somesh chandra prakash centre for agribusiness … · packaging defectives of marie gold biscuit....

PROJECT ON STUDIES ON PACKAGING DEFECTIVES OF MARIE GOLD BISCU IT AT BRITANNIA INDUSTRIES LIMITED, HAJIPUR BIHAR.

SOMESH CHANDRA PRAKASH

CENTRE FOR AGRIBUSINESS MANAGEMENT

FACULTY OF AGRICULTURE

BIRSA AGRICULTURAL UNIVERSITY

KANKE, RANCHI – 834006 (JHARKHAND)

2015

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STUDIES ON PACKAGING DEFECTIVES OF MARIE GOLD BISCU IT AT BRITANNIA INDUSTRIES LIMITED, HAJIPUR BIHAR.

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RRegd No. : MBA/BAU/ 4804 /13

2015

CENTRE FOR AGRIBUSINESS MANAGEMENT FACULTY OF AGRICULTURE

BIRSA AGRICULTURAL UNIVERSITY RANCHI- 834006

CC EE RR TT II FF II CC AA TT EE

This is to certify that the work recorded in the project report entitled “STUDIES ON

PACKAGING DEFECTIVES OF MARIE GOLD BISCUIT.” at Britannia Industries Ltd.

submitted in partial fulfillment of the requirements for the degree of MASTER OF

BUSINESS ADMINISTRATION IN AGRIBUSINESS of the Faculty of Post-Graduate

Studies, Birsa Agricultural University, Ranchi (Jharkhand) is the record of the bona fide

project work carried out by Mr. SOMESH CHANDRA PRAKASH under my guidance and

supervision. No part of the report has been submitted for any other Degree or Diploma.

It is further certified that such helps or information received

during the course of this investigation and preparation of the report

have been duly acknowledged.

ENDORSED

Dr. Hari Haran Dr.S.Sengupta Consultant Director Major Advisor Center for Agribusiness Management



(Certificate of the Advisory Committee Members and Endorsement of Dean, Agriculture)


I, the undersigned, as Major Advisor of the student for the degree of MASTER OF BUSINESS

ADMINISTRATION IN AGRIBUSINESS have gone through the manuscript of the report and

agree that the project entitled “STUDIES ON PACKAGING DEFECTIVES OF MARIE

GOLD BISCUIT.” at Britannia Industries Ltd. may be submitted by Mr. SOMESH

CHANDRA PRAKASH in partial fulfillment of the requirements for the degree.

Dr.S.Sengupta

Dr.S.Karamkar Dr. Pramod Rai Dr. Binay Kumar

ENDORSED Dr. R.Thakur Dr. Hari Haran Dean Consultant Director Faculty of Agriculture Center for Agribusiness Management Birsa Agricultural University



(Certificate of approval by the Chairman of the Advisory Committee and External Examiner)


This is to certify that the work recorded in this report entitled “STUDIES ON PACKAGING

DEFECTIVES OF MARIE GOLD BISCUIT.” at Britannia Industries Ltd’’ Submitted by

Mr. SOMESH CHANDRA PRAKASH in partial fulfillment of the requirements for the

Degree of MASTER OF BUSINESS ADMINISTRATION IN AGRIBUSINESS of the

Faculty of Agriculture, Birsa Agricultural University, Ranchi (Jharkhand) was examined and

approved on ………………2015.

Dr. S.Sengupta External Examiner Major Advisor Dr. S.Karamkar Dr. Pramod Rai Dr.Binay Kumar Dr.Hari Haran Consultant Director

Centre for Agribusiness Management

Dr. Z.A. Haider DRI-cum-Dean PG Birsa Agricultural University

Ranchi

ACKNOWLEDGMENTS

I am greatly indebted to my guide Dr.S.Sengupta University Assistant

Professor (Dept. of Horticulture) for his valuable technical guidance and moral

support during the course of my project. I am grateful to Dr. Hari Haran, Consultant

Director (CABM) for their valuable suggestions during my project work.

I would like to thank Britannia Industries Ltd. for giving me the opportunity for

conducting the project.

I would also like to thanks all the other members of advisory committee for

their cooperation and regular feedbacks during our informal discussions.

I owe my special regards to God, My parents and my elders for their

blessings and good wishes,

Somesh Chandra Prakash

DDDDEDEDEDEDICATED ICATED ICATED ICATED TO TO TO TO

MY PARENTSMY PARENTSMY PARENTSMY PARENTS

Mr.Mr.Mr.Mr.SunilSunilSunilSunil Prasad guptaPrasad guptaPrasad guptaPrasad gupta & & & &

kiran devikiran devikiran devikiran devi

PREFACE

To start any business the success entirely depends on the of Material

research done about the particular and the consumer attitude towards the

product. Marketing research plays a vital role in a business to make it success.

