Type of Manufacturing Process & Manufacturing Layout of Yakult Australia
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The document describes the manufacturing process of Yakult in Australia. It began production in 1994 and produces 300,000-450,000 bottles per day using a mass production and product layout. The process involves dissolving and sterilizing ingredients, culturing and fermenting the probiotic bacteria, homogenizing, blending, bottling, packaging and cold storage before distribution. Quality control checks are conducted throughout the process.
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Type of Manufacturing Process & Manufacturing Layout of Yakult Australia
- 1. Brought to you by: Sharandhass Radakrishnan Hugasangaran Veeramani EE2063 – IND. ENG. & MGMT. FACULTY OF ENGINEERING
- 2. “
- 4. Company Background ◍ Commenced production on 22nd January 1994 ◍ Located in Dandenong South, Victoria, Australia ◍ First English speaking country to launch Yakult ◍ $30 million investment by Yakult Honsha Co. Ltd. Japan
- 6. Type of Manufacturing Process ◍ Mass production – high volumes of Yakult products are mass-produced with narrow variety ◍ Two types – Yakult Original & Yakult Light ◍ Injection blow-moulding machines – 11,000 bottles per hour ◍ Bottling line – 40,000 ~ 45,000 bottles per hour ◍ 300,000 ~ 450,000 bottles per day
- 9. Type of Manufacturing Layout ◍ Product layout – Yakult is processed through repetitive & continuously, from raw ingredient to final product ◍ Each process taken place in respective station ◍ End product of a station another station – through pipes , filters and valves ◍ Low unit cost & material handling cost ◍ Dull, repetitive job – workers might lose interest in job
- 12. ProductLayout ◍ Quality Control (QC) Dissolving and Sterilisation Culturing and Fermentation Homogenisation Blending, Mixing and Storage Bottle Making and Storage Bottle Filling, Capping and Sealing Control Panel Packaging Cold Storage Quality Assurance (QA) Cold Chain Distribution
- 13. Product Layout 1) Quality Control (QC) ◌ Examining, testing and inspection of product, bottles and packaging ◌ Randomly checked for defects
- 14. Product Layout 2) Dissolving and Sterilisation ◌ Water sterilised blended with skim milk powder, sucrose, etc ◌ Milky solution HTST natural colour produced (caramelisation)
- 15. Product Layout 3) Culturing and Fermentation ◌ Transferred into fermentation tank (37˚C) ◌ Lactobacillus casel Shirota strain injected into solution ◌ Allowed to multiply until desired number of bacteria reached
- 16. Product Layout 4) Homogenisation ◌ Fermented milk placed under high pressure ◌ Pass through small holes to create smooth consistency
- 17. Product Layout 5) Blending, Mixing & Storage ◌ Mixed with citrus flavour large storage tank containing sugar syrup Yakult concentrate ◌ Chilled below 4˚C mixed with equal amount of sterilised water
- 18. Product Layout 6) Bottle Making & Storage ◌ Injection blow-moulding machines ◌ Pellets melted injected onto core rods sterile air blown into mould Yakult bottle
- 19. Product Layout 7) Bottle Filling, Capping & Sealing ◌ Empty bottles selector machine filling line ◌ Printed with label information while travelling along continuous line ◌ Bottles filled with 65ml fresh Yakult sealed with foil lid
- 20. Product Layout 8) Control Panel ◌ Process & production line Computer Integrated Manufacturing (CIM) ◌ Bottle count, capacity & operating time retrieved from control panel
- 21. Product Layout 9) Packaging ◌ Two packaging line arrange five or ten bottles into groups wrapped in polyethylene film ◌ Quickly pass through heat tunnel tight wrap around packages ◌ 50 bottles wrapped in polyethylene film and heat shrunk ◌ Slabs stacked onto a pallet & stored (<4˚C)
- 22. Product Layout 10) Cold storage ◌ Pallets placed on moving racks in energy-saving storage facility ◌ LED lighting synchronised to switch on & off with moving rack
- 23. Product Layout 11) Quality Assurance (QA) ◌ QMS of Yakult obeys ISO 9001:2008 ◌ Covers manufacturing, sale & distribution of product
- 24. Product Layout 12) Cold Chain Distribution ◌ Corporate delivery: refrigerated trucks deliver to warehouses. ◌ Route delivery: refrigerated vans deliver to supermarkets and outlets. ◌ Home delivery: door-to-door delivery in public housing estates ◌ Refrigerated transportation deliver to overseas.
