INTRODUCTION

Genesis

The name that epitomizes mineral water

today was first introduced in Mumbai in
the early 60's. In 1965 Signor Felice
Bisleri an Italian by origin, came up with
the idea of selling bottled water in India.
His company Bisleri Ltd. offered mineral
water in two variants - bubbly and still.
In 1969 Parle bought over Bisleri (India)
Ltd. and started bottling Mineral water in
glass bottles under the brand name
'Bisleri'. In due course Parle switched
over to PVC non-returnable bottles and
finally advanced to PET containers.

Expansion

Under the leadership and vision of Mr. Ramesh J. Chauhan, Bisleri has undergone
significant expansion in their operations. The company has witnessed an
exponential growth with their turnover multiplying more than twenty times in a
short span of 10 years. The average growth rate over this period has been around
40% with Bisleri enjoying more than 60% of the market share in the organized
mineral water segment.
Currently Bisleri has 11 franchisees and 8 plants across India, with plans of setting
up 4 new plants on the anvil. The overwhelming popularity of 'Bisleri' and the fact
that we were the pioneers of the bottled water industry in India has made us
synonymous to Mineral water and a household name. So naturally 'When you think
of bottled water, you think Bisleri'.

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OBJECTIVES OF THE PROJECT

1. The project will helped us to understand how different departments

in production process works.

2. We will come to know how to do effective management of

inbound logistics and outbound logistics, which in turn helps in
bringing down the cost for the organization.

3. With the help of this project we would come to know different

stages of production. i.e. inputs, conversion subsystem and finished
goods stage.

4. To understand how and what types of machines are used while

production.

5. To understand what are the factors which is to be considered while

selecting the plant layout.

6. To do the ABC analysis of Bisleri inventory.

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 TABLE OF CONTENT

Sr. NoParticulars Pa
ge
No
1.About the Industry
2.About Bisleri
3.Departments in M/s Parle Bisleri Pvt. Ltd.
4.Production System Model
5Production Process
6Planning for production function
7Plant Location
8Plant Layout
9Principles of Plant Layout
10.ABC Analysis
12.Conclusion

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 ABOUT THE INDUSTRY
Corporate control over water and water distribution in India is growing rapidly: the
packaged water business is worth Rs 1,000 crore, and it's growing at a huge 40-50%
annually. Around 1,200 bottling plants and 100 brands of packaged water across the
country are battling over the market, overdrawing groundwater. Bottled water, one of
India's fastest-growing industries, is a business built on the foundation of bad
governance, inequity and exploitation. It is Hard to believe, but its true. Around 1.2
billion people worldwide lack access to clean drinking water. Today, there are more
people in the world's hospitals suffering from waterborne diseases than any other
ailment.. Providing safe drinking water is the responsibility of the state. That they are
failing miserably is evident from the fact that over 1,600 Indians reportedly die every day
because of waterborne diseases. Despite these astounding figures, the Indian state has
literally washed its hands of the responsibility of providing clean drinking water to its
citizens.

Multinational corporations would have us believe so. And the reason is not hard to find:
along with imported water treatment technology like activated carbon and ultra violet
(UV) disinfection (Aquaguard), reverse osmosis (Reviva) and resins (Zero-B), the water
treatment market is estimated to be worth around Rs 700 crore. According to the Bureau
of Indian Standards, there are 1,200 bottled water factories all over India (of which 600
are in the state of Tamil Nadu). Corporate control over water and water distribution in
India is rapidly growing. As globalisation opens up opportunities for private players,
investing in water and/or manipulating water scarcity makes increasingly good business
sense for corporations.

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 ABOUT BISLERI
Parle bought over Bisleri (India) Ltd. In 1969 & started bottling Mineral water in
glass bottles underthe brand name 'Bisleri'. Later Parle switched over to PVC non-
returnable bottles & finally advanced to PET containers.

Presently we have 8 plants & 11 franchisees all over India. command a 60%
market share of the organized market. Overwhelming popularity of 'Bisleri' & the
fact that we pioneered bottled water in India, has made us synonymous to Mineral
water & a household name. When you think of bottled water, you think Bisleri.