I have tried to put our best effort to complete this task on the basis of skill

that I have achieved during our studies in the institute.

I have tried to put my maximum effort to get the accurate data. However

I would appreciate if any mistakes are brought to me by the reader.

Packaging is that part of management concerned with the people at work

and with their relationships within the organization.

Training is the process of increasing the knowledge and skill for doing a

particular job. It is an organized procedure by which people learn knowledge

and skill for a definite purpose. The purpose of training is basically to bridge

the gap between job requirements and present competency of an employee.

TABLE OF CONTENTS Sr.no Content Page no

Abstract

1. Introduction

2. Review of Literature

3. Methodology

4. Results and Discussion

5. Suggestion to the organization

6. Summary

7. Reference

ABSTRACT

The study entitled “studies on Packaging Defectives of Marie gold in Britannia biscuits” was conducted at Hajipur, Bihar.The objectives were to study Packaging Defectives of Marie biscuits as well as economics of the plant in the context of Packaging Defectives. Packaging is the science, art and technology of enclosing or covering or protecting products till it reaches in the hands of consumer. Packaging also refers to process of design, evaluation and production of packages. four types of defect has been observed viz.coding problem, empty packets, sealing problem and joint packets which being substantial losses both in terms of economics as well as efficiency of the production. Hence, the present investigation has been formulated to observe genesis, extent, pattern and magnitude of losses being occurred due to packages pertaining to Marie biscuits, a product of BIL.Relevant data were collected to draw inferences for the undertaken project at BIL.Process used for collection of primary data was opening of lamroll,Issue of lamroll,closing of lamroll,consumption of lamroll,Total Production of biscuits, Standard consumption of biscuit. It was observed that packet defects due to cumulative defect of coding problem, joint packet problem, faulty sealing problem was in the tune of 44.50 kg(29/4/2015) to 0 Kg(15/4/2015).On the basis of observation it is evident that there is marked difference in the magnitude of defects of packaging and if the entire production process is kept under précised and vigilant ambient condition, the occurred defects can be kept at minimum which in turns will add substantially in terms of economic output of the product of Marie gold biscuit(BIL).

.

CHAPTER-1

INTRODUCTION

INTRODUCTION

The story of one of India's favorite brands reads almost like a fairy tale. Once

upon a time, in 1892 to be precise, a biscuit company was started in a

nondescript house in Calcutta (now Kolkata) with an initial investment of Rs.

295. The company we all know as Britannia today.

The beginnings might have been humble-the dreams were anything but by

1910, with the advent of electricity, Britannia mechanized its operations, and

in 1921, it became the first company east of the Suez Canal to use imported

gas ovens. Britannia's business was flourishing but, more importantly,

Britannia was acquiring a reputation for quality and value. As a result, during

the tragic World War II, the Government reposed its trust in Britannia by

contracting it to supply large quantities of "service biscuits" to the armed

forces.

As time moved on, the biscuit market continued to grow and Britannia grew

along with it. In 1975, the Britannia Biscuit Company took over the

distribution of biscuits from Parry's who till now distributed Britannia biscuits

in India. In the subsequent public issue of 1978, Indian shareholding crossed

60%, firmly establishing the Indianans’ of the firm. The following year,

Britannia Biscuit Company was re-christened Britannia Industries Limited

(BIL). Four years later in 1983, it crossed the Rs. 100 crores revenue mark.

On the operations front, the company was making equally dynamic strides.

In 1992, it celebrated its Platinum Jubilee. In 1997, the company unveiled its

new corporate identity - "Eat Healthy, Think Better" - and made its first foray

into the dairy products market. In 1999, the "Britannia Khao, World Cup Jao"

promotion further fortified the affinity consumers had with 'Brand Britannia'.

Britannia strode into the 21st Century as one of India's biggest brands and the

pre-eminent food brand of the country. It was equally recognized for its

innovative approach to products and marketing: the Lagaan Match was voted

India's most successful promotional activity of the year 2001 while the

delicious Britannia 50-50 Maska-Chaska became India's most successful

product launch.

In 2002, Britannia's New Business Division formed a joint venture

with Fonterra, the world's second largest Dairy Company and Britannia New

Zealand Foods Pvt. Ltd. was born. In recognition of its vision and accelerating

graph, Forbes Global rated Britannia 'One amongst the Top 200 small

companies of the World', and The Economic Times pegged Britannia India's

2nd most trusted brand.

Today, more than a century after those tentative first steps, Britannia's fairy

tale is not only going strong but blazing new standards and that miniscule

initial investment has grown by leaps and bounds to crores of rupees in wealth

for Britannia's shareholders. The company's offerings are spread across the

spectrum with products ranging from the healthy and economical ‘Tiger

biscuits’ to the more lifestyle-oriented ‘Milkman Cheese’. Having succeeded

in garnering the trust of almost one-third of India's one billion populations and

a strong management at the helm means Britannia will continue to dream big

on its path of innovation and quality.

