaging, trying to sell their biscuits as Parel-G, Parle-Jee etc

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HISTORY OF THE COMPANY
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 of biscuits to be introduced, which later went on to become leading names for great taste and quality. Apart from being the world's largest selling biscuit, Parle - G is winner of 8 Gold and 11 Silver awards at the Mond Selection Awards – the global standard for quality in Food category

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PARLE G - THE EVOLUTION!!!
Parle-G has 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 called Parle Glucose 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 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. Originally packed in the wax paper pack, today it is available in a contemporary, premium BOPP pack with 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 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 positive values of life like honesty, sharing and caring.

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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 overall 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 at Paris & Singapore; meeting their favorite film star Hrithik Roshan; free ride on a chartered plane; 20 scholarships worth Rs 50,000; a special cricket coaching camp with the Australian cricketer - Ricky Ponting; etc. The year 2002 will go down as a special year in Parle-G's advertising history. A year that saw the birth of G-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. A TV commercial that showed G-Man saving the children from the evil force called Terrolene launched this campaign. It was also supported by print medium through posters and streamers put up at the retail outlets. G-Man, a new superhero of Parle-G has the potential of making it big. And will be supported by a campaign that will see many a new creative in the future so as to keep the children excited and generate pride in being a consumer of Parle-G. 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-G Magix is available in two exciting tastes - „Choco? and „Cashew?. The year 2002 also witnessed the launch of ParleG 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 you would expect from the Parle-G World's Largest Selling Biscuit. 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.

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QUALITY CONTROL OF FMCG PRODUCT PARLE
QUALITY
Quality is a customer?s determination and not manufacturer?s or marketeer?s determination. The modern view of quality is that product should totally satisfy the customer?s need and expectations in every respect on a continuous basis .The new concept of quality calls for: Well –designed product with functional perfection first time right Providing satisfaction beyond customer?s expectation Excellence in service Absolute empathy customer Quality system is defined as “Organization structure, responsibilities, procedure and process and resources for implementing quality management “. Analysis of this definition reveals that the enterprise should clearly define the organization structure for ensuring quality, the level at which quality is to be checked

The success of any quality system would depend upon the attitude of personnel towards quality. That is, the management should persuade the personnel to have the correct attitude of mind towards quality. This implies that the personnel should not look for the “easiest” way to do the things rather the “correct” way to perform the job or various operation the management should take adequate step to ensure that each person in the organization adequately stimulated to commit himself/herself to quality.

The quality of a product can be ensured if the enterprise takes action to maintain the quality at tow level namely, firstly, within the enterprise during the process of manufacturing and secondly, consistencies in the quality of supplies from its suppliers i.e supply chain management.

The quality system should identify those activities that directly affect the quality of the product and delegate adequate authority to those responsible for their completion. The quality of the product through various stages will have to be properly codified so that the personnel have the reference guide to ensure the quality of the operation and various activities. The codification is done in the form of series of document collectively referred to as “Quality Manual”

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Quality Control

The responsibility of every member of the workforce for the quality of products and services provided by the business. Emphasis on reducing defects, etc. before it gets to the final stage of production and certainly of consumer. Why is Quality a Concern?

Gives competitive advantage Encourages return purchases Provides customer with information and builds consumer confidence in the brand Reduces costs incurred in solving post sales problems TQM (Total Quality Management)

Features of TQM: – Quality Circles – meetings of relevant workers to discuss issues relating to maintenance and improvement of quality in the business – may also double as a form of empowerment and motivation. – Statistical Process Control – statistical data generated to inform the evaluation of processes within the business. – Zero defects – systems in place to ensure that no product leaves the business with a defect – important in building supplier relationships, image, reputation.

