During visit report

Sushil engineers
&
Sushil bakers

Submitted by:
Apuri Jaya Sai Prathap
20172227

MBA Sec-B
Sushil bakers:
This organisation was started as a power generating company where it is very successful and
before 2 years it started the bakery unit. Though it started before 2 years it is running in
profits. The products are being sold in Sonipat, Delhi, and some neighbouring states like
Rajasthan, Punjab. There is only one unit regarding this bakery which is situated in Sonipat.

Products:
The products produced by Sushil bakers are Rusk, Burger, Naan, Pav, and some kinds in
Bread. The main item produced is Rusk.

Raw materials:
The raw materials used are Maida, sugar, oil, and yeast. The Maida is purchased from Delhi,
Sugar from Sonipat and Oil is bought from Rajasthan. All these raw materials are purchased
through distributors.

Process:
The rusk is made through some part of bread which it produced, the bread is dried, and it is
made into rusk. It is made yeast free. There are 4 steps in processing. They are Mixing,
Toffing, Fermentation, and Baking.

Mixing- In this process Maida, Sugar, Oil, and Yeast are mixed by using mixer. The
quantities are mixed as per the different product mixture ratios.

Toffing- The mixture then is set into trays with moulds and then the trays are kept in moisture
room for an hour. This process is called toffing. This is for cooling the dough. If the dough is
cool then yeast can easily break down sugar, in case if the mixture is hot there is a chance of
spoiling of the final good in very short period.

Fermentation- In the process yeast will involve in effervescence and giving the heat to the
dough. Yeast will consume the sugar in the absence of oxygen. With this fermentation the
dough becomes sponge, and burger, naan, pav will also seem like sponge. It takes 2 hours for
fermentation.

Baking- After fermentation the trays are moved to oven for baking. In 250 degrees of heat the
rusk is baked. After baking they are kept aside for cooling. If they are packed hot there is a
risk of breakage. There are two types of trays, single tray and double tray. The double trays
are sent in big oven and single trays are sent to small oven.

Packing:
The packing is done manually in the company. The covers are made by other company PVC
on a contract. There are 2 types of packing covers in case of rusk one is blue and the other is
orange. One packet is of 85 grams consists of 16 rusks of rupees 10. Another packet is of 100
grams consists of 20 rusks of rupees of 15. Whereas other products are packed in transparent
bag where it contains the company name on it.

Capacity of machines:
There are 3 machines in total in the factory. 1st machine used is mixer with a capacity of
100kgs. Then next 2 machines are ovens. First oven is capable of baking 25 kgs., the other is
bought after 2 years which is 3 times bigger than old one. The ovens are ruined by diesel.

Production capacity:
The lot size they used to mix every day is 70 kgs. Per day the production of rusk is 500-600
kgs. and burger is 60-70 kgs., bread is 500-600 kgs. where some part is used for selling and
some part of preparing rusk and finally naan and pav are like 50-60 kgs. Where as they may
change according to demand.

Labour:
They are 10 people working in the industry. 2 are working at mixing department, then 2 are
working at baking and remaining at packing. The company took some measures regarding
labour safety. There are 4 fire extinguishers in the industry if needed. Also, the exit gates are
constructed very big so that it will be easy to exist if there is any fire. Also, insurance has
been taken for workers. The working hours per day is 8 hours and 2 hours’ overtime.

Wastage:
There are 2 types of wastage here in the industry. One is at the time of cutting and the other at
the time of packing. The wastage is breakage of the rusk, bread, burgers etc., The breakage is
due to least fermentation, no yeast, packed or cut when it is very hot. This also happens due
to defective raw materials.

The wastage is sold as animal feed. They are sent to cow sheds sometimes for money and
sometimes freely. Per day nearly 10% of production is wasted. But they are sold at some
lower prices.

Problems:
1. Due to the very hot temperature in the oven there is a chance of breakage of diesel
pipes.
2. The other problem is wastage
3. One more problem is scarcity and increase in prices of raw material Maida. At this
time another substitute called Gluten is used in place of Maida which also costs same
as Maida (Rs.700).

Transport:
The products are transported by the company itself. They are transported to Sonipat, Delhi,
Panipat and some other neighbouring states. Sometimes the buyers only arrange their
transport.

Some smalls trucks are also maintained by Sushil bakers for transport. There is no
outsourcing because this is small scale industry and outsourcing leads to increase in cost.

Sushil engineers:
There are 2 units maintained by the industry. There are 2 stages of manufacturing in this
industry. Each stage is performed in each unit. This company works as authorised dealers for
Sudhir gensets and company from many years.

Products:
Mixers, Generators, Control Panels, Transformers

First unit:
In this unit there is a single machine for punching the tin sheets (made of steel and
aluminium). The machine is named as CNC Turret punching machine. The sheets are
punched according to the design they need. The design is formed in computer and copied to
pen drive. The pen drive is fixed to machine so that the punching will be done according to
given design and measurements. After punching all the sheets, they are collected transferred
to second unit.

Second unit:
In this unit they cut the punched sheets and they are used in manufacturing machines like
mixers, after cutting sheets the sheets made into different shapes by using vending machines.

Raw materials;
The raw materials are aluminium sheets, carbon, cutters, etc., these are directly bought from
manufacturing companies from Delhi and Sonipat.

Labour:
There 15 people employed in both the units. In first unit 5 people will work and others will
work in second unit. The labour is also very skilled and technical because this is captive
based.

Working hours:
The working hours are 8-10. And 2 hours in total is given as leisure period.

Wastage:
While cutting the sheets there is some wastage. The wastage is sent steel industries for re
manufacturing. They sell the scrap for some price.

Problems:
The problems are due to wastage of material, machinery problems, repairs in machinery
cause time break for production.