THE INDUSTRY

Biscuits derive its name from a French word meaning twice backed

bread; Biscuits in general have a good shelf life, which is higher than all other

snack items available in the market.

India is the second largest producer of biscuits in the world after the USA

but still the per capita consumption is only 2.3 kg/year of developed countries

which is far below of the average of developed countries. As per the latest

survey done by N.C.A.E.R., 49 biscuits are consumed in rural areas. The

penetration of biscuits into households stands at an average of 83.2% with the

rural penetration at 77% and urban penetration at 88%. Biscuits are reserved for

the small scale sector but there are strong possibilities of the industry being

deserved in line with the government policy of liberalization. The net effect

thus would be greater choice for the consumer as well as a check on the costs.

Britannia, makers of Britannia biscuits, doubled capacity from 25 tonnes a day

to 50 tonnes and plans to be a national brand soon. In an aggressive mode, the

North dominated biscuit player has increased its add budget to Rs. 5 crore this

year from Rs. 3 crore last year. Britannia has also recently invested about Rs. 5

crore in the modernization and expansion of its production and packing its

production capacity of 40 tons per day to 100 tons per day by next year. The

aim is to take the current turnover of Rs. 50 crore to Rs. 100 crore by the year.

The company's strategy has been to attract new consumer segments and widen

its consumer base with its well packaged low priced offerings. Britannia's

success has also come from its formidable.

It gives me immense pleasure to introduce the Summer Training Report. It is

based on the survey conducted in East Delhi region on Biscuit industry. The

applicability of various branding strategies play crucial role in marketing of

product. The applicability has grown due to the liberalization, competition and

technological changes taking place in corporate world.

In this project the various branding strategies adopted by the company has been

studied and compared on the basis of current market scenario. It gives the idea

about the market share enjoyed by the different companies in the Biscuit

Industry. It provides the adequate coverage of many issues related to biscuit

industry. The objective of this report is to give the market share of Britannia

biscuits in the Indian capital (New Delhi). It has been made possible by

knowing the consumer's behavior and by studying the patterns adopted by the

retailers.

It gives us very precise view about the existing demand of Britannia biscuits

and demand of their products as compared to other competitors. It also

highlights the changing market trends and consumer preferences, why they have

shifted from finally pack to pouch pack. The annual growth rate of the industry

is about 12.5%. However, the growth of cream biscuits, assorted or special

variety is the range of 30-40%.

The organized sector consists of large, medium and small scale biscuit

manufacturers who produce packed biscuits. The major players in this sector

are Britannia, Bakeman’s, and Parle, etc. The unorganized sector comprises of

small bakery units, cottage and household type manufacturing plants. These

units distribute their biscuits in the surrounding vicinity of their manufacturing

locations of say 20-50 kms.

Little Hearts

Little Hearts was launched in 1993 and

targeted the growing youth segment. A completely unique product, it was the

first time biscuits were retailed in pouch packs like potato wafers. In 1997, the

'Direct Dil Se' campaign encouraged youngsters to openly express their

feelings. And in 2003, two variants called Little Hearts Chocolate and Little

Hearts Sesame were rolled out with a campaign "Dil sabka actually sweet hai".

With Little Hearts, Britannia has tasted the sweet taste of success.

Britannia tiger

Britannia is committed to help secure every

child s right to growth and development through good food every day. Purpose

fully taking forward the credo of ‘Eat Healthy Think Better’ launched a new

variant under their power brand tiger.

Britannia Tiger Banana packed with IRON ZOR and goodness of banana is

accessible to all, being available to convenient pack priced at Rs.2, Rs.4and

Rs.10.

Britannia Good Day

Britannia Good Day was launched in 1986 in two delectable avatars - Good

Day Cashew and Butter. Over the years, new variants were introduced - Good

Day Pista Badam in 1989, Good Day Chocochips in 2000 and Good Day

Coconut in 2004.

TIGER

Tiger, launched in 1997, became the largest brand in Britannia's portfolio in the

very first year of its launch and continues to be so till today. Tiger has grown

from strength to strength and the re-invigoration in June 2005 has further

helped bolster its growth in the highly competitive glucose biscuit category.

MARIE GOLD

Britannia's oldest brand enjoys a heritage that spans the last 50 years - and

going strong. In a market swamped with me-too products and where even the

name 'Marie' has become generic, Britannia Marie Gold has maintained its

stronghold. Today, the ever-popular Marie Gold is synonymous with the 'Tea

Time Biscuit'. Its taste, crispiness and lightness make it a must for every tea

break. It is the #1 brand in its category by a long shot.