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NEED FOR QUALITY MANAGEMENT SYSTEM

The intense competition at the market place has brought into sharper focus the need for gaining the confidence of the customer in the firm and its product. The confidence (of the customer) in the firm as a reliable supplier of goods can be gained by providing him consistently with better quality product. This helps a firm to improve its image in the minds of its customer and enhance their satisfaction level. This task becomes much easier if the firm manages the quality of its product and secures certification of its quality management system from an independent third party. Thus a supplier of goods has readily recognizable assurance of the quality of his product or a service which he can use as a marketing tool. Similarly, the customer also feel assured about the quality of the goods as the same has been assured through a properly managed system of quality control certified by an independent third party. Thus there is need of third party certification of the quality system introduce by the firm for maintaining the quality of their goods.

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QUALITY PLANS
The company has been manufacturing the established production of Parle-G and cream biscuits since 1990. The requirements of quality plans. These have been evolved based on the experience gained over a period of time. Quality plans are made and documented for each new product that may be introduced requiring additional details to be addressed and also for capacity expansion. These plans includes:? ? ? ? ? ? Identification of control process equipment, instruments, skills etc. required to achieve desired quality. Product specifications and key parameters for verifying achievement of quality. Test/ Inspection plan. Storage, handling and packing requirements. Waste control. Control of variations.

These elements of the quality plan are incorporated in the existing documentation structure by suitable amendments/ additions. The amendments are carried out as per the document control procedure given in the manual.

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QUALITY ASSURANCE OF BISCUIT:

Quality of manufactured biscuits is not only depending upon the quality of input of raw and packaging material but on so many other factors such as;

a) Procedure: the food product should be manufactured as per standardized and agreed method, otherwise, it is likely to have variations.

b) Plant and Machinery: Proper checking and inspection procedure need to be instituted for timely action, for not only detection, but elimination, but elimination of possibility of contamination arising due to material handling and processing equipment itself. All measuring equipments are under calibration control system.

c) Personnel: Proper training of all concerned staff in the areas of manufacturing and packing with respect to use of established procedures at all times, good hygiene. This also includes proper storage ,handling aspects of biscuit safety etc.

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QUALITY POLICY
Vile parle Food Product is one of the contract manufacturing unit of M/s Parle Products Private Ltd. For manufacturing Biscuits. The policy of Vile parle Food Product is to maintain the confidence of customer through – ? ? ? ? ? Constancy in quality Transparency of operation Continual Improvement through Human resources development Customer satisfaction

It is ensured that the quality policy is understood, implemented and maintained at all the levels of the organization through suitable training and regular monitoring. To identify the customer satisfaction the following data to be analyzed. 1. Monthly Production schedule 2. Monthly delver schedule 3. Follow up of purchase orders issued by customer 4. Parle?s Production Executive Report To measures the continual Improvements in process in quantifiable terms with targets. For carrying out its various operations the company has been adequately equipped with the entire infrastructure including a suitable laboratory with required test apparatus. The tests performed are adequate in ensuring complete quality control. Suitable trained and experienced manpower have been provided for the execution of various jobs. A detailed training procedure ensures that skills of the personnel are constantly updated. Company's association with its customer, namely, M/s Parle Products Pvt. Ltd; also ensures that it benefits of latest knowledge and quality analysis capability are available form time to time. [11]

In order to meet additional production targets, the company has the policy to employ labour on casual basis for unskilled operations/jobs that can be done with very little training. The company's quality policy objectives in such cases are ensured and protected by grater monitoring by the supervisors of such staff. The company?s organization has been designed to meet its quality objectives. The responsibility and authority of key personnel, who plan, monitor and ensure the implementation of the installed quality system.

