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
PPRROOJJEECCTT OONN
STUDIES ON PACKAGING DEFECTIVES OF MARIE GOLD BISCU IT AT BRITANNIA INDUSTRIES LIMITED, HAJIPUR BIHAR.
SSUUBBMM II TTTTEEDD TTOO TTHHEE
CCEENNTTRREE FFOORR AAGGRRII BBUUSSII NNEESSSS MM AANNAAGGEEMM EENNTT
FFAACCUULL TTYY OOFF AAGGRRII CCUULL TTUURREE
BBII RRSSAA AAGGRRII CCUULL TTUURRAALL UUNNII VVEERRSSII TTYY
RRAANNCCHHII ((JJHHAARRKK HHAANNDD))
BBYY
SSOOMM EESSHH CCHHAANNDDRRAA PPRRAAKK AASSHH
II NN PPAARRTTII AALL FFUULL FFII LL MM EENNTT OOFF TTHHEE RREEQQUUII RREEMM EENNTTSS
FFOORR TTHHEE DDEEGGRREEEE OOFF
MM AASSTTEERR OOFF BBUUSSII NNEESSSS AADDMM II NNII SSTTRRAATTII OONN II NN
AAGGRRII BBUUSSII NNEESSSS
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
CENTRE FOR AGRIBUSINESS MANAGEMENT FACULTY OF AGRICULTURE
BIRSA AGRICULTURAL UNIVERSITY RANCHI- 834006
(Certificate of the Advisory Committee Members and Endorsement of Dean, Agriculture)
CC EE RR TT II FF II CC AA TT EE
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
CENTRE FOR AGRIBUSINESS MANAGEMENT FACULTY OF AGRICULTURE
BIRSA AGRICULTURAL UNIVERSITY RANCHI- 834006
(Certificate of approval by the Chairman of the Advisory Committee and External Examiner)
CC EE RR TT II FF II CC AA TT EE
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
3/4/2015 Coding Problem 1.20
4/4/2015 Coding Problem 6.4
6/4/2015 Coding Problem 2.0
7/4/2015 Coding Problem 14.2
8/4/2015 Coding Problem 7.20
9/4/2015 Coding Problem 4.2
10/4/2015 Coding Problem 5.3
11/4/2015 Coding Problem 1.20
13/4/2015 Coding Problem 1.1
14/4/2015 Coding Problem 7.6
15/4/2015 Coding Problem 14.20
16/4/2015 Coding Problem 2.0
17/4/2015 Coding Problem 5.50
18/4/2015 Coding Problem 12.00
20/4/2015 Coding Problem Closed
21/4/2015 Coding Problem 1.50
22/4/2015 Coding Problem 00
23/4/2015 Coding Problem 0.6
24/4/2015 Coding Problem 4.50
25/4/2015 Coding Problem Closed
27/4/2015 Coding Problem 4.5
28/4/2015 Coding Problem Closed
29/4/2015 Coding Problem 24.50
30/4/2015 Coding Problem 8.0
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
DATE REASON 12 HOUR (KG)
4/5/2015 Coding Problem 6.5
5/5/2015 Coding Problem 5.5
6/5/2015 Coding Problem 0.5
7/5/2015 Coding Problem 9.6
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
LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)
TABLE NO. - 3
MACHINE 16 & 17
DATE REASON 12 HOUR (KG)
2/4/2015 SEALING PROBLEM 0.2
3/4/2015 SEALING PROBLEM 1
4/4/2015 SEALING PROBLEM 3.2
6/4/2015 SEALING PROBLEM 1.2
7/4/2015 SEALING PROBLEM 10.3
8/4/2015 SEALING PROBLEM 5
9/4/2015 SEALING PROBLEM 1
10/4/2015 SEALING PROBLEM 3.2
11/4/2015 SEALING PROBLEM 1.15
13/4/2015 SEALING PROBLEM 0.5
14/4/2015 SEALING PROBLEM 10.2
15/4/2015 SEALING PROBLEM 6.05
16/4/2015 SEALING PROBLEM 5.5
17/4/2015 SEALING PROBLEM 2.0
18/4/2015 SEALING PROBLEM 20.40
20/4/2015 SEALING PROBLEM CLOSED
21/4/2015 SEALING PROBLEM 00
22/4/2015 SEALING PROBLEM 1.73
23/4/2015 SEALING PROBLEM 00
24/4/2015 SEALING PROBLEM 3.0
25/4/2015 SEALING PROBLEM CLOSED
27/4/2015 SEALING PROBLEM 2.0
28/4/2015 SEALING PROBLEM CLOSED
29/4/2015 SEALING PROBLEM 15.00
30/4/2015 SEALING PROBLEM 5.10
Maximum Lamroll loss(20.40kg) due to sealing problem was observed on