NUTRICHOICE

In continuation of the promise of "Swasth Khao, Tan Man Jagao," Britannia

introduced NutriChoice range of healthy biscuits in 1998. The brand is targeted

towards overall health and wellness for adults.

The range has for long comprised of three popular variants, namely

NutriChoice Thin Arrowroot, NutriChoice Cream Cracker and NutriChoice

Digestive.

MILK BIKIS

Milk Bikis, the favorite growth partner of Kids, now brings greater value and

delight to all with its new product and pack design. Recently re-launched in its

existing Southern & Eastern markets, and extended across India, the new Milk

Bikis is all set to add excitement and appeal to ‘nutritious’ food. Whoever said

that ‘good food’ needs to look ‘dull and boring’, will just have to take a look at

MilkBikis.

With a unique and attractive honeycomb design and an enhanced product

experience, the new biscuit prompts the ‘Kid’s will love it’ reaction amongst

mothers

ACTIVITIES OF THE BIL COMPANY

SALES FINANCE & IT

MARKETING

EXPORT

PRODUCTION

RESEARCH & DEVELOPMENT

TECHNICAL & OPERATION

HUMAN RESOURCE &LEGAL

QUALITY ASSURANCE

ACT IVI T I ES OF THE COMPANY

THE MANAGEMENT TEAM:

Name Designation

Mr. Nusli Neville Wadia Chairman

Mr. Varun Berry Managing Director

Mr. Neeraj Chandra VP & Chief Operating Officer

Mr. P. Shyam Sunder VP & Head of Quality

Mr. Rajesh Kumar Lal VP & Chief Technology Officer

Mr. Raju Thomas Chief Financial Officer

Mr. AlaguBalaraman VP- HR& Process Architect

Mr. AtulSinha VP- New Business Development

INTRODUCTION

TO

THE

HAJIPUR UNIT

Hajipur plant of Britannia industries limited was established on 25 August

,2011 about 20 km from Patna in the area of approximately one acres mainly

for the purpose of production of biscuits as this area is free from almost all

types of taxes.

In Britannia Industries Limited there are many spectrum of departments which

are inter connected to each other and work in collaboration for the welfare of

the company as the whole. There is a well built communication system inside

the company which helps in doing the work on time and with full efficiency and

effectiveness.

The Departments of the company includes Quality assurance, Stores,

Production, Purchase, Maintenance, Engineering, Packaging and dispatch,

Personnel and training, Finance, Legal and administrative security.

New concept like 5S is also being implemented in Britannia Industries Limited.

The Company has got ISO 22000:2005 certificate and it is ISO 22000 certified.

There are Three plants in operation of the BIL Company at this branch. First

plant is for ‘Good day’ which has a flexi line for ‘Milk Bikis’ also. Second

plant is for ‘Tiger cream’, Third one is for ‘MarieGold’.

PACKAGING

INTRODUCTION:

Packaging is one of the most important and vital part for any food processing

industry. A package must ‘protect what it sell’ and ‘sell what it protects’.

Package contains lots of necessary information related to products. The most

obvious purpose of packaging is to physically protect the product inside.

Packaging can be made to protect the product from extreme heat and cold. It

can also protect the product from weather, such as rain and sunlight, during

transport. In addition, packaging can protect the product from being

contaminated by airborne pathogens or from being damaged by handling or

pressure. Packaging also aids in the grouping of small objects for efficiency.

Packaging is next to grading and branding.

WHAT IS PACKAGING?

Packaging is the science, art and technology of enclosing or protecting products

for distribution, storage, sale and use. Packaging also refers to process of

design, evaluation and production of packages.

TYPES OF PACKAGING

1. Primary Packaging: - The material that first envelops the product and

holds it. This usually is the smallest unit of distribution or use and is the

package which is in direct contact with the contents.

2. Secondary Packaging: - Is the outside of the primary packaging,

perhaps used to group primary packages together.

3. Tertiary Packaging: - Is used for bulk handling, warehouse storage, and

transport shipping.

FUNCTIONS OF PACKAGING

• Protection - Packaging helps in protection of products. It increases the

life cycle of a product.

• Preservation – It preserves original color, quality etc.

• Economy – Packaging of a product should be economical.

• Convenience – Packaging should be light to handle.

• Presentation – Presentation of a product should be attractive and eye

catching.

• Containment - Small objects are typically grouped together in one

package for reasons of efficiency.

• Identification – Packaging helps to identify the products easily.

• Suitability – Packaging should match with the product.

• Labeling – It helps to promote the sale of goods.

• Handling – When package is light in weight it facilitate easy handling of

cargo.

BASIC FUNCTIONS OF PACKAGING

• Protection – Packaging helps in protection of products.

• Containment – Small objects are typically grouped together in

one package for reasons of efficiency.