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QUALITY MANUAL
PARLE (INDIA) LTD. has established a documented Quality System as per the requirements of ISO 9001:2000 Quality System. The entire authorized holder shall be responsible for the implementation of the quality systems as defined in this manual in their respective area and for keeping this document updated by in corporating the latest amendments issued from time to time. The Manager has been assigned the responsibility of the Management Representative as required under the ISO 9001: 2000 Quality System. He shall be responsible for planning, implementation and maintenance of the quality system as per the ISO 9001: 2000 Requirements. He shall also plan and co-ordinate the audit and management review activities of the factory. He shall be responsible for implementation of the corrective actions including the recommendations of management review to execute his responsibilities effectively and efficiently. He had also been authorized to co-ordinate all the quality related activities within the production center and also for interacting with external organizations/individuals for all quality related matter. This manual is designed as per the requirements of ISO 9001: 2000 conformity. The quality systems described with in this manual establishes the Biscuit

Responsibilities and Authority In order to carry out the various functions of the factory the responsibilities and authority of its personnel are clearly defined. In the following parts the responsibility and authority of some of the key elements is defined below, however the responsibilities and authority of concerned supervisors, operators and other relevant personnel are defined in the relevant function manuals/work instructions. All the concerned personnel who have been included in the company's Quality Systems, have been given the sufficient authority commensurable to their responsibilities to ensure the effective execution of their assigned work, so that the intended quality policy and quality objectives of the company as well as the requirement of ISO 9001: 2000 are continuously fulfilled. [13]

As the chief executive officer of M/s Vile parle Food Product Pvt. Ltd., he shall be responsible for over all management and operation of the unit. He shall also nominate the management representative with requisite responsibility and authority for planning, implementation and maintenance of the Quality System in the company in conformance of the Quality System in the company in conformance to the requirement of ISO 9001: 2000 Quality System. In fulfilling this task, he shall be assisted by the Manager and the heads of different departments. He shall be responsible for ensuring the effective implementation of the company's Quality Policy and its objectives, in all the areas of operation more emphasis on automation and continual improvements. He shall also be responsible for holding and chairing the Managements. He shall also be responsible for holding and chairing the Management review meetings from time to time and shall verify the effective implementation of the decision taken by the review committee. He shall also ensure that adequate training is provided to the staff. He shall also be responsible for contract review and customer complaints/feedbacks to ensure that customer?s requirements are fully complied. . Co-ordination between different departmental heads and also between different shifts working to ensure full communications. Recruitment of new and casual workers. The office staff and shift supervisors shall assist him in this task. He shall also ensure that all production standards are maintained and shall monitor the delivery schedules. Planning total productive maintenance schedule form time to time with the help of maintenance Incharge. He shall be responsible for the work instruction written on the display boards at different places in the factor. He shall ensure their clarity and effectiveness for the concerned workers. Ensuring good housekeeping and hygienic condition in the factory. Monitoring the effectiveness of implementation of the identified corrective and preventive actions. Planning internal audit schedules and conduct of internal audits. Analysis of customer complaints / feedbacks. Asst. Production Manager (APM) He will be responsible for overall production and quality of product in all 3 shifts. He shall have adequate authority for executing the following responsibilities.

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? ? ? ? ? ?

Plan production schedule as per requirement. Allocation of different jobs to workers in production department shift wise. Arranging on the job training of new workers and refreshers course to old workers form time to time in the production department. Co-ordination between production and packing department. Ensuring the satisfactory quality of output of the cream sandwiching section. To ensure adherence to the FIFO system of Raw Material Issues. In case a material which has been accepted with deviation is being sued, he shall ensure that it is known to all concerned and shall ensure that the performance of first batch using this material is immediately reported and shall ensure the rejection of the concerned lot if the performance of the first batch is unacceptable. Control on production wastage at all levels. To ensure that the required test are carried out at different stages in order to verify the quality control/assurance. To co-ordinate with Parle Site Officer with quality related problems in house. To co-ordinate with Laboratory Incharge for early Testing. Ensuring Hygienic condition in production department. Member Management Review committee.

? ? ? ? ? ?

Shift Incharge: He shall be responsible for packing of product received from production department as per the specifications of the customer. He shall have the adequate authority for executing the following responsibilities. ? ? ? ? ? ? Plan packing manpower requirement as per need. Ensure speedily and timely completion of the packing job. Allocation of the job to the workers in packing department shift wise. Co-ordination between packing and production department and the store-keeper. Tight control on packing wastage of biscuits as well as packing material. Compiling information on packing, productivity/quality problems for the F Manager. [15]

?

