biscuit manufacturing

1. SAKET ANAND

2.  Yield Is The Classical Process To Estimate
Performance.
 Yield Refer To: Measures Of
Output/Input*100. or
 100% - (Scrap%+GA%)

3. It is difference b/w actual
input to the actual out
put.
Give away & Scrap.

4.  Usable losses :- That can be recycle
directly(like dough) or indirectly(like biscuit
dust).
 Unusable losses :- That can not be recycled.
 Give Away :- A weight given above mentioned
standard weight.
 Rejected FG:- Quality defect.

5.  Root cause analysis
High Yield
losses
Man
Measurement
Machine
Material
Method
Environment
lack of focus on wastage
Lack of manpower at stacker end
Maintenance delay
communication problem
check weigher reject good packet
Maida supplied more in mixer.
PT4 operating at higher speed
maintenance require
high % moisture Maida used
check weigher problem
Broken biscuit reach to packing
machine
Change over
Unhygienic condition
High humidity
High temp

6. Process
flow of
line 1

7. RM
store
Air vent +
pre mixing
Mixer
Dough
feeder
rotary
Panner
web
oven
Cooling
conveyor
stacker
PT4
Slug loader
Cross
conveyor
Multipack
Section
Family
packing
section
CFC
packing
and
tapping
FG
store

8. Station Losses (in kg
per shift)
Reason
1.Premixing 2.5(all) Due to sieving , handling
2.Air vent 20(all) Due to spreading out of Maida while tilting, some time
leakage in valve.
3.Mixer 8 Due to change over and while pouring of dough in trolley.
4.Dough hopper 5 Due to change over ; leakage of dough through roller below
dough hopper.
5.Rotary 5 Due to gap between mould and forcing roller; dough stuck
on the belt and knife is not able to release all of it.
6.Rotary 15 Due to change over; washing of forcing roller.
7.Oven 7(normally) Cutting shell from rotary, colour defect in start up, wooden
knife is rub off due to which biscuit get turn over, biscuit got
block and fall down.

9. station Losses (in kg
per shift)
reason
8.Oven end 20+ Batch problem(loose batch or tight batch); oven
problem(dark colour or light colour).
9.Cooling conveyor
2 and 3
1-2/ 1-2 Due to metal strip as a kaizen is not properly oriented and
conveyor belt is loose./ due to tracking of MD belt.
10.Beginning of
stacker
2 Due to tracking of belt; blocking of biscuit shell due to
defected biscuit
11.Stacker end 50 + 10 Defected shell, handling, biscuit is not properly stacked;
biscuit are not in uniform density in each line .
12.Peter 70+ 10 Starting ;after down time; lumps formation in cream; broken
shell choke the magazine; broken shell come between the
sensor and metal strip due to which sensor stop sensing;
loose carrier pin; peter speed is not maintain in it’s optimum
speed due to which carrier pin are loose frequently & home
out issue is frequently occur.

10. station Losses( in kg
per shift)
reason
13. Slug loader 25 Broken sandwich fall down, less biscuit (<7), frequently
bending of butterfly rod; biscuit break due to striking
of pusher (when >7 sandwich due to kaizen)
14. Cross conveyor 50 Defected sandwich sorting and falling; cross pusher
break the sandwich.
15.Packing section 30 % of total
about 150kg
During de-rapping sorting of defected
sandwich(broken sandwich, cream short; cream oozing
out, extra shell.); Breaking of rejected biscuit due to
falling; every down time; check weighing machine
problem.
16.cream 60 Due to change over this much are in pipe only.
17 cream 20-30 Extra cream left, not kept in cold storage.
18 Rejected FG 25 Due to high moisture ( biscuit are not kept in DH room,
high moisture Maida use.); less gauge; foreign material

11. 0
20
40
60
80
100
120
140
160
scrap
usable
X=Station
Y=kg per shift

12. 0
20
40
60
80
100
120
0
5
10
15
20
25
30
Packing
section
Peter
Stacker
end
Cross
conveyor
cream
Oven
Slug
loader
Rejected
FG
Air
vent
Rotary
change
over
Dough
hopper
Mixer
Rotary
Cooling
conveyor
2…
Premixing
Beginning
of
stacker
% wastage
cum %

13. Station Improvement Result
1. Premixing Cloth is rounded around the opening. Mark
on hopper of sieving machine .
pending
2. Rotary Tray is kept under the rotary. 70% recover b/c tray is small.
3. Oven end Knife changed. Turn up reduces, falling of
biscuit shell decrease by 2kg
per shift.
4. Cooling
conveyor 2
Kaizen at cooling conveyor 2 is improved. Falling of biscuit zero.
5. cooling
conveyor 3
Kaizen is require. pending
IMPROVE

14. station improvement result
5. Stacker Side blades are bended. Mark at the end
side blade.
Falling of biscuit reduce by
2kg.
6. Stacker end One person is for shorting. Usable shell is reduce by
15kg.
6. PT 4 Lock tight is applied on thread; PT4 should
run on optimum speed*; improvement in
kaizen*.
(* pending)
Usable sandwich reduce .
7. Slug loader Clearance increase between retailer and
pusher; extra butterfly rod should be there
to change it quickly, bearing should check
regularly before start up.
Pending
8. Cream section One person should given responsibility to
kept the extra cream in cold storage.
Pending

15. 0
20
40
60
80
100
120
140
160
before
after

16. STATION before after
Packing section
150 145
Peter
90 80
Stacker end
70 55
cream change over
60 60
Cross conveyor
50 45
Oven
29 27
Slug loader
25 24
Rejected FG
25 24

17. STATION before after
Air vent 20 20
cream 20 20
Rotary change over 15 15
Dough hopper 10 10
Mixer 8 8
Rotary 5 1.5
Cooling conveyor 2
and 3 3 1
Premixing 2.5 2.5
Beginning of
stacker 2 1

18.  Yield = (out put / input)*100
At 30 June
Split cream out put= 128.4 ton
Split cream standard input =139.536
Yield = (128.4/139.535)*100
= 92.02%
 At may month yield = 91%
 Yield has been improved from 91% to 92%.
 Target for July 2017 is 93%.

19. 0.9
0.905
0.91
0.915
0.92
0.925
0.93
may
june
july
Yield
Yield

20. 1. Automation in biscuit sorting.
2. Change in design of forcing roller in rotary section &
kaizen require.it not only increase in yield but also
reduction in power consumption.
3. One biscuit alignment section require after oven
section. So that defected biscuit can be short out at
oven end(without increasing any man power) and
proper stacking can be take place and biscuit are
coming with uniform density in each line.

21.  Improve in RM yield.
 Improve the overall production.
 Increase in overall profit.
 Improve the line efficiency.
 Improve quality.
 Encouraging creativity.
 It make us understand where its need to work for
improvement first.
 It help in judgement about the efficient work of
manpower.
 It enhance moral of the employee.

22. Thanking