Bisleri has developed 8 unique pack sizes to suit the need of every individual. They
at present have 50ml cups, 250ml bottles, 500ml, 1L, 1.5L, 2L which are the non-
returnable packs & 5L, 20L which are the returnable packs.
Bisleri Water is put through multiple stages of purification, ozonised & finally
packed for consumption. Rigorous R&D & quality controls has made us a market
leader in the bottled water segment. Strict hygiene conditions are maintained in all
plants.

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 DEPARTMENTS IN M/S PARLE
BISLERI PVT. LTD.

“M/S Parle Bisleri Pvt. Ltd.” It is a medium scale company and it manufactures
and sells “Packaged Drinking Water”.
The different departments of this company are: -

1. Filler Department: -
This is the plant in which the bottles are filled and packed under strict levels of
hygiene and safety as per the EU norms.
2. Plastics Department: -
• Caps Section
• Preforms Section
Caps are made from a mixture of HDPE and LLDPE using 4 Cincinnati
Milacron and 2 Windsor injection-moulding machines.
Preforms Department where raw material is processed to make preforms
using 6 Ekou injection moulding machine of 180 and 330 tonnes as per the
requirements of the preform. Preforms are available in various sizes according
to the size of bottle.

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 Bottle Sizes Preform Sizes
250 Ml 15 Gms
500 Ml 17Gms
1 Ltr 21Gms
1.5 Ltr 32 Gms
2 Ltr 34 Gms
5 Ltr 75 Gms
20 Ltr 710 Gms

3. Water Treatment Plant: -

Over here the Raw water from the bore wells is treated in several stages before it is
filled thus making it very pure for human use.

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4. Blowing Department: -

Over here the preforms are blown into bottles. This department has various manual
and fully automatic stretch blow moulding machines.

5. Water Testing Laboratory: -

The water-testing lab ensures that the water safety standards are maintained as per
the BIS and EU norms.

6. HORAI Department (Grinding Department): -

All rejected bottles, caps, jars and lumps of plastic material are sent over here for
grinding in order to re-use it. Before it can be grinded it is very carefully
segregated in different groups. They also buy plastic bottles from outside and grind
them for resale. It is a fully automatic plant

7. Stores Department: -

All the stock of finished, semi-finished goods are stored over here and are
dispatched as per the orders. Up to 50 tonnes of stock are dispatched in a day.

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 PROCESS FLOW CHART
hgf

CONVERSION
INPUTS OUTPUT
SUBSYSTEM

Environment
Legal FDA, BIS, Bisleri
BMC
Bottles
Technological
automatic inj. Physical
Mldg. m/c, auto
blow mldg. m/c.
Manufacturing

Market
Locational Services

Competition with
Aquafina, Kinley Transportation
etc.
Customer Desire
50 m.l., 100 m.l., Exchange
25 litres
Primary and low
Resources
price
Services
Material: - Wholesaler
Refill
Water from bore wells
HDPE, LLDPE, PET.
Other Private
Services
Personnel: -

Plastics Engineering, Utility

Production Managers.

Capital Assets: -

Auto Filling Machine,

Blow moulding
machine, recycling Control Subsystem
machine

Sealed bottle, FDA, Quality

Control
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 PRODUCTION SYSTEM MODEL

• INPUTS

Environment

1) Legal: -
Parle Bisleri being a company involved in selling water which is fit for
consumption it comes under the FDA, it also follows the standards of BIS.
Therefore ensuring its quality and the public perceive the right image of being
100% safe.

2) Technological: -
Parle Bisleri believes in keeping up with times and they are trying constantly to
increase their share market. This is the reason Bisleri has automatic Injection
Moulding Machine in order to increase their production capacity 3 folds.
Bisleri already has 2 automatic Blow Moulding Machines.

Market

1) Competition: -
Parle Bisleri Pvt. Ltd.
1992 at that time
Bisleri enjoyed
almost a complete

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 monopoly. Recently however, companies like Pepsi and Coco cola have entered
the market to give tough competition to Bisleri by introducing brands like
kinley

and Aquafina.