To ensure hygienic conditions maintained in packing area.

MAINTENANCE INCHARGE The maintenance Incharge shall have minimum ITI degree. He shall be responsible for the upkeep of all machinery side by side he will responsible for automation. He shall have the adequate authority for executing the following responsibilities. ? ? ? ? He shall plan for Total Productive Maintenance schedule in consolation with the Factory Manger. He shall ensure that breakdowns/faults reports received from production/packing department are attended at the earliest. Training of shift supervisor for attending to minor faults on their own. In required, arranging repairing work from outside with the approval of the Manager.

Quality Control Incharge (Lab Incharge) : He shall report to the Manager. He shall be responsible for testing/checking of all Raw Materials/Packing Material as per the customer's requirements. He shall have adequate authority for executing the following responsibilities. ? The Laboratory Incharge shall ensure that the various tests on different materials collected from various stages of production process, shall be carried out as per the standard procedures. On the basis of the findings of these tests he shall act as per the established procedure. This would also include acceptance/rejection of incoming raw materials. He shall be responsible for ensuring the proper up keep and calibration validity of the various laboratory equipment as per the established procedure. Proper storage and handling of chemicals and test samples. He shall be responsible for SPC/SQC training and analysis.

? ? ? ?

The company has installed a quality systems in conformity with the requirements of ISO 9001: 2000 quality systems standards and its operations are so designed that they also meet the statutory Regulatory requirements of Govt. of India, namely the requirements of "Prevention of Food Adulteration Act, 1954", The standards of weights and measures Act, 1976. Similarly the relevant requirements of "The factories Act 1948" and "The Water (Prevention and Control of Pollution) Act, 1974" of the Govt. of India are being complied.

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THE QUALITY PLAN The following table briefly summarizes the above information Process Stage Mixing Quality Characteristic to Responsible be controlled Mix, Time, creaming & lay time Rotary Weight, Shape, gap between two biscuit Dough Consistency Rotary Operator Mixing operator Baking Wt, Color size Gauge taste Oven operator Size-thickness & weigh & Taste & Color Cooling Packing Temp Sealing weight & No. of Biscuit Packing Sup. Packing Sup. Temp. Heating Temp. Biscuit . Store I/c Tap sticking By thermometer Indicator Visual Balance By weight By measurement By lab test Consistency Weigh Shape By Weighing & visual By hand Function Prod. Sup. Time & Weight Parameter Method of Check Visual

Delivery

Box Taping

Visual

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CONTROL OF CUSTOMER SUPPLIED PRODUCTS

All the raw material used in the biscuit manufacturing including the packing material is supplied by the Parle Product ltd through its approved vendors. Information of this received through copy of Purchase Orders sent by the customer. Procedure has been developed for inspecting the customer supplied products and they are accepted only after inspection as per the established procedures. Even the supplied itself are so regulated that that storage time is limited to following : Raw Material Item Maida Sugar Vanaspati Loose Vanaspati Tins Salt and Soda Other Raw Material Storage Time 04 days 04 days 15 days 03 month 03 month 03 month

Packing Material Item Wrapper Others Storage Time 10-15 days 01 months

Through the supplies are stored for limited period as described. However the company has the policy to report the loss, damage and unsuitable quality of material for its use.