• Information – Packaging conveys necessary information to the

consumers. The common information that packaging provides

includes general features of the products, ingredients, name of the

manufacturer, manufacturing date etc.

• Utility of use - The convenience packaging has been devised for

foods, household chemicals, drugs, adhesives, paints, cosmetics,

paper goods and a host of other products. This type of packaging

includes dispensing devices, prepackaged hot metals, disposable

medical packaging.

• Promotion - Companies use attractive colours, logos, symbols and

captions to promote the product that can influence customer

purchase decision.

FACTORS INFLUENCING PACKAGING DESIGN

TYPES OF PACKAGING MATERIAL USED IN BISCUIT INDUSTR Y

I. Primary Packaging:- Laminate/Wrapper

II. Secondary Packaging:- CBB(Card board boxes)

Fig.- Primary Packaging Fig.- Secondary Packaging

Fig.- Packaging Machine

TYPES OF DEFECTS

I. Coding Problem – Refers to if wrapper doesn’t contain

manufacturing date, price, and lot no. etc.

II. Empty Packets – Packets are devoid of products.

III. Sealing Problem – When the end side of the wrapper doesn’t

sealed properly.

IV. Joint Packets – When two packets are joined together and cannot

be properly separated.

Fig.-symbols used by Packaging

REVIEW OF LITERATURE

Karel and Heidelbaugh (1975) reported in their view indicated the

imperativeness of food package as an essential element requiring adequate

attention to forestall the potential of defective packaging negating all a food

processor has attempted to accomplish by the most meticulous forms of

manufacturing processes.

Lampi (1980) reported as Early suggestions for the packaging leakers included

wrinkles in the seal area, or holes in the packaging material itself.

Daniel et al., (1985); Dixon and Kell, (1989) reported as Carbon dioxide as a

bacteriostatic influencing agent and is therefore commonly used in food

packaging.

Porter (1986) reported as Flexible paper and laminates or multi-layers may

combine paper, plastic and foils to achieve properties unattainable with any

single component.

Gilchrist et al., (1989) Micro leaks can either occur temporarily or remain a

permanent defect.

Gilchrist et al., (1989) this is very common in flexible packages, in which an

intentionally formed pinhole can reduce in size due to the flexibility of the

package.

Guise (1989) Package material should be able to withstand the change in

temperature which is likely to be encountered without any loss in performance

or appearance. Therefore the rate of change of temperature and the type of heat

may influence the choice of packaging material.

Stauffer (1990) Package integrity is vital to both food quality assurance and

food safety.

IFST ( 1992) reported that Shelf-life is explained in relation to the period of time during which the food product will remain safe and retain desired sensory, chemical, physical and microbiological characteristics and comply with any label declaration of nutritional data, when stored under the recommended conditions.

Yeh and Benatar (1997) an aseptic food package is defined as a hermetically

sealed container that holds sterile food and maintains the integrity of the food

throughout a long shelf life.

Coles (2003) reported the principal roles of food packaging are to protect food

products from outside influences and damage, to contain the food, and to

provide consumers with ingredient and nutritional information.

BPF (2006) reported as Food packaging is known to employ a very wide

variety of materials including the rigid metals (Cans and drums), flexible metal

(aluminum and tin foils), glass (jars and bottles), rigid and semi-rigid plastics

(canisters and squeeze bottles).

Lord (2008) reported as the development of polypropylene, polyester, and

ethylene vinyl alcohol polymers led the incredible move away from metal,

glass, and paperboard packaging to plastic and flexible packaging.

In the light of entire set up of BIL pertaining to packaging defects of

Marie Gold biscuits (BIL) the following objectives were derived to fulfill

the analytical view of investigation:

1. To find out the magnitude of Packaging defectives.

2. To enhance the economics of the Plant in the context of Packaging

defectives.

CHAPTER-3

METHODOLOGY

METHODOLOGY

PROBLEM IDENTIFICATION:

This is the first and important step in any research that is a very

significant step to identify the problems. On the other hand if the problem is not

well defined regularly then the research maybe useless for the management of

the organization for which the research is being conducted.

TYPE OF RESEARCH:

The research work being undertaken by the researcher is purely analytical

work because the research is an attempt to analyze the financial position of the

organization on the basis of the annual reports.

RESEARCH DESIGN:

Before starting the research every researcher should know the objective

of the study. The objective is already given to attain it various data is analyzed.

Research design is analytical.

ANALYSIS:

Analysis of data is most essential and difficult task in the present report

an attempt has been made to analyze each & every financial statement of the

company effectively so that proper analysis can be made of financial condition

of the company.

Relevant data were collected to draw inferences for the undertaken project at

BIL.

(a) PRIMARY DATA – Data observed or collected directly from the first

hand expression by the investigator.It is the used in research originally

obtained through direct efforts of the researchers through

surveys,interviews and direct observations.

