PROJECT PLANNING PROCESS

(Data Analysis)

1. Purpose of the project.

 Reducing the Delivery time of the Set yogurt product to the market.

2. Available resources.

Men (M1) Machines and Equip (M2) Materials and

Service.(M3)

Labors(a1, a2, a3, a4 ) Pipes (f) Milk (p)

Workers(b1, b2, b3, b4, b5) Filter(g) Flavors(q)

Operators(c1, c2 , c3) VAT 1(h) Empty yogurt Cups(r)

Rep ( d) Boiler(i) Cup Lid (s)

Helper (e) Containers(J1,J2, J3, J4, J5 ) Ink (t)

Homogenizer(k) Boxes(u)

Cooling tank(l) Bill book(v)

Balance(m)

Yogurt filling and packing

machine ( n)

Delivery Vehicle(o)
3. process begin to end – process chart

Activity Time
1. Fill Raw milk in to Storage tank 10 minutes
2. Filtration of Raw milk in Filter 10 minutes
3. Adjust milk composition 5 minutes
4. Sending adjusted milk to boiler 5 minutes
5. Pasteurize milk to 95oc 25 minutes
6. Weight Sugar and Gelatin according to the requirement 5 minutes
7. Add Sugar and Gelatin 5 minutes

8. Send the Milk to Homogenizer and start mixing 30 minutes

9. Send Milk to Cooling tank and set 450c 10 minutes

10. Weight the flavors according to requirement 10 minutes

11. Add Flavors to cooled milk 5 minutes

12. Place the empty cups on machine convey belt 1minutes
13. Add milk to the cups in yogurt packing machine (4 cups for one 1 minutes
set)
14. Fix lid on the cup 1 minutes
15. Send cups to date printing machine and print date 1 minute
(Expire date, Manufacture date)
16. Send yogurt cups to cool to 4oC 10 minutes
17. Pack the set yogurt cups in to boxes 20 minutes
18. load the yogurt packed Boxes in to the delivery Vehicle and arrive 10 minutes
to the shop and meet shop owner
19. Ask for the Required Amount and record 2 minutes

20. Count and unload the required amount of Yogurt Cups and 10 minutes
provide the bill
21. Receive the Pavement for the provided amount of sent yogurt 5 minutes
4. process end to begin – System chart - Attached
5. customer requirements across the process. - Kanban System

Process Customer Requirement

A Fill Raw milk in to Storage Communicate with the milk providers and
tank get the required amount of Milk at the right
time. Keep storing the sufficient amount of
storage to provide the raw milk in JUST IN
TIME
B Filtration of Raw milk in Filter Clean the filters at usual time and make
aware the cleaner about the time and way
of cleaning.
C Adjust milk composition Educate the worker on the milk
composition and inspect him by the quality
checkers.
D Sending adjusted milk to Clean the containers and pipes which
boiler carry the milk.
E Pasteurize milk to 95oc Keep checking the required temperature
F Weight Sugar and Gelatin Wight the correct amount of Sugar and
according to the requirement gelatin and provide

G Add Sugar and gelatin Add the those ingredients in correct time
at the correct place.
H Send the Milk to Homogenizer Send milk to Homogenizer at just after the
and start mixing addition of ingredients. Do mixing at
appropriate speed and time.
I Send Milk to Cooling tank and Keep checking the required temperature
set 450c
J Weight the flavors according Weight the correct amount of flavors
to requirement needed to keep the quality and customers
taste.
K Add Flavors to Cool milk Add the flavors in correct amount to keep
the required taste of the product according
to the customer requirement.
L Place the empty cups on Workers keep concentrating on the
machine convey belt process to place the cups correctly on the
belt.
M Add milk in to the cups in Machine operator keeps looking the
yogurt packing machine (4 process and correct if there is any
cups for one set) deviations on the process.

N Fix lid on the cup Nicely fix the lid on the cup to make a good
outlook.(Decoration)
O Send cups to date printing Estimate the Correct expire date and print
machine and print date the correct data.(Expire date, Manufacture
(Expire date, Manufacture date and the prize)
date)
P Send yogurt cups to cool to Send the yogurt for cooling at the right
4oC time of the process and keep it to cool at
the required temperature.
Q Pack the set yogurt cups in to Nicely pack the cups in to the boxes
boxes without damaging the product.
R load the yogurt packed Boxes Carefully load the boxes in to the vehicle
in to the delivery Vehicle and and arrange them orderly to provide to the
arrive to the shop and meet customer easily and quickly.
shop owner
S Ask for the Required Amount Politely communicate with the customer
and record and ask for the requirement and provide
the product.
T Count and unload the required Unload the yogurt cups and arrange them
amount of Yogurt Cups and nicely in the shops refrigerator and display
provide the bill the product at a good place where
customers can easily get.
U Receive the Pavement for the Be polite and have a good communication
provided amount of sent with the customer and get the pavement.
yogurt
6. Build quality standard into each activity of the process.