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INSPECTION OF THE RAW MATERIAL: On arrival of the material it is examined physically from out side for ensuring absence of weevils, insect?s dampness unusual appearance and sticking dirt or foreign matter if these are found, the same are segregated and rejected. SAMPLING Testing is done on the basis of sampling done. The sampling method followed at M/s AFP is developed by M/s AFP in consultation/ agreement with customer i.e. M/S PARLE PRODUCTS PVT. LTD. The amount of sample drawn basis on the supply received is given in table as below :

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Table for selecting randomly the number of Bags/ Bundles/Rolls/Container for drawing the test sample Sr. No. Material Tested to be Percentage received, of which total is quantity Quantity of sample req. randomly for actual laboratory by

selected for drawing the test sample testing from of

prepared

Bags/ drawing approx. equal amounts from items

Bundles/Rolls/Container

selected at (3) and missed well 1. 2. 3. Maida Sugar Vanaspati (Loose) 4. 5. 6. Vanaspati (Tins) Edible Common Salt Food Flavour / Color (a) Orange Oil (b) Parle Flavour (c) Pineapple Flavour (d) Milk Condensed 9. Poly Bags (Each Type) 10. Wrapper (Each Type) 5% 100% Screening 100% Screening 100% Screening 100% Screening 5% of bal. (Packed in 1000 no.) Received 50ml. 50ml. 50ml. 50ml. 15-20 bags collected from each unit 5% 10% 10% 10% 100% Screening 200 GM. 200 GM. Taken 100ml. from each compartment of tanker

200 GM 200 GM.

1-2 mtr are randomly

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collected from all samples.

SPECIFICATION AND TESTING OF RAW MATERIAL Maida (Wheat Flour) The flour should be free flowing and dry to touch, should not pack when squeezed, should be off white to creamy color and free from any visible bran practical. The flour shall have a characteristic taste, free from musty flavour and undesirable smell and rancid taste. There should be no insects, fungus, infestation and rodent excrete, dirt and other extraneous matter. Sampling Methods: Sampling is employed for collecting the test ample of wheat flour as detailed. The requirement desired from the maida (wheat flour) are :

S.No. (a) (b) Moisture percent by mass

Parameters

Requirements 12+1%

Total ash [on dry basis] percent by mass acid insoluble ash [on dry 0.65 (Max.) basis]

(c)

Acid insoluble ash [on dry basis]

0.03% (Max.)

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(d) (e) (f) (g) (h)

Gluten percentage by mass [on dry basis] Alcoholic Acidity as [H2SO4] in 90% Alcohol, percent by mass Water absorption percent Granularity, sieving through 180 micron IS Sieve Sedimentation Value

8.5 to 10% 0.075% (Max) 55 to 60% 0.1 (Max) 20 to 22

SUGAR : Sugar shall be white/ yellowish in color with characteristic sweet taste and in crystal from having moisture content of less than 0.05%. It shall not pack when squeezed in hand. It shall be free from black speck, foreign odour, other extraneous matter such as insects, straw, grain etc. It shall be free from lumps and cakes from. It shall be free from painting ink or color act.

VANASPATI: Vanaspati means any refined edible vegetable oil or oils, subjected to a process pf hydrogenation in any form. The material on melting shall be clear in appearance and shall be free from staleness or rancidity and sediment suspended. Water, added colouring or flavoring substance or any other such substance or any matter dexterous to health. It shall have a completely odour less and characteristic taste and shall be free from foreign odour and taste. Vanaspati for cream preparation n cream biscuits should be creamy white and in plastic from melted vanaspati should not be used for this. TESTING FOR VANASPATI: It shall not be grainy in tusture, but creamy in nature for supplies in tins. It shall not be hard and finger should pierce easily when pressed on the top surface of vanaspati. SPECIFICATION Requirements for bakery shortening (Vanaspati)

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S.No.