Process for collection of Primary Data:

i.Opening of Lamroll – was recorded by digital display of the equipment.

ii.Issue of Lamroll - was quantified as per the stock register.

iii.Closing of Lamroll - was quantified as per the produce register.

iv. Consumption of Lamroll (Kg) – [(Opening + Issue) – Closing]

v.Total Production of Biscuits

vi.Standard Consumption- it is fixed by BIL @ 12.50kg for per tone of the

product(biscuits) in India & 13.50 for per tone of the product (biscuits) in

Nepal.

vii. Defectives = Total Production x Standard consumption – Consumption

CHAPTER-

RESULTS AND

DISCUSSION

Identification and study of different types of defects occurred viz.

1. Defects due to coding problem

2. Defects because of sealing problem

3. Defects due to joint packets

4. Defects because of empty packets

5. Integral study of cumulative defects (Defects due to

Coding+Sealing+Empty+Joint Packets.

Objective -1: Magnitude of packaging defectives in Marie gold.

Quantification of Packaging Defectives in Marie gold biscuits helped to find out

the magnitude of defects viz. coding problem, joint packets, empty packets and

sealing problem in mentioned product.

DEFECTS RELATED TO CODING PROBLEM IN MARIEGOLD

BISCUITS (BIL) FOR THE MONTH OF APRIL, 2015 EXPRESSED IN

LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)

Table No.-1

MACHINE 16 & 17

DATE REASON 12 HOUR (KG)

2/4/2015 Coding Problem 0.4















20/4/2015 Coding Problem Closed


22/4/2015 Coding Problem 00








Maximum Lamroll loss(24.50kg) due to coding problem was observed on

29/4/2015.However,minimum value of 0.0 Kg was observed on 22/4/2015 i.e. on that

day there was no lamroll loss due to coding problem(table-1 and fig-1).

Fig.1 – Graphical representation of day to d ay loss of lamroll

(Kg) in a 12 hours shift due to coding problem for the month of April,

2015 in Marie gold biscuit (BIL).

DEFECTS RELATED TO CODING PROBLEM IN MARIEGOLD

BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN LOSS OF

LAMROLL (KG) IN ONE SHIFT (12 HRS)

TABLE NO.-2

MACHINE 16 & 17






8/5/2015 Coding Problem 3

Maximum Lamroll loss(9.6kg) due to coding problem was observed on

7/5/2015.However,minimum value of 0.5 Kg was observed on 6/5/2015 i.e on that

day there was no lamroll loss due to coding problem(table-2 and fig-2).

Fig.2 – Graphical representation of d ay to day loss of lamroll

(Kg) in a 12 hours shift due to coding problem for 4 th -8th may, 2015

in Marie gold biscuit (BIL).

DEFECTS RELATED TO SEALING PROBLEM IN MARIEGOLD

BISCUITS (BIL) FOR THE MONTH OF APRIL, 2015 EXPRESSED IN


TABLE NO. - 3

MACHINE 16 & 17


2/4/2015 SEALING PROBLEM 0.2

3/4/2015 SEALING PROBLEM 1














20/4/2015 SEALING PROBLEM CLOSED










Maximum Lamroll loss(20.40kg) due to sealing problem was observed on


day there was no lamroll loss due to sealing problem(table-3 and fig-3).

Fig.3- Graphical representation of day to day loss of lam roll (Kg) in

a 12 hours shift due to sealing problem for the mon th of april , 2015

in Marie gold biscuit (BIL).

DEFECTS RELATED TO SEALING PROBLEM IN MARIEGOLD

BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN LOSS OF

LAMROLL (KG) IN ONE SHIFT (12 HRS)

TABLE NO. - 4

MACHINE 16 & 17







Maximum Lamroll loss(5.0kg) due to sealing problem was observed on


day there was no lamroll loss due to sealing problem(table-4 and fig-4).

Fig. 4- Graphical representation of day to day loss of lamroll (Kg) in a 12 hours

shift due to sealing problem for 4 th -8th may, 2015 in Marie gold biscuit (BIL).

DEFECTS RELATED TO JOINT PACKET PROBLEM IN

MARIEGOLD BISCUITS (BIL) FOR THE MONTH OF APRIL, 20 15

EXPRESSED IN LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)

TABLE NO.- 5

MACHINE 16 & 17


2/4/2015 JOINT PACKETS 0.6




7/4/2015 JOINT PACKETS 10











20/4/2015 JOINT PACKETS Closed





25/4/2015 JOINT PACKETS CLOSED


28/4/2015 JOINT PACKETS CLOSED



Maximum Lamroll loss(10kg) due to joint packet problem was observed on

15/4/2015.However,minimum value of 0.0 Kg was observed on

21/4/2015,22/4/2015,23/4/2015 i.e on that day there was no lamroll loss due to joint

problem(table-5 and fig-5).