- 25. 5. DISCUSSION
- 26. Discussion ◍ Each company have its type of manufacturing layout and manufacturing process ◍ Depends on company’s production ◍ Manufacturing process project, jobbing, batch, mass & continuous ◍ Manufacturing layout process, product, fixed- position & cellular
- 27. 6. CONCLUSION
- 28. Conclusion ◍ Different companies use different types of process and layout ◍ Learnt about how Yakult Australia produces fermented milk drink ◍ Learnt about how effective the companies are in overseas
- 29. 7. REFERENCE
- 30. Reference ◍ Radcliffe, B. (2017). Manufacturing. [online] Investopedia. Available at: http://www.investopedia.com/terms/m/manufacturing.asp ◍ Chegg.com. (2017). Chegg.com. [online] Available at: http://www.chegg.com/homework- help/definitions/manufacturing-processes-5 ◍ Kumar (2013). Types of production processes. [online] Slideshare.net. Available at: https://www.slideshare.net/anupamkr/types-of- production-processes
- 31. Reference ◍ Staff, I. (2010). Mass Production. [online] Investopedia. Available at: http://www.investopedia.com/terms/m/mass-production.asp ◍ YourArticleLibrary.com: The Next Generation Library. (2014). Four Main Types of Plant Layout. [online] Available at: http://www.yourarticlelibrary.com/industries/plant- layout/four-main-types-of-plant-layout/34604/ ◍ Yakult.com.au. (2017). Yakult Australia. [online] Available at: http://yakult.com.au/product-line.html
- 32. Reference ◍ Money Matters | All Management Articles. (2016). Product Layout | Suitability | Advantages | Disadvantages. [online] Available at: https://accountlearning.com/product-layout-suitability- advantages-disadvantages/
- 33. Thanks!Any questions? Try not to ask :) 👍
Editor's Notes
- Yakult Australia Pty Ltd commenced production on the 22nd January 1994. Australia was the first English speaking country to launch Yakult, chosen due to its proximity to Asia. It is an increasing desire amongst Australians for a healthier lifestyle. Melbourne was chosen as the launch city and Dandenong selected for Yakult’s purpose built complex. Construction of the office and technologically advanced manufacturing facility represented a $30 million investment in Australia by Yakult Honsha Co.Ltd,Japan. The targeted audience is Yakult’s advertising primarily targeted the major household grocery buyer. The marketing objective is to create awareness, develop consumer interest, provide relevant information and convert knowledge into purchases. The main marketing slogan is “Every body. Every day”.
- Yakult produces its product through mass production; high volumes of Yakult products are mass-produced with narrow variety. Only two types of Yakult is produced, which is Yakult Original and Yakult Light. Standard products are repeatedly made using the just in time (JIT) system. Each of 3 Yakult’s Injection blow-moulding machines are able to make 11,000 bottles per hour. The bottling line has the capacity to produce between 40,000 to 45,000 bottles per hour. Overall, 300,000 to 450,000 bottles are produced daily to supply to the Australian and New Zealand markets.
- Yakult Australia manufactures their product using product layout. Yakult is processed through repetitive and continuously, from raw ingredient to final product. Process such as sterilisation, fermentation, blending, mixing, capping, sealing, and so on, are taken placed in respective station. From one station, the end product of it will be transferred to another station using an automated one way process through closed system of pipes, filters and valves. This is to ensure protection from potential contaminants. Using product layout, high volumes of Yakult can be produced daily, with established routing and scheduling. Besides, the unit cost and material handling costs are low. However, it creates a dull, repetitive job. Workers might lose interest in the job and they have less chance to display their talent.