Characteristics

Requirements Winter Summer 0.10%

(a)

Free fatty acids, percent by mass when expressed as oleic acid maximum

0.10%

(b) (c) (d) (e)

Iodine value maximum Peroxide Value Melting point maximum Temperature of the vanaspati inside the tanker at time of receipt

53-65% 1.25% (Max) 36 to 39oC 50oC(Max)

63-65% 1.25% (Max) 36 to 39oC 45oC(Max)

(f) (g)

Odour Taste

Odour Less

Odour Less

Characteristic Characteristic

SAMPLING & TESTING : APPEARANCE OR COLOUR OF VANASPATI : It shall have white to yellowish color or dark brown or any unnatural color is observed, resample from 6 more tins is selected on random basis and if repeated then reject the consignment. In case of tanker supply, take sample again from each of the compartment. BULK HANDLING OF VANASPATI IN TANKERS : Before unloading the vanaspati check the temperature of the melted vanaspati in the tank. Test free fatty acid, lodine value, peroxide value and melting point. If the tests are within the limits of requirements of standard then the consignment is to be unloaded. Record of the findings is maintained. [23]

SKIMMED MILK POWDER: The milk powder shall be white or white with greenish tinge or light cream in color. It shall be free from lumps or caking, practically, free from scorched black particles. It shall be free from dirt and other extraneous matter such as insects/weevils etc. Take sample at random from the consignment. SPECIFICATION : Requirement for skimmed milk powder (SMP) are as under :

S. No. 1. 2. 3. 4.

Parameters Moisture Percentage by Mass Total Solids percent by Mass Titrable Acidity (as Lactic Acid) Total Ash (On Dry Basic percent by Mass)

Requirements 4.0% (Max) 96.0% (Min) 1.2% (Max) 8.2% (Max)

EDIBLE COMMON SALT : The material is used conforming with ISI marking. The material shall be crystalline white powder and fairly free flowing and free from any visible impurities such as black speck, grains, jute, fibers, sand etc. it shall have characteristic taste of salt. SODIUM BI CARBONATE (SBC) : The material is used conforming to with ISI marking. The material shall be white in color with minutely crystalline powder in nature free from dirt and other foreign matter. It is stable in dry air, but slowly decomposes in moist air, freshly prepared solution in cold water without shaking is alkaline to litmus. QUALITY CONTROL OF BISCUITS :

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The final quality of the biscuits is always ensured by ensuring adherence to established procedures at all stages of manufacturing and inspection. The in-process inspection of the biscuits is carried out .The requirement of the biscuits are.

S.No. 1. 2. Stack-Height Dimension (a) Length (b) Width

Parameters

Requirements 116+2mm

55+0.75mm 35+0.5mm 100g.m. (Min.) 500g.m. (Min.)

3. 4.

Weight of 16 biscuits Weight of 79-80 biscuits

SPECIFICATIONS The requirement desired from the biscuits are :

S.No. 1. 2. 3. 4. Moisture Total Ash

Parameters

Requirements 2.25% (Mix.) 1.50% (Mix.) 0.05% (Mix.) 1.25% (Mix.)

Acid insoluble ash Acidity of Extracted fat

INSPECTION AND TEST STATUS :

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As a preventive strategy, to ensure that no non-conforming product gets mixed up at any stage, the inspection and test status of the product is clearly identified by following means. The non conforming biscuits are removed from the oven line and immediately segregated in separate area bins marked "BROKEN BISCUIT FOR REUSE" and "WASTE BISCUITS FOR DISPOSAL". These biscuits are collected and subsequently stored in separate identified areas for them which are wide apart. The broken biscuits which reach the packing stage ?broken due to handling in transit? get segregated into bins marked. . INSPECTION AND TESTING M/s AFP views inspection and testing an important tool for objectively ensuring that the product quality is being consistently maintained and only conforming products are allowed to pass to the customer. Established procedures for inspection and testing the quality of the product at all stages of the manufacturing processes for incoming raw material inspection and testing to that of the packing quality of the final product are available. These inspecting and testing requirements are decided in consolation with the customer. For achieving these objectives, M/s AFP has established a special test laboratory under the control of incharge quality control. This ensures prompt testing of the raw material and final product and other material and also ensures fast decisions which helps in achieving tight delivery schedules. The chemicals used in the laboratory are clearly marked and kept in their designated places. Established and documented test procedures have been developed for performing the various tests listed above and records shall be maintained in the Laboratory. The various tests that are performed at M/s AFP during the different stages and at different frequencies, along with the responsibility for these taste. Only biscuits of acceptable quality are allowed to sent for packing/further processing in case of cream biscuits by the oven operator. In case of any problem or doubt, he shall segregate such items, and seek clarification/advise from the superiors.