Fig.5 – Graphical representation of day to day loss of lamr oll (Kg) in

a 12 hours shift due to joint packet problem for the month of April,


DEFECTS RELATED TO JOINT PACKET PROBLEM IN

MARIEGOLD BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN


TABLE NO.-6

MACHINE 16 & 17


4/5/2015 JOINT PACKET 2.0


6/5/2015 JOINT PACKET 00


8/5/2015 JOINT PACKET 2

Maximum Lamroll loss(5kg) due to join packet problem was observed on


day there was no lamroll loss due to joint problem(table-6 and fig-6).

Fig.6 – Graphical representation of day to day loss of lamroll (Kg) in a 12

hours shift due to joint packet problem for 4 th -8th may, 2015 in Marie gold

biscuit (BIL).

DEFECTS RELATED TO EMPTY PACKET PROBLEM IN

MARIEGOLD BISCUITS (BIL) FOR THE MONTH OF APRIL, 20 15

EXPRESSED IN LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)

TABLE NO.-7

MACHINE 16 & 17


2/4/2015 EMPTY PACKETS 0.475




















28/4/2015 EMPTY PACKETS Closed



Maximum Lamroll loss (5kg) due to empty packet problem was observed on

17/4/2015.However,minimum value of 0.475 Kg was observed on 2/4/2015 i.e on

that day there was no lamroll loss due to empty problem(table-7 and fig-7).

Fig.7- Graphical representation of day to day loss of lamroll (Kg) in a

12 hours shift due to empty packet problem for the month of April,


DEFECTS RELATED TO EMPTY PACKET PROBLEM IN

MARIEGOLD BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN


TABLE NO.-8

MACHINE 16 & 17




6/5/2015 EMPTY PACKETS 00



Maximum Lamroll loss (7kg) due to Empty packet problem was observed on


day there was no lamroll loss due to empty problem(table-8 and fig-8).

Fig. 8 – Graphical representation of day to day los s of lamroll (Kg) in a 12

hours shift due to empty packet problem for 4 th -8th may, 2015 in Marie gold

biscuit (BIL).

Objective -2: To enhance the economics of a plant in the context of

Packaging Defectives

Data has been collected on the hourly basis with help of the respondents of

industries to minimize the defects which ultimately enhance the economics of

the plants .The whole process was done to get a brief idea about defectives due

to several reasons like coding problem, sealing problem, joint packets problems,

empty packets problem. With the help of table that how different defects with

reference to packaging occurred and how prevention of these defects are useful

to boost up the economic profit ability of the plant.

CUMULATIVE PACKAGING DEFECTS OF MARIE GOLD BISCUITS (BIL) DURING 2 ND APRIL TO 8 TH MAY, 2015 TABLE NO.-9

MACHINE 16 & 17

Date Opening of lamroll(Kg)

Issue of lamroll(Kg)

Closing of lamroll(Kg)

Consumption of

lamroll(Kg)

Total production of

biscuits(tonnes)

Packet Defected

(Kg)

Packet Defected

(%)

Empty Packet (Kg)

Empty Packet

(%) 2/4/2015 88 219 180 127 10.29 1.2 0.11 0.475 0.04 3/4/2015 56 243 126.24 12.76 14.24 3.25 0.22 2.015 0.14 4/4/2015 95 208 58.5 244.5 21.21 14.8 0.69 5.825 0.27 6/4/2015 68 194.5 173 89.5 7.85 5.3 0.074 3.325 0.04 7/4/2015 40 143.5 82.5 101 12.61 34.5 2.73 22.62 1.79 8/4/2015 175 153.1 121.5 206.6 18.55 18.7 1.00 6.575 0.35 9/4/2015 62 219.2 186 95.2 8.55 8.4 0.104 3.275 0.04 10/4/2015 135 133 117 151 13.55 11.5 0.84 6.87 0.50 11/4/2015 153 168.2 140 181.2 15.11 4.3 0.28 3.37 0.22 13/4/2015 190 105 94 201 16.35 2.1 0.12 1.275 0.07 14/4/2015 72 201 180 93 9.85 21.8 0.23 8.325 0.09 15/4/2015 47 105.6 81.93 70.67 8.14 24.42 0.30 7.0 0.08 16/4/2015 35 138.26 76.6 96.66 8.78 10.5 0.12 2.64 0.03 17/4/2015 54 241 124.24 170.76 12.24 12.50 1.02 5.26 0.42 18/4/2015 92 206 55.69 242.31 15.21 36.4 2.39 15.71 1.03 21/4/2015 151 166.13 137 180.13 14.11 1.50 0.10 2.23 0.15 22/4/2015 97 274.87 203 168.87 13.72 1.73 0.12 1.0 0.07 23/4/2015 90 221.8 182 129.8 10.29 0.6 0.05 0.5 0.04 24/4/2015 130.72 212.29 161 182.01 13.53 9.50 0.70 3.31 0.24 27/4/2015 48 0 128 80 7.34 7.5 0.10 4.3 0.06 29/4/2015 180 159.3 126.6 212.7 11.57 44.50 3.84 23.48 2.02 30/4/2015 138 0 28.62 109.38 6.73 17.10 0.28 8.04 0.13 4/5/2015 65.9 223.4 190 99.3 9.50 12.5 0.13 7.0 0.07 5/5/2015 188 112.3 181 116.3 10.56 9.5 0.89 6.2 0.58 6/5/2015 138 136 120 154 12.36 0.5 0.04 00 0 7/5/2015 70 197.1 178 89.1 8.88 19.6 0.24 2.3 0.02 8/5/2015 229 113.3 193 149.3 12.60 6.0 0.47 2.2 0.17