- QC check includes examining, testing and inspection of the product, bottles and packaging. Individual bottles are randomly checked along the production line to check for incorrect printing, lid sealing and other defects. Raw ingredients include live Lactobacillus casel Shirota strain, skim milk powder, sucrose, dextrose, flavouring and water are tested through extensive variety of test such as microbiological quality, composition and taste to ensure high quality of Yakult is produced.
- Through reverse osmosis, water is filtered to remove chlorides and fluorides, which is then sterilised using ultraviolet light and stored in a holding tank. The sterilised water is then blended with skim milk powder, sucrose and dextrose to produce a milky solution. This solution is then sterilised using High Temperature Short Time (HTST) that is above 100˚C. HTST kills any bacteria present in the mixture for a short amount of time. Due to the high temperature, Yakult’s natural colour produced as a result of milk proteins and sugars undergo a caramelisation reaction.
- Via a closed system of pipes and valves, the milk solution is transferred into a fermentation tank with a temperature of 37˚C. A starter culture of Lactobacillus casel Shirota strain is injected into the milk solution. During the fermentation process, the bacteria are allowed to multiply, until a desired number of bacteria are reached. In this process, the Lactobacillus casel Shirota strain breaks down lactose found in milk into lactic acid.
- The milk solution undergoes a process known as homogenisation soon after the fermentation period. This process allows the fermented milk to be under high pressure while passing through a structure with tiny holes in order to create a smooth consistency.
- The fermented milk solution is then allowed to be mixed with a citrus flavour and is transferred into a large storage tank containing sugar syrup, which then creates Yakult concentrate. The Yakult concentrate is then chilled to below 4˚C before mixing with equal amount of sterilised water. The final product is then ready to be bottled.
- Injection blow-moulding machines are used to produce the Yakult’s unique-shaped plastic bottles made out of recyclable pellets. These pellets are melted and injected onto core rods under high pressure. Through each core, cool sterile air is blown into the mould creating the shape of bottle. Empty bottles are then kept in storage tank until ready to be labelled, filled, capped and sealed.
- From the storage funnel, empty bottles are released into a selector machine which positions the bottles in an upright position, and releases onto the filling line. These upright bottles are then printed with required label information while travelling along in one continuous line. After the printing process, the bottles are filled with 65ml of fresh Yakult and electromagnetically sealed with a foil lid before travelling to the packaging area via a conveyor.
- The automated processes and production line of Yakult is managed by Computer Integrated Manufacturing (CIM). All information includes bottle count, capacity and operating time are retrieved from the control panel.
- Two packaging lines arrange five or ten bottles of Yakult into groups, which are then wrapped in polyethylene film. The bottles quickly pass through a heat tunnel to create a tight wrap around the packages. The packages are then automatically sorted together forming a slab of 50 bottles wrapped in polyethylene film and heat shrunk. Quality control check are done on the packs. A robotic arm stacks the slabs onto a pallet and stored between 0 - 4˚C.
- Yakult pallets are placed on automated moving racks below 4˚C, which are capable of holding 330 pallets of Yakult. This innovative racking system reduces energy required to cool storage facility. Energy efficient LED lighting is installed and synchronised to switch on and off with the moving racks so that only the lights over open aisle turn on when in use.
- Yakult’s Quality Management System (QMS) obeys the requirement of the International Organisation for Standardisation (ISO9001:2008), which covers the manufacturing, sale and distribution of the products and certifies that the products and services meet the highest international food manufacturing standards.
- Four ways of distributing Yakult once ready to leave the factory: a)Corporate delivery: refrigerated trucks deliver to warehouses. b)Route delivery: refrigerated vans deliver to supermarkets and outlets. c)Home delivery: door-to-door delivery in public housing estates d)Refrigerated transportation deliver to overseas.
- Each company have its type of manufacturing process and manufacturing layout, depending on the company’s production. Generally, there are five types of manufacturing process, namely project, jobbing, batch, mass and continuous process. For manufacturing layout, there are four types, namely process layout, product layout, fixed-position layout and cellular layout. Yakult Australia practises mass production with product layout.
- Based on the information that we have collected, we have learnt that different companies use different types of process and layout. Besides, we have also learnt about how Yakult Australia produces the fermented milk drink and delivers it throughout the country. We are also able to learn more about companies in overseas and how effective they are.