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The respective shift incharge and or oven operators are authorized to release the product for packing after ensuring ensuring that the product has successfully completed the baking and other previous stages of manufacturing and relevant inspection and manufacturing records are maintained. It is ensured by the Asst. Production Manager/Production supervisors/lab Incharge that the product has successfully completed the previous stages of manufacturing. The representatives of the customer M/s Parle Products Pvt. Ltd; stationed in the company premises also randomly verify the achievement of satisfactory quality. Only such finished product which has satisfied all the requirements of quality are allowed to be kept in out going store. The finished goods are dispatched only after necessary authorization by director/ Manger. STORAGE AND ISSUE Since M/s AFP is involved in the business of a food product namely Biscuits, extensive care and though has been exercised in the storage and issues of raw materials used in the manufacturing process. Established procedures have been developed for storage, handling and packing of raw material semi-finished/finished product so that they are clearly identifiable and their quality is maintained. Counted or weighed quantities of materials is issued on FIFO system i.e. First In and First Out for the factory stores to production department or from the final dispatch to the customer. Proper records are maintained for issue of each item and quantity. Daily cumulative issues of all materials is recorded. HANDLING ? ? ? ? Handling of the biscuits is extremely important with a view to ensure adequate. Hygiene and safety of operator as also the safety of the product. At the raw material stage the mixing operation is mechanically performed. However at the feeder stage the mixed raw material or dough is handled only with clean hands. The PARLE flavour is brought in container from the packing material godown in required volumes ensuring that no spillage shall be caused in transit. Since the manufacturing process is a continuous one, the biscuits in the open trays do not remain in that condition for long. Even if storage is required, it is done mostly in the hot room having heaters and dehumidifier and being a closed room, the dust problem is negligible. [27]

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The packaged biscuit design has been adopted from the PARLE-G design and each packet contains 16 Parle-G biscuits or 8 sandwiched cream biscuits as the case be.

PACKING ? The required quantity of printed wrapper is issued from Factory stores is just, adequate for day?s requirement. The biscuits are packed by automatic line. 16 biscuits of Parle-G for 100 gm. size is one waxed printed wrapper are packed. The filled wrapper of the packet is properly sealed using heat sealer set on packing machine at appropriate temperature. In order to ensure that moisture content of the biscuits is kept within specified limits, they are packed on continuous basis and the practice of over storage in hot room or dehumidified chamber is not permitted except in absolute emergency situations.

INTERNAL AUDIT Conduct of internal audits has been institutionalized and are conducted regularly as a means of ensuring the effectiveness of the installed quality system. The frequency of the internal audits is based on the following considerations: ? ? ? ? ? ? ? ? ? The importance of the function/ activity. The management priorities and ISO-9001-2000 requirements. The customers feedback and complaints. Findings of the previous internal audit reports. Waste management data. Recommendations of earlier review meetings and their status of implementation. Preventive and corrective action reports. Process related problems and change in technology. Joining of fresh personnel (on transfer/ new requirements), and the degree of technical confidence in the independent operation of the staff.

At least internal audits shall be conducted in four months as a minimum. The audits shall be performed by trained internal auditors who are not directly related with the activity under audit.

[28]

The relevant audit report shall be intimidated to the concerned auditor and final audit report shall be submitted to Manager. The findings of the audit shall be placed before the management for review during the review committee meetings. In case of any non conformity observed during the audit, the HOD?s/ sectional heads shall be responsible for the necessary corrective actions. The close up audit shall be conducted after completion of necessary corrective action to ensure that the non conformity is corrected and the corrective actions are effective. In such reviews if it is felt that the procedures/ installed system requires amendments, these shall be incorporated as per the requirements of the procedure on document control.