It is evident from table 9 and figure 9 that there was marked difference in daily record of

packaging defects within the course of investigation (2nd April to 8th May). Packet defect was

expressed in terms of Lamroll loss (Kg) and it was observed that packet defects due to

cumulative defect of coding problem, joint packet problem, faulty sealing was observed

maximum in the tune of 44.50 Kg (29/4/2015)while minimum was 0.5

Kg(6/5/2015).Similarly due to empty packets, packet defects loss was in the range of 23.48

Kg(29/4/2015) to 0(15/4/2015). Packet defect on the other days were varied in the range of

1.2 to 34.50 Kg loss of lamroll.It is clearly indicated that packaging loss in Marie gold biscuit

varies in very long range which can be minimized easily, if the entire operation is closely &

vigilantly monitored

FINANCIAL LOSS OBSERVED IN THE OVERALL PROJECT DUE TO

PACKAGING DEFECTS OF MARIE GOLD (BIL) EXPRESSED IN

RUPEES FOR EACH SHIFT OF 12 HOURS.

TABLE-10

Serial

No.

Particulars Physical

Loss

Unit

Cost

(Rs)

Financial

loss(Rs)

1. Loss of Lamroll 17.06 Kg 300.00 5118

2. Loss of

Produce(Biscuit)

141.13 Kg 93.33 13171.66

3. Loss of Labour cost

4.69

mandays

194.00 909.86

4. Loss of Maintenance

cost(Electricity,fuel,repair

etc)

Lump Sum 500.00

TOTAL Rs.19701.63

Table 10 reveals that in a shift of 12 hrs of a day,if packaging defect are nullified with the

help of tools and informations suggested by the study of this project, a sum of 19701.63 can

be saved which will be highly beneficial in strengthening economic profitability of the

company on a whole.

SUGGESTION

Suggested techniques for reducing defects of packaging in Marie gold biscuits

at BIL are as follows:-

1) Technical efficiency of the operator - The organizations should impart proper

knowledge & training for efficient handling of the equipment and operation.

2) Maintenance of the produce fixed as per technical specifications – Operator

should strictly run the machine as standard fixed by the company.

3) Hardware as well as software maintenance and Up gradation of equipments

involved in production – Proper checking of machine time to time, because if

chain length of the machine increases it leads to cause of various defects.

4) Enhancing efficiency of the monitoring by curtailing twelve hours shift to

eight hours for the supervisors.

5) There should be proper record of wastage for further study.

SUMMARY

Detailed studies on defects related to packaging of Marie biscuits of BIL was

conducted during the month of march to may 2015 and it was observed that

packet defects due to cumulative defect of coding problem, joint packet

problem, faulty sealing was observed maximum of 3.84% on 29/4/2015 while

minimum was 0% 6/5/2015.Similarly due to empty packets, packet defects loss

was in the range of 0.00% (6/5/2015) to 2.02% ( 29/4/2015) . On the basis of

observation it is evident that there is significant difference in the magnitude of

defects of packaging and if the entire production process is kept under précised

and vigilant ambient condition, the occurred defects can be kept at minimum

which in turns will add substantially in terms of economic output of the

production of Marie gold biscuit (BIL).

CONCLUSION

The entire study was based on operative exposure of the plant and the

informations supplied by the BIL. The growth rate of BIL is still on higher side

in comparison to other biscuit industries and moreover by virtue of very sound

set up of HRD.The working environment, discipline and application of skill and

knowledge in production process varied significantly. Lastly it can be clearly

inferred that packaging defects in Marie gold biscuits (BIL) has been varied

substantially and highly influenced economic output of the production process

which can be managed efficiently with the incorporation of judicious

monitoring and some technical additions as observed and traced out in due

course of investigation and suggested accordingly for the ultimate benefit of the

company in terms of economic profitability.

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www.wadiagroup.com

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