Presentation of Production

Management &

Material Management

with special study of Breweries Industry

Vidylankar School Of

Information Technology(VSIT)

S.Y.B.M.S.-CGROUP NO.:-3

1.Monit• 11B906

2.Bhavesh• 11B908

3.Vikas• 11B916

4.Chaitali• 11B9325.

Stewart• 11B940

6.Sorabh• 11B942

7.Kaveshna• 11B944

8.Arif• 11B953

9.Smit• 10B922

Material Department

QCD and Homercile Department

Stores and Inventory Department

Maintenance Department

HR Officer

Keg and Can plant Department

Brewery Department

Material handling system warehousingsystem

Safety Department

Departmental managers

of UBL

About and Why was this subject started?

In the field of management, production and materials are early management subjects.

In the competitive structure of the business both show the importance.

This can give impact on the profitability of the companies and even so on the existence of the companies.

About United Breweries Ltd.

The firm we have chosen is United Breweries Group ltd .

The UB Group was founded by a Scotsman, Thomas Leishman, in 1857.

UB group was taken up by Vitthal Mallya in 1947.

United Breweries Group or UB Group is an Indian conglomerate company based in Bangalore, India.

The company has annual sales of over US$4 billion and a market capitalization of approximately US$12 billion.

 United Breweries now has greater than a 40% share of the Indian brewing market with 79 distilleries and bottling units across the world.

About United Breweries Ltd.

Its core business includes beverages, aviation, electrical and chemicals.

The company markets beer under the Kingfisher brand and has also launched Kingfisher Airlines, an airline service in India, with international flights operating recently.

They have 32 breweries in total of which 22 of their own and 12 are on contract basis.

Recently UB financed a takeover of the spirits business of the rival Shaw-Wallace company giving it a majority share of India's spirits business.

The group owns the Mendocino Brewing Company in the United States.

Introduction to the plant

It was established on 12th april,1995.

It was inaugurated by Mr. Vijay Mallya.

The plant which we visited Is Bombay Brewery Unit Of United Breweries Ltd. located in MIDC area in the Raigad district.

This plant is fully automatic and the software of this plant is made by Allen and Bradley

This plant is the largest Brewery in India.

The size of the plant is 22 acres.

On the initial stage it should make 1,25,000 cases per month.

Now it is making 15,00,000 cases per month.

Introduction to the plant

There are 15 managerial staff.

35 junior management staff.

66 permanent workmen

80 head loaders registered with mathadi org.

250 contract workmen including security,canteen,bottle handling.

In a day the plant manufactures 25,000l of beer in one batch.

At an average in a day they manufacture 16 batches.

Introduction to the product

The product we have chosen is kingfisher beer.

United Breweries is India's largest producer of beer with a market share of around 55% by volume.

In Mild beer level of alcohol is uptill 5% and in strong beer level of alcohol is above 5% and below 8%.

Kingfisher beer has been awarded with hazardous analysis critical control point(HACCP) and ISO 9000

These are quality maintaining organizations.

Types of

Beer

Strong beer

Mild beer

Ultra beer

Draught beer

KEG(Unpasteurize

d Beer)

waterYeast for

fermentation

Rice flakes

SugarBarley malt

Hops

Ingredients used in making Beer

Separation Process

Separation of dust

Separation of stones

and metals

Separation of

ungrown barley Malt

Crushing of

Barley malt

Brewery House

Hot Water Ketttle

Lauter Turnel

wort

Whirl pool

Process

Adding yeast

Boiling

fermentation

Lagering

Filtration

Brewing

KEG(unpasturised Beer)

It is stored in steel or aluminum drum.

It is the beer that does not go through the process of pasteurization.

It is perishable beer and is made on demand.

It is served in Five star hotels and pubs.

Can plantDE- Palletizer

Can washer

Can filling

Lead Fixing

Pasteurization

Coding

Box making

Bottle plant

DE-palletizer

Bottle Washer

Bottle Filling

Cap Fixing

Pasteurization

Labeling

Bottle putting in the box

Sealing

palletizing

Material management

Raw Material

Packaging Material

Raw Material

Barley Malt

Stored in siloEach silo has a capacity of 200 metric tonnes

Rice Flakes

Stored at a dry place

Water

MIDC supplies water.

Hops

It is stored in cold storage

Sugar

It is stored in the sugar house

Packaging material

Cans are imported from Thailand, UAE and Singapore.

UB group doesn’t produce bottles but they obtain second hand bottles from local scrap dealers

Corrogated boxes are purchased and kept aside and stored in dry place till come in use.

Material Handling system

Before production process• RM is

automatically sent by a computerized software.

• Only hops and sugar is manually put into the kettle.

• For the other process there is no labour required.

During production process• Everything is

operated by computerized software

• PM material is carried by cranes to the respective plant

After production process• There are head

loaders who load the cases to the FLI godowns.

KEGs• Kegs are manually

operated

Inventory management

One month in advance a general plan is made by the corporate office regarding production of the product.

They use FIFO method

After every 10 days 200 metric tons of barley malt is added in the silo

Rice & Sugar – They are brought at regular intervals

Hops is stored at freezing temperature & bought at regular intervalsording to .

Bottles and cans are puchased according general plan made by the corporate office.

Stores management

Receiving materials

•Checking the quantity and the products

Sent to the QCD for testing

Stored in the reqd. places

•Eg.barley stored in the SILO, HOPS in cold storage

Automated software for

transfer of RM.

Packaging material is

stored in the place of

production.

After production Process it is

directly moved by transport to

the FLI godowns

Maintenance Management

Total maintenance is done once a week.

Separate department take care of it.

When total maintenance is done the production process is stopped for one complete day.

Cleaning the

kettles

Checking the bottle and can

plant

Replacing the

damaged parts

Total Maintenance

Includes

Scrap department

The scrap is managed by the homercile department.

Husk generated in the lauter kettle is sold to the cattle

Collection of broken glass is recycled

Gunny bags, empty drums,wooden plates, aluminium sheets are sold together by calling a tender.

Quality control department

Quality and hygiene are the key elements of the UB groups’ manufacturing philosophy.

To this end the Central Scientific Laboratory(CSL) headquartered at

Bangalore sets standards for all its breweries.

Quality Management Systems laid out along the lines of ISO 9000 are strictly adhered to, controlling quality at every stage of production.

Quality of the beer is checked electronically at the end of each process and the quality of the final packaged product is manually checked.

Warehousing management

The finished goods are stored in bounded gowdowns .

They are FLI godowns.

The finsihed goods produced in the plant are send to 3 godowns. KURLA

Aurangabad

Panvel

Production Unit Safety Standards

Employees at packaging units are provided with Face Masks, Helmets,

Goggles, Gloves, Gas Mask, Gumboots

General Safety Standards

The company believes that its Human resources are its main important assets

and therefore, gives highest priority to safety and health of its employees as

well as contractors workmen, including the environment management at work.

Conclusion

It was a memorable experience.

We learnt a lot from this industrial visit.