2. receiving of raw materials
(khoya, maida, chena, wheat fibre and suji)
cleaning of khoya
preparation of dough with maida, chena, wheat
fibre, suji
balls making
Raw materials for filling
( khoya, kesar, kaju, elaichi powder)
Mixing and filling the stuffing
(only in canned products)
frying in ghee at 130-140 o C
(till it becomes brown)

3. dipping of fried balls in hot syrup(50-55 degree brix for 10-15mins)
again dipping of balls in syrup from 60 to 70 degree brix
loose gulab jamun prepared
(without filling )
Formation of cans
(only for stuffed gulab jamun)
put in container
packaging
dispatch
Sealing from one side (bottom)
Batch code printing
Sending for sterilization

4. hot filling of product with syrup
temperature to be from 90 to 100
seaming from top side
immediate cooling in water with
temperature 30-45
drying of cans in air
dryer
filling in folding
packaging in cartons
ready for dispatch and
transportation

5. Lean manufacturing, lean enterprise, or lean production, often simply,
"lean", is a production practice that considers the expenditure of
resources for any goal other than the creation of value for the end
customer to be wasteful, and thus a target for elimination. Working from
the perspective of the customer who consumes a product or service,
"value" is defined as any action or process that a customer would be
willing to pay for.
Essentially, lean is centered on preserving value with less work. Lean
manufacturing is a management philosophy derived mostly from
the Toyota Production System (TPS) (hence the term Toyotism is also
prevalent) and identified as "lean" only in the 1990s. TPS is renowned for
its focus on reduction of the original Toyota seven wastes to improve
overall customer value, but there are varying perspectives on how this is
best achieved

6. : Transport (moving products that are not actually require to
perform the processing)
: Inventory (all components, work in process and finished
product not being processed.
: Motion (people or equipment moving or walking more
than is required to perform the processing)
: Waiting (waiting for the next production step,
interruptions of production during shift change)
: Overproduction (production ahead of demand
: Over Processing (resulting from poor tool or product
design creating activity)
: Defects (the effort involved in inspecting for and fixing
defects)

7. I : Inventory
NEGATIVE
 If there is a break balls made
are left open, and are then
processed after the break.
 During canning, the sterilized
cans are left open during break
and are not sterilized again
when processing starts.
SOLUTIONS
 They should either be kept in
storage area or should be
processed in such a way that
there is no waiting time.
 they should stop sterilize
extra cans before break or if
they do so they should not be
filled and should be sterilized
again.

8. II. MOTION
NEGATIVE
 More Labour is there thus
reducing efficiency of work.
SOLUTION
 reducing the no. of people
working or when finished with
one work should align
themselves in another work.
III. OVER PROCESSING
NEGATIVE
 End point is estimated that
leads to over processing
SOLUTION
 Workers should be provided
with proper equipments for
the estimation of end point .

9. 1. SEIRI
2. SEITON
3. SEISO
4. SEIKETSU
5. SHITSUKE
SORT (Remove unnecessary items and dispose of them
properly)
SET IN ORDER (Arrange all necessary items in order so
they can be easily picked for use)
SHINE (Clean your workplace completely)
STANDARDIZE (Maintain everything in order and
according to its standard.)
SUSTAIN (To keep in working order)

10. Production HO-GHEE
Gulab
Jamun
Table Used for Gulab Jamun
production Loose to Finish &
Raw Material under the Table
T-45
Production HO-GHEE
Gulab
Jamun
Table Used for Gulab Jamun
production
T-46
Production HO-GHEE
Gulab
Jamun
Gulab Jamun Ball Making
Machine
M-35
Production HO-GHEE
Gulab
Jamun
Weighing Machine (Big) M-85
Production HO-GHEE
Gulab
Jamun
Gulab Jamun Bhati B-23
Production HO-GHEE
Gulab
Jamun
Gulab Jamun Bhati B-24
Production HO-GHEE
Gulab
Jamun
Gulab Jamun Bhati B-25
Production HO-GHEE
Gulab
Jamun
Gulab Jamun Bhati B-26
Production HO-GHEE
Gulab
Jamun
Milk Lachha Bhati B-27
Production HO-GHEE
Gulab
Jamun
Milk Lachha Bhati B-28
DEPARTMENT LOCATION SECTION
CONTENT
PARTICULARS
A R S T M B K C P F TS

11.  The ghee is used continously for the whole day which should
be changed after every 4 to 5 hour.
 every worker should wash their hands with IPA solution after
every half an hour
 The ghee containers are kept all time open near the bhati
which should be removed as oxidation of oil takes place rapidly
 The instrument for measuring temperature is given but they
rarely use it and mainly work on estimation.
 Cans and trays should be kept on palates which is not there
in the canning area