MANAGEMENT REVIEWS ? ? ? The management shall ensure that management review meetings are held regularly to verify the effectiveness of the installed quality system. At least one management reviews shall be held in a six months as minimum. Management review meetings shall among other things also discuss the following:

1. Findings of the previous internal audit reports. 2. Training of personnel. 3. Customer feed back. 4. Waste management data. 5. Recommendations of earlier meetings and their status of implementations. 6. Preventive and corrective actions reports. 7. Process related problems. 8. Any changes in the statutory/ regulatory requirements. CORRECTIVE AND PREVENTIVE ACTIONS PREVENTIVE ACTIONS [29]

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It is the policy of the M/S AFP to identify preventive action for all the probable potential causes of non conformity including those affecting the process and/ or the quality system of the company. Information for identifying these potential cause is obtained by analysis of the following: Finding based on the analysis of audit report. Customer feedback/ complaints. Analysis of the waste management data. Effectiveness of earlier corrective/ preventive actions and their status of implementation. Improvement in process control reports. Deviations/ concessions issued for the raw material/ packing material. Recommendation of quality circles. Inspection and test records. Process monitoring. Regulatory authority?s observations. Observations and reports by personnel. Preventive maintenance reports. If this requires additional inspection and as policy tighter control measures/ raw material quality shall be preferred. In the non conformity is noticed in baked biscuits during laboratory testing, the matter shall be brought to the notice of the MR and Parle Representative. The seriousness of it shall be reviewed by them or by a larger committee, (if required) and the necessary preventive and corrective actions as decided by the committee shall be implemented. The MR shall ensure the effectiveness of the implementation of all such decisions. Records of such preventive actions taken are maintained and reviewed during the management review meetings.

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? ?

PREVENTIVE MAINTENANCE ? The manufacturing operation at M/s AFP has been geared to maintain consistency in quality. [30]

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The main objective of the maintenance is to reduce the down time of the plant machinery, ensuring its smooth and consistent operation. Machine breakdown has a direct impact on both production and quality. The frequent occurrence of the break down increases the down time of machinery.

SUMMARY OF PALNT SANITATION SCHEDULE : Area Routine to follow Frequency of cleaning Processing, Packaging, Godown, office Wastage Dry cleaning of all processing packaging godown, office. All wastage removal from processing, packaging godown and office Conveyor belts Die Cleaning Band Clean off dropped material With hot water (a) Through brushes and dough rotation (b) Through heat, brushes and dough with rotation Cooling water supply tube of all automatic packing machines Floor wall, ventilation dusts & Dry or wet cleaning sweep & or clean fan Trays Storage water tank Dry or wet cleaning Drain tank, wash interior surface with Frequently & regularly weekly Monthly Monthly Clean with Dr ANEX Weekly Daily Daily Daily Weekly Daily Daily

[31]

water containing detergent Rinse toughly

WORK ENVIRONMENT With a view to ensure good quality of processed biscuits, it is imperative to keep all processing/ surrounding areas and machinery connected with various stages of processing in good hygienic and sanitary conditions. All processing, packing and laboratory areas are designed to be fool proof to the entry of birds, flies, rodents etc. If at any point of time any infestation is found, then appropriate remedial actions are taken immediately. Electrocuters are used in processing and packing area and the entry doors from the outside to eliminate any possibilities of flying insects from coming the factory processing/ packing areas. Eating and smoking is not be permitted in any part of the factory , except in designated areas. Unwanted materials are kept from usual areas of shortage storage. Frequent cleaning of rods below the cooling conveyor where the black mass accumulates adopted. Though company has established the plant hygiene as a preventive measure, however the banking of the biscuits at a temperature of approximately 3000C for approximately 3 minutes kill the bacteria and provides the adequate immunization for all practical purposes.

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