Lingaraj Biscuits is a franchise of Parle that manufactures Parle-G and Happy Happy biscuits. The manufacturing process is highly automated with mixing, forming, baking and packaging stages. Lean techniques like Andon and Kaizen are used to identify quality issues and continuously improve the process. Only a safety stock of 3 tons is maintained to avoid overproduction and unnecessary inventory. Transportation costs are minimized through a two-way logistics network between facilities. The company focuses on employee safety, health and working conditions through regular assessments and certification.

1. LEAN MANUFACTURING AT
LINGARAJ BISUITS PVT. LTD. –
A PARLE FRANCHISE
Submitted By: Group 3
Arupananda Rout UM16193
R Priyanka UM16207
Amlan Lenka UM16210
Sourav Pattanaik UM16233
Suman Panigrahi UM16233
S Seemanchal Mohanty UM16238
Aprameya Bhol MG16002

2. COMPANY PROFILE
LINGARAJ BISCUITS:
• Lingaraj Biscuits Private Limited is a CMU of Parle Biscuits Private Limited.
• It was incorporated on 23rd August 2004
• Its authorized share capital is Rs. 30,000,000 and its paid up capital is Rs. 14,750,000.
PARLE:
• Parle was started in India in 1928 by Shri Mohanlal Dayal for making confectionaries.
• Parle enjoys 40% market share of the total biscuit market in India.
• Parle-G biscuit brand is the largest selling biscuit brand in the world with 80% market share in the
glucose biscuit category in India and has a huge global presence.
• It 12 manufacturing units for biscuits and 75 manufacturing units for confectioneries. It also
operates plants based on a franchise model.

3. QUALITY CONTROL
• Testing of raw
materials that are
going to be used.
• This would come
under Preventive
costs.
• Ingredients addition
• Sugar solution
• Milk solution
• Preparation of flour
• Fat
• Ammonia
• Additives
• Flour sifters sugar
grinders
PRE MIXING MIXING FORMING
BAKINGCOOLINGPACKAGING
• Mixers
• Mixing time
• Water
• Creaming
• Dough Consistency
• Biscuit grinders
• Laminators
• Gauge rolls
• Sheet Reduction
• Cutter
• Moulders
• Shape and size of
dough piece
• PPM
• Metal detection
• Stackers
• Feeding Chute
• Horizontal flow
form wrap
• Vertical filling
• Cream
sandwiching
• Cooling time
• Cooling conveyer
• Baking ovens
• Baking time
• Temperatures
• Burners
• Steam Extraction
• Oven Output
FLOWCHART OF THE MANUFACTURING PROCESS OF PARLE

4. MANUFACTURING EQUIPMENT IN LINGARAJ BISCUITS
STEPHAN MIXER
BISCUIT BAKING OVEN
ROTARTY MOULDER

5. Profit
Satisfy
customer
demand
• Best Quality
Lowest cost
• Best prices
Shortest lead
time
• Supply on time
OBJECTIVES OF LEAN MANAGEMENT

6. ANDON
 It’s a term referring to a system to notify the management, maintenance and
other workers of a quality or process problem.
 In Lingaraj Biscuits, the concept of Andon has been implemented by installing
three buttons in every unit i.e. the six steps from mixing to packaging.
 The three buttons red, yellow and green send the below message to the shift in-
charge and supervisor:
Process needs attention but need not stop.
A defect in the product is detected and the process stops. Every other units also stop till the defect is solved.
This indicates the process is running fine. It is also pressed once the identified defect is resolved.

7. UTILITY OF LEAN TECHNIQUES
LEAN TECHNIQUES USED
• Check of the entire
process and incorporate
minor changes which has
cumulative effects
KAIZEN
• Immediate identification
of problems in an
automated process
JIDOKA
LEAN TECHNIQUES NOT USED
• Aimed at reducing flow
times within production
system as well as
response times from
suppliers and to
customers
JIT
• It is an inventory-control
system to control
the supply chain
KANBAN

8. • There are two types of biscuits manufactured here – Parle G and Happy Happy.
• A forecast of the demand is given by Parle to the factory every month and that exact amount is
supplied.
Over Production
• If Parle Company does not collect the order, they do not send further demand data for
production.
• A safety stock of 3 tones is maintained constantly.
Unnecessary Inventory
•Biscuits are immediately transported to a warehouse located in Bihar.
•The trucks return with stock for the Odisha warehouse for distribution of biscuits in Odisha.
•The movement of the trucks is monitored online through real-time GPS.
Transportation
• Though the process is automated there is still a risk of over processing at the baking stage.
• Such defective products are sold as fodder for poultry or for use in the farms.
Over Processing
• Human intervention occurs only in the mixing and cooling stages.
• Due to this there are high chances of incurring waiting costs due to delay.
Waiting
• The process is entirely automated
• The use of conveyor belts, mixers, molders, coolers, etc. ensure that the process is not
wasteful in nature.
Unnecessary Motion
WASTE MANAGEMENT

9. After the end of third shift, the Production Manager and Shift-in-Charge along
with a representative of Parle perform an end to end check on machines and
maintenance is carried out for 2 hours every day.
38
38.5
39
39.5
40
40.5
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1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
SAMPLEAVERAGEWEIGHT
TIME
CONTROL CHART (FROM 12:00 pm TO 4:00 pm)
UCL LCL CL SAMPLE AVG
QUALITY CONTROL & PREVENTIVE MAINTENANCE

10. The company organizes health check up camps for its workers on a
monthly basis
PEOPLE PRACTICES AND SAFETY ASPECTS
The workers are provided accommodation inside the company in case of
emergency situations
The company has a separate training and orientation department for
onboarding of new workers
The company has a separate safety officer who is responsible for all safety
aspects inside the plant premise
The company is certified in ISO 22000-Food Safety Management and ISO
9001- Quality Management Systems

11. KEY LEARNINGS
Lean Techniques
applied: Andon, Kaizen
and Jidoka
Not Implemented: JIT
and Kanban
A safety stock of 3 tonnes
is maintained, which are
sent to Parle the very next
day.
Over Production,
Unnecessary Inventory and
motion, Product Defects
and Waiting Time Avoided
Transportation Costs
Minimized by a two way
transport between the
Bihar and Odisha
facilities.
Regular feedbacks
taken from employees
and working conditions
assessed for safety
standards.
Quality checks and
Preventive maintenance
done on a regular basis
daily.

12. THANK YOU !!