2) Customer desire:-

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 Bisleri has become a household name to the extent that people instead of calling
it packaged water are calling it Bisleri.

Primary resources: -

1) Material: -
The raw water is obtained from bore wells. The bottles are made from polymers
such as HDPE, LLDPE and PET.

2) Personnel: -
Bisleri requires mostly skilled and semi skilled labourers. The skilled labourers
include production and plastic engineers.

3) Capital assets: -
Bisleri has got 14 injection moulding machines, 2 automatic blow moulding
machines and 4 semi automatic blow moulding machines. It has also got 2
plants located side by side for production purposes.

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 Conversion Subsystem

1) Physical: -

Parle Bisleri Pvt. Ltd is considered to be a manufacturing unit as it

manufactures the semi finished product i.e. bottles and caps and also produces
the finished products.

2) Exchange services: -

The distribution network of Bisleri is maintained by its distributors and

wholesalers. To supply to big corporates they have their own distribution
network.
3) Outputs: -

The final output of whole manufacturing process is we get clean pure drinking
water in bottles of different sizes according to the needs of the consumers.

Quality control subsystem

The motto of Bisleri is “play safe” and Bisleri has implemented every measure
to produce the safest product possible. It has employed measures such as:-
1) The quality of every single raw material that goes into the products are

minutely inspected in order to ensure optimum quality standards.

2) The caps of all the bottles are tamper proof so when the consumer buys a

Bisleri product he ensures that the product is untampered.

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3) The production process of Bisleri is such that a human hand never touches a

Bisleri product.
4) There is 24 hours quality checking so that no defective product reaches the

consumer.

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 Production Process

1) The raw material (HDPE, LLDPE, PET) that is stored in the warehouses is
transported to the processing plant near by.

2) In the cap department where caps are produced. HDPE and LLDPE which are
in the form of granules are emptied into the hopper of the injection moulding
machine with a colorant and the caps are produced of the characteristics green
colour of Bisleri. The caps that are produced are automatically packed into
cartons. This semi finished product is transported, after quality testing has been
done, to what is called the filling department. In the caps department there are
7 injection moulding machines

3) In the preforms department which is located in next to the cap department it is

located in the same plant. In the preforms department PET material is used to
manufacture preforms which are semi finished bottles. They are produced by
using injection moulding machine. After the preforms are tested by the quality
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 assurance department, they are packed in cartons and transported to the filling
department. In the preforms department there are 7 injection moulding
machines.

4) In the blowing department the preforms which are obtained from the preforms
department are blown to form bottles. There are a total of 2 fully automatic
blowing machines which are directly connected from to the filler. There are
about 5 more semi automatic and automatic blowing machines which are
producing bottles everyday.

5) The filling department is situated in a closed and a controlled environment to

maintain the hygiene. The bottles are transported from one operation to another
on conveyor belt. The bottles are directly loaded onto the conveyor belt, first
bottles passed through UV light to kill the bacteria, then the bottles are cleaned
by pure water, then the bottles are filled to the desired quantity and then they
are automatically capped, then the sticker is put on the bottles and the price,
manufacturing date, batch number are printed by spraying machine on the
bottle itself, then the bottles pass through a screen of white light where workers
manually check all the bottles for any defects, lastly they are packed in cartons
and stored in the warehouse ready for transportation to its destination.

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6) All the waste bottles are separated and they collected and send to the recycling
department for recycling where they are cleaned, grinded to a coarse powder
which is again used in the manufacturing process thus reducing wastages and
being environmentally friendly. This plant is also used for recycling of outside
PET bottles and thus earning extra revenue.

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7) In the water treatment plant the water form the 8 bore wells are stored in the
Chlorinated Raw Water Tank (CRWT), the chlorine in this tank is used to kill
the germs, after that the water goes through the sand filter where the solid
wastes are removed, after this the water passes through the carbon filter to
remove the foul odour, then the water passes through the Ultra Violet Light
Chamber where the Water passes through it to cure the bacteria and viruses,
then the water passes through a reverse osmosis process to remove the dead
membranes of bacteria and viruses, then the water is passes through the
silverisation chamber to give the sparkle to the water, then the water passes
through the ozonisation process to remove the chlorine and to remove the and
its stale odour.

