1.Monit Material Department •11B906 2.Bhavesh QCD and Homercile Department •11B908 3.Vikas Stores and Inventory Department •11B916 4.Chaitali Maintenance Department •11B9325. Stewart HR Officer •11B940 6.Sorabh Keg and Can plant Department •11B942 7.Kaveshna Brewery Department •11B944Departmental 8.Arif Material handling system managers •11B953 warehousingsystem 9.Smit of •10B922 Safety Department UBL
In the field of management, production and materials are early management subjects. In the competitive structure of the business both show the importance. This can give impact on the profitability of the companies and even so on the existence of the companies.
About United Breweries Ltd. The firm we have chosen is United Breweries Group ltd . The UB Group was founded by a Scotsman, Thomas Leishman, in 1857. UB group was taken up by Vitthal Mallya in 1947. United Breweries Group or UB Group is an Indian conglomerate company based in Bangalore, India. The company has annual sales of over US$4 billion and a market capitalization of approximately US$12 billion. United Breweries now has greater than a 40% share of the Indian brewing market with 79 distilleries and bottling units across the world.
About United Breweries Ltd. Its core business includes beverages, aviation, electrical and chemicals. The company markets beer under the Kingfisher brand and has also launched Kingfisher Airlines, an airline service in India, with international flights operating recently. They have 32 breweries in total of which 22 of their own and 12 are on contract basis. Recently UB financed a takeover of the spirits business of the rival Shaw-Wallace company giving it a majority share of Indias spirits business. The group owns the Mendocino Brewing Company in the United States.
It was established on 12th april,1995. It was inaugurated by Mr. Vijay Mallya. The plant which we visited Is Bombay Brewery Unit Of United Breweries Ltd. located in MIDC area in the Raigad district. This plant is fully automatic and the software of this plant is made by Allen and Bradley This plant is the largest Brewery in India. The size of the plant is 22 acres. On the initial stage it should make 1,25,000 cases per month. Now it is making 15,00,000 cases per month.
Introduction to the plant There are 15 managerial staff. 35 junior management staff. 66 permanent workmen 80 head loaders registered with mathadi org. 250 contract workmen including security,canteen,bottle handling. In a day the plant manufactures 25,000l of beer in one batch. At an average in a day they manufacture 16 batches.
Introduction to the product The product we have chosen is kingfisher beer. United Breweries is Indias largest producer of beer with a market share of around 55% by volume. In Mild beer level of alcohol is uptill 5% and in strong beer level of alcohol is above 5% and below 8%. Kingfisher beer has been awarded with hazardous analysis critical control point(HACCP) and ISO 9000 These are quality maintaining organizations.
Strong beer Mild beer Types of KEG Beer(Unpasteurize Ultra beer d Beer) Draught beer
Ingredients used in making Beer Yeast for water fermentation
Separation Process Crushing of Separation of Barley malt ungrown Separation barley Malt of stones and metalsSeparation of dust
Hot Water KetttleBrewery Lauter House Turnel wort Whirl pool
Process Brewing Filtration Lagering fermentation BoilingAddingyeast
KEG(unpasturised Beer) It is stored in steel or aluminum drum. It is the beer that does not go through the process of pasteurization. It is perishable beer and is made on demand. It is served in Five star hotels and pubs.
DE- Palletizer Can washer Can filling Lead FixingPasteurization Coding Box making
DE-palletizer Bottle Washer Bottle Filling Cap Fixing Pasteurization Labeling Bottle putting in the box Sealing palletizing
Raw Material Materialmanagement Packaging Material
Barley MaltStored in siloEach silo has a capacity of 200 metric tonnesRice FlakesStored at a dry placeWaterMIDC supplies water.HopsIt is stored in cold storageSugarIt is stored in the sugar house
Cans are imported from Thailand, UAE andSingapore. UB group doesn’t produce bottles but they obtain second hand bottles from local scrap dealersCorrogated boxes are purchased and keptaside and stored in dry place till come in use.
Material Handling systemBefore During After KEGsproduction production production • Kegs are manuallyprocess process process operated• RM is automatically • Everything is • There are head sent by a operated by loaders who load computerized computerized the cases to the FLI software. software godowns.• Only hops and • PM material is sugar is manually carried by cranes put into the kettle. to the respective• For the other plant process there is no labour required.
One month in advance a general plan is made by the corporate office regarding production of the product. They use FIFO method After every 10 days 200 metric tons of barley malt is added in the silo Rice & Sugar – They are brought at regular intervals Hops is stored at freezing temperature & bought at regular intervalsording to . Bottles and cans are puchased according general plan made by the corporate office.
•Checking theReceiving quantity andmaterials the products Sent to the QCD for testing •Eg.barley Stored in the stored in the reqd. places SILO, HOPS in cold storage Automated software for transfer of RM. Packaging material is stored in the place of production. After production Process it is directly moved by transport to the FLI godowns
Total maintenance is done once a week. Separate department take care of it. When total maintenance is done the production process is stopped for one complete day.
Cleaning the kettles Total CheckingMaintenance the bottle and can Includes plant Replacing the damaged parts
The scrap is managed by the homercile department. Husk generated in the lauter kettle is sold to the cattle Collection of broken glass is recycled Gunny bags, empty drums,wooden plates, aluminium sheets are sold together by calling a tender.
Quality and hygiene are the key elements of the UB groups’ manufacturing philosophy. To this end the Central Scientific Laboratory(CSL) headquartered at Bangalore sets standards for all its breweries. Quality Management Systems laid out along the lines of ISO 9000 are strictly adhered to, controlling quality at every stage of production. Quality of the beer is checked electronically at the end of each process and the quality of the final packaged product is manually checked.
The finished goods are stored in bounded gowdowns . They are FLI godowns. The finsihed goods produced in the plant are send to 3 godowns. KURLA Aurangabad Panvel
Employees at packaging units are provided with Face Masks, Helmets, Goggles, Gloves, Gas Mask, Gumboots
The company believes that its Human resources are its main important assets and therefore, gives highest priority to safety and health of its employees as well as contractors workmen, including the environment management at work.
It was a memorable experience. We learnt a lot from this industrial visit.