18/4/2015.However,minimum value of 0.0 Kg was observed on 21/4/2015 i.e on that
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
DATE REASON 12 HOUR (KG)
4/5/2015 SEALING PROBLEM 4.0
5/5/2015 SEALING PROBLEM 3.0
6/5/2015 SEALING PROBLEM 00
7/5/2015 SEALING PROBLEM 5.0
8/5/2015 SEALING PROBLEM 1
Maximum Lamroll loss(5.0kg) due to sealing problem was observed on
7/5/2015.However,minimum value of 0.0 Kg was observed on 6/5/2015 i.e on that
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
DATE REASON 12 HOUR (KG)
2/4/2015 JOINT PACKETS 0.6
3/4/2015 JOINT PACKETS 1.05
4/4/2015 JOINT PACKETS 5.2
6/4/2015 JOINT PACKETS 2.1
7/4/2015 JOINT PACKETS 10
8/4/2015 JOINT PACKETS 6.5
9/4/2015 JOINT PACKETS 3.2
10/4/2015 JOINT PACKETS 3
11/4/2015 JOINT PACKETS 1.02
13/4/2015 JOINT PACKETS 0.5
14/4/2015 JOINT PACKETS 4
15/4/2015 JOINT PACKETS 10.01
16/4/2015 JOINT PACKETS 3.0
17/4/2015 JOINT PACKETS 5.0
18/4/2015 JOINT PACKETS 4.0
20/4/2015 JOINT PACKETS Closed
21/4/2015 JOINT PACKETS 00
22/4/2015 JOINT PACKETS 00
23/4/2015 JOINT PACKETS 00
24/4/2015 JOINT PACKETS 2.0
25/4/2015 JOINT PACKETS CLOSED
27/4/2015 JOINT PACKETS 1.0
28/4/2015 JOINT PACKETS CLOSED
29/4/2015 JOINT PACKETS 5.0
30/4/2015 JOINT PACKETS 4.0
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,
2015 in Marie gold biscuit (BIL).
DEFECTS RELATED TO JOINT PACKET PROBLEM IN
MARIEGOLD BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN
LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)
TABLE NO.-6
MACHINE 16 & 17
DATE REASON 12 HOUR (KG)
4/5/2015 JOINT PACKET 2.0
5/5/2015 JOINT PACKET 1.0
6/5/2015 JOINT PACKET 00
7/5/2015 JOINT PACKET 5.0
8/5/2015 JOINT PACKET 2
Maximum Lamroll loss(5kg) due to join packet problem was observed on
7/5/2015.However,minimum value of 0.0 Kg was observed on 6/5/2015 i.e on that
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
DATE REASON 12 HOUR (KG)
2/4/2015 EMPTY PACKETS 0.475
3/4/2015 EMPTY PACKETS 2.015
4/4/2015 EMPTY PACKETS 5.825
6/4/2015 EMPTY PACKETS 3.325
7/4/2015 EMPTY PACKETS 22.625
8/4/2015 EMPTY PACKETS 6.575
9/4/2015 EMPTY PACKETS 3.275
10/4/2015 EMPTY PACKETS 6.87
11/4/2015 EMPTY PACKETS 3.37
13/4/2015 EMPTY PACKETS 1.275
14/4/2015 EMPTY PACKETS 8.325
15/4/2015 EMPTY PACKETS 7.0
16/4/2015 EMPTY PACKETS 2.64
17/4/2015 EMPTY PACKETS 25.26
18/4/2015 EMPTY PACKETS 15.71
21/4/2015 EMPTY PACKETS 5.23
22/4/2015 EMPTY PACKETS 1.0
23/4/2015 EMPTY PACKETS 0.5
24/4/2015 EMPTY PACKETS 3.31
27/4/2015 EMPTY PACKETS 4.3
28/4/2015 EMPTY PACKETS Closed
29/4/2015 EMPTY PACKETS 23.48
30/4/2015 EMPTY PACKETS 8.04
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,
2015 in Marie gold biscuit (BIL).
DEFECTS RELATED TO EMPTY PACKET PROBLEM IN
MARIEGOLD BISCUITS (BIL) FOR 4 th- 8th MAY, 2015 EXPRESSED IN
LOSS OF LAMROLL (KG) IN ONE SHIFT (12 HRS)
TABLE NO.-8
MACHINE 16 & 17
DATE REASON 12 HOUR (KG)
4/5/2015 EMPTY PACKETS 7.0
5/5/2015 EMPTY PACKETS 6.2
6/5/2015 EMPTY PACKETS 00
7/5/2015 EMPTY PACKETS 2.3
8/5/2015 EMPTY PACKETS 2.2
Maximum Lamroll loss (7kg) due to Empty packet problem was observed on
4/5/2015.However,minimum value of 0.0 Kg was observed on 6/5/2015 i.e on that
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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