Raw Chlorinated Raw Sand

Water Water Tank Filter
Wa

Carbon U.V. Filter Reverse

Filter Osmosis

Silverisation Ozonisation

ter Purification Process of Parle Bisleri Pvt. Ltd.

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 Planning for production function

1) Material

Without materials there can be no output. Material input may account for as
much as 80% of the value of the output. This fact indicates the importance to
be attached to material purchasing.

The materials required for the production process of packaged drinking water
are: -
a) Raw water
b) HDPE
c) LLDPE
d) PET
e) Recycled PET granules
f) Cartons
g) Stickers

2) Methods

This function analyses possible methods of manufacture and tries to define the
best method compatible with a given set of circumstances and facilities.
The method for producing packaged drinking water starts with the production
of bottles and caps. After that the semi finished products are transported from
the cap and performs division to the filling division where the caps are added
to the filling machines and the performs to the corresponding size of the
bottle, these bottles are then added to the conveyor belt to complete the
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 process of filling the bottle automatically. After the bottle is filled to the
desired level the bottle is automatically capped and then sticker is put on the
bottle the price is printed through a spray gun. Then it is visually inspected
and after that put into cartons readily for delivery.

3) Machines and Equipment

Industrial production is closely related to available production facilities

coupled with appropriate machine and equipments. Considerations:

1) Equipments can be purchased fresh or second hand

2) Equipment can be lease or rented

3) Equipment can be fabricated within the plant

Machines used in Bisleri are injection moulding machines for the production
of preforms and caps. For making bottles blow moulding machines are used to
blow the bottles to the required size and shape of the bottles by the use of
moulds. Automatic fillers are employed for the purpose for clean and efficient
filling of the bottles with the least amount of rejection.

4) Routing

The determination of where each operation on a component part, subassembly

or assembly is to be performed results in a route for the movement of a
manufacturing lot through the factory.
The route of the production process is designed in such a way that in process
transportation is at a minimum. The plant layout is in such a way that it is easy
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 to transport the semi-finished product. First comes the semi finished product
then it is blown filled and sealed, now ready for delivery.

5) Estimating

Estimating is a special type of forecasting.

Bisleri being an old company has being estimate the demand for its production
due to its past experience it is able to estimate the demand. As a general rule
the demand for Bisleri is very less but the production of Bisleri continues as
the demand in summer is so high that the production cannot keep pace with
the production requirement. They also take help of market surveys and past
trends to determine the production requirements.

6) Loading and Scheduling: -

Both scheduling and loading help in production planning. Scheduling refers to

the preparation of a time table for various operations covering the beginning
and finishing times of various operations. Loading refers to the time gap for
various work loads booked in advance for different products. Thus scheduling
guarantees the observation of delivery times and loading guarantees the
maximum utilisation of the available facilities.

According to the schedule of the delivery and amount to be delivered and

where they are to be delivered the trucks are loaded to be sent to wholesalers
and retailers

7) Dispatching: -
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 Dispatching refers to the actual issuing of orders for performing operations in
different sections or units. It involves the following steps:
1) To make raw materials, equipments, tools and machines available to
the worker
2) To issue orders and instructions in writing about the method of work
and time for completion
3) To note start and finish time of each process
4) To evaluate the performance and progress of production schedule
5) To introduce suitable changes in schedules

Distribution of the bottles is done using trucks of different sizes if the deliver
has to be done in the city the smaller trucks are used which are of Eicher. If
the delivery has to be made outstation then the larger Tata Trucks are used.
The normal distribution to the distributors within the city the delivery takes
place 7:00 a.m. every morning except Sunday.

8) Follow Up: -
The effectiveness of any production control system is dependent upon timely
and adequate information regarding actual performance. This information
usually originates with the dispatcher..

After the delivery has been made the marketing people visit the retailer,
wholesalers, distributors for their complaints if any written and left for the
consideration of their superiors.

