PARLE QUALITY SYSTEM & HR TECHNIQUES BY:- SUNIL DHANKHAR ROLL.NO. 0810155. HSB HISAR HARYANA INDIAINTRODUCTION Bakery industry in India is the largest of the food industries with annual turnover of about Rs.3000 crores. The biscuits are becoming quite popular in rural areas as well. Nearly 55% of the biscuits are consumed by rural sectors. The biscuit industry in India comprises of organized and unorganized sectors. The FBMI represents the organized biscuit industry consisting of small scale, medium and large biscuit manufacturers located in all zones and all states of the country. Major brands of biscuits are:- Britannia, Parle, Priya Gold, Elite, Cremica, Dukes, Anupam, Horlicks, Craze, Nezone, besides various regional/ State brands.COMPANY OVERVIEW Parle Biscuits Limited is a subsidiary of the Parle Products Limited, Mumbai, which is a closely held company run by the Chauhans. Today Parle enjoys a 40% share of the total biscuit market and 15% share of the total confectionery market in India. Plants of Parle Biscuits Pvt Ltd are at: Bahadurgarh (Haryana) Neemrana (Rajasthan) Rudrapur (Uttranchal) NasikThe production capacity of Bahadurgarh unit per month is- Parle-G 3300 Metric Tones Krackjack 1500 Metric Tones Monaco 1200 Metric Tones The plant also has a Auditorium and viewing gallery, which is used during the visits of the school children. A retail shop at the plant provides Parle products at MRP rates. The total turnover of Parle Biscuits Pvt Ltd is around 4000 crores.\ \\, PARLE-G :THE EVOLUTION “QUALITY, HEALTH AND GREAT TASTE”PARLE QUALITY SYSTEM Hygiene is the precursor of every process at Parle. From husking the wheat and melting, the sugar to delivering the final products to the super market and store shelves nation wide care is taken at every step to ensure the best product with long lasting freshness. Every batch of biscuits and confectionery are thoroughly checked by the expert staff, using the most modern equipments hence ensuring the same perfect quality across the nation and abroadPARLE PRODUCTS — ‘AN EPITOME OF QUALITY’ Tany QUALITY POLICY PARLE PRODUCTS LIMITED will strive to provide consistently Nuttitious and quality food products to meet customers’ satisfaction by using quality materials and by adopting appropriate processes. To facilitate the above we Will strive to continuously train our employees and to provide them an open and participative environment. Ben \Viey Chauhan Chairmen & Meneging DirectorAll Parle products are manufactured under the most hygienic conditions. Great care is exercised in the selection & quality control of raw materials; packaging materials & rigid quality standards are ensured at every stage of the manufacturing process. Every batch of biscuits & confectioneries are thoroughly checked by expert staff, using the most modern equipment. All these factories are located at strategic locations, to ensure a constant output & easy distribution. Each factory has state-of-the-art machinery with automatic printing & packaging facilities,HACCP Hazard Analysis and Critical Control Point is systematic preventive approach to food safety and pharmaceutical safety that addresses physical, chemical, and biological hazards as a means of prevention rather than finished product inspection. HACCP is used in the food industry to identify potential food safety hazards. The seven HAGCP principles are included in the inetrnational system ISO 22000. this standard is a complete food safety management system incorporating the elements of prerequisite programmers for food safety, HACCP and quality management system which together form an organization's Total Quality ManagementHR TECHNIQUES ADOPTED AT PARLE.... 5S KAIZENS SQc TQM POKA-YOKE5S 1S:- SEIRI 2S:- SEITION 38:- SEISO 4S:- SEIKETSU 5S:- SHITSUKEKAIZENS Kaizen, a Japanese term that basically translates to ‘continuous improvement' or ‘change to become good’. Kaizen is aimed at producing more and more value with less and less wastes (higher efficiency), attaining better working environment, and developing stable processes by standardization.TQM Total Quality Management (TQM) is a business management strategy aimed at embedding awareness of quality in all organizational processes. Total: Involving the entire organization, supply chain, and/or product life cycle Quality: With its usual definitions, with all its complexities Management: The system of managing with steps like Plan, Organize, Control, Lead Staff, provisioning and organizing.POKA-YOKE Poke Yoke is a Japanese technique which means mistake proof system. “Yokeru” means to avoid and “Poka” means inadvertent errors. Poka Yoke methods are simple concept for achieving this goal.DATA ANALYSIS % of workers who strongly agree to the following statements 5Shas OQCreduced SShasine. OPL Jagruti HACCPhas Small Group Feduced — wastage eff, improves grouphas improved activities has wastage knoweldge improved quality improved the quality efficiency% of workers who think rejection can be fully eliminated BYES NOthe following factors are main cause of wastage %, OOPERATOR AWAY B MACHINE PROBLEM ODELAY IN MATERIAL CPOWER CUT%of workers who think Kaizens has reduced the wastage% of workers thinking Kaizens are importantDeptt wise result of PQS quiz @ PERSONNEL | @ ACCOUNTS 18% Also a PQS test was taken of workers and their average score was 75.86%SUMMARY The company has effectively implemented the HR techniques in the plant. The workers and employees are well aware of the concepts of these techniques. The HACCP applied in the plant is working in its most effective manner. The wastage in the plant is least and the production team and the workers try their level best to reduce it even more. The wastage of the biscuits that fall on the floor is minimized by the use of trays under the machines.The use 5S in the plant has helped in keeping the plant well and tidy. The under baked or over baked biscuits are reprocessed by sending them back to the chura store and thus minimizing the wastage. The Kaizens given regularly by the employee and the workers has also helped in reducing the wastage and increase the effective production. The total wastage of the plant is sent to the poultry farms and it is around 1 truck in 6 months. All the workers have positive response towards the techniques and methods being adopted by the plant.Suggestions 1) The company should focus more over the application of the Kaizens. 2) The drop down belt at the Krackjack biscuit must be replaced by the straight belt as used in Monaco since it costs least wastage. 3) The company may also use the other HR techniques so as to make more effective production like Andon, Six thinking Hats, etc 4) The power cuts that affect a lot to the production and results in wastage must be controlled. Since one power cut of 3-5 seconds wastes at least 10-15 packs of biscuits.5) Another cause of wastage is machinery breakdown. So regular checks on the machines must be adopted. 6) Some kaizen like cuts in the conveyor belt at Krackjack machine to assure the safety requirements of the operator, a railing of nearly 1 and % inches must be put along the sides of the conveyor belt so as to minimize the falling of biscuits during the in line process of the manufacturing, that would also minimize the use of trays under the machines.