9) Inspection: -
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 Inspection is an integral aspect of quality control programme. It helps in
maintaining and raising the quality of products. Inspection judges production
against established standards.
There is a very efficient quality control process followed by Parle Bisleri Pvt.
Ltd. it inspects everything from the water to the bottles very regularly, in fact
it is one the main issues in quality control of the company. The first thing the
quality control head does is to check the previous days rejection and to finds
its individual reasons of rejection and steps if required.

10) Evaluating: -

Evaluating is the important link between control and future planning.

Evaluating function provides a feedback mechanism on a longer term basis so
that past experience can be evaluated with a view to improve use of methods
and facilities.
Operations of Parle Bisleri are inspected by:-
• FDA (food and drug associations).
• BIS (Board of Indian Standards).

PLANT LOCATION

An ideal plant location may not be enough by itself to ensure the success of the
enterprise but it surely ensures the smooth running of a factory The need for
selection of the location may arise when a business is started or for the purpose of
expansion or for opening branches etc.
PLANT LAYOUT
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The subject plant layout refers to the arrangement of machinery, equipment and
other industrial facilities for the purpose of achieving the quickest and smoothest
production at the least cost.
Bisleri plant at Andheri (E) has two different plants where the complete production
takes place. In the one plant the cap and the bottle preforms are manufactured and
the other plant has the place for preforms to be blown into bottles and the filling of
the bottles is done. This building also has the purification process of the water
which has to be filled.

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 PLANT OUTLET OF ANDHERI (E) UNIT

I P
G
N R
A
V O
R
E C
TRANSPORTATI D
ON N E
E
T S
N
O S

R I

ADMINISTRATO N
Y
R DEPARTMENT
G

U
W
N
A
I
SECURITY S
CABIN T
T

W A S T E -D E P T

ENTERANCE
Analysis of Bisleri on the layout of its Factory

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B) Type of Industry: -

1) The type of industry and the method of the manufacturing process

exercise a significant influence on plant layout.

Bisleri falls under the category of conditioning industry. A conditioning

industry is industry which is involved in the change of form or the physical
properties of a substance in this case water. Also:

Bisleri falls under the category of a continuous industry. A continuous

industry is an industry that manufactures a product uninterrupted of standard
size.

C) Nature of plant location: -

the location of the plant determines the mode of transportation, depending

upon the distances from the source of raw materials and market to the plant.

Parle Bisleri Pvt, Ltd. is located in Andheri (East) in Mumbai. The plant is
located on a large plot near the western express highway. The terrain of the
place where it is located is that it is in step form i.e. the full plot is not at the
same level, this helps in the transportation of semi-finished product to be
transported to the filler.

D) Machinery: -

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 The type of product, the volume of its production, the type of process and
management policy determines the size and type of the machinery to be
installed which, in turn, influences the plant layout. Also the fixed and
stationary parts of the machines should also be taken into considerations
while designing the plant layout.

In Parle Bisleri Pvt. Ltd. the machines are laid with many considerations
such as: -

1) There is enough space for the repair and maintenance of the machinery
can be done easily.

2) The machines are placed in such a way that there is enough place for
moving and relocation of the machines

3) There is enough space for workers to move about the machines and work
comfortably.

E) workers:
The layout designer should also consider the type, position and requirements
of employees. If women workers are employed, the layout must be planned
after keeping in mind their particular requirements. The position of
employees, that is whether they remain stationary or moving, also influences
the layout.

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Parle Bisleri Pvt. Ltd. has provided its workers with many facilities such as:
-

1) Canteen conveniently located and providing hygienic food at

concessional rates.

2) Toilets for men and women conveniently located and of sufficient

number maintained in hygienic conditions.

3) Due to the location of the plant it is very convenient for all the workers to
reach work.

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 CONCLUSION
In conclusion it can be inferred that production management is very important in
today’s competitive world where cost cutting is a norm rather than exception.
Production management provides a science for effective profit maximization and
optimum resources utilization.

Bisleri who ahs been in the past been facing tough competition from the other
brands has adopted production management in a big way in order to maintain its
lead in the packaged drinking water market.

By this project we have tried to highlight some of the measure taken by Bisleri in
order to improve its production processes and to show the significance and the
benefits of production management in today’s globalised market.

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