Activity Quality Standard Tolerance Remarks

A Raw milk from different farmers Acceptable Good-quality raw milk is required
or bulked milk from various range of to make good-quality dairy
collecting centers must be test results products. Once raw milk is
checked for wholesomeness, defective, it cannot be improved
bacteriological, and chemical during processing.
quality.
B Check for particles present in - -
the raw milk
C Milk composition may be must Often dry milk is added to
adjusted to achieve the desired contain at increase the amount of whey
fat and solids content. least protein to provide a desirable
8.25% texture. Ingredients such as
solids not stabilizers are added at this time.
fat.

D Smoothness and the sizes of - Less friction on the pipes of

the pipes to deliver the
required amount of milk
discharge. Also the sizes of
the containers which carry
the milk
E pasteurized at 185°F (85°C) for
30 minutes or at 203°F (95°C) for
10 minutes
F Weight required to achieve -
the required taste
G ensure that the cultures -
remain active in the yogurt
after fermentation to act as
probiotics
milk flow makes the smooth
flow of the milk. Clean and
optimum size containers
enhance quality and easy.
+5 to -5 The high heat treatment also further
reduces the number of spoilage
organisms in the milk to provide a
better environment for the starter
cultures to grow
-
if the yogurt is pasteurized after
fermentation the cultures will
be inactivated.
H Homogenized 2250 psi to mix all +250 psi This improve yogurt consistency.
ingredients thoroughly to -250 psi
I Smoothness and the sizes of - Less friction on the pipes of
the pipes to deliver the milk flow makes the smooth
required amount of milk flow of the milk. Clean and
discharge. Also the sizes of optimum size containers
the containers which carry enhance quality and easy.
the milk
J Weight required to achieve - -
the required taste
K Flavor is added in the bottom of added at Sometimes flavors are blended with
the cup and then the inoculated different the fermented, cooled yogurt prior
yogurt is poured on top and the steps to packaging.
yogurt is fermented in the cup depending
on the type
of yogurt
L 4 cups at once Exact 4 Machine can produce 4 cups at
cups a once
M 4 cups at once Exact 4 Machine fills and 4 cups at a
cups once
N 4 cups at once Exact 4 Machine fix the lid on 4 cups at
cups once
O 4 cups at once Exact 4 Machine Print date on 4 cups at
cups once
p Smoothness and the sizes of - Less friction on the pipes of
the pipes to deliver the milk flow makes the smooth
required amount of milk flow of the milk. Clean and
discharge. Also the sizes of optimum size containers
the containers which carry enhance quality and easy.
the milk
Q Boxes can pack 36 or 60 Exact 36 -
yogurt cups for each box or 60
R Loading boxes according to +5 boxes -
customer requirement
S Check for the available - -
numbers in the shop and
discuss with the shop owner
T Reduce the value for the - Return means the expired
return amount and provide yogurts.
the bill
U Cash or check Check -
date

7. Method data Base

Process Activity Method

A Fill Raw milk in to Storage Make a parking with enough space and
tank easy access to the raw milk bowsers.
Feed the storage tanks with raw milk using
appropriate pipes. Use appropriate
methods of filling raw milk in to the storage
tanks.
B Filtration of Raw milk in Filter Use good filtration methods in filtering the
raw milk
C Adjust milk composition Milk composition may be adjusted to
achieve the desired fat and solids content.
D Sending adjusted milk to Adjusted bilk was send to the boiler
boiler through containers manully.To be
effective and efficient pipe system
implemented.
E Pasteurize milk to 95oc Boiler indicated the temperature of the
heated milk and the person is looking at
the boiler and switch off at the correct
time.Automatic off also there and will be
more effective and efficient.
F Weight Sugar and Gelatin Weighing is done manually using balance.
according to the requirement
G Add Sugar and gelatin Sugar and gelatin is been added just after
the pasteurization as high heat can mix
the materials well.
H Send the Milk to Homogenizer Mixing is done automatically in the
and start mixing Homogenizer using the technique of
Centrifugation.
I Send Milk to Cooling tank and Milk was send to the cooling tank using
set 450c milk fill containers and the worker is
responsible of keeping the required
temperature at the time.
J Weight the flavors according Weighing is done manually using balance.
to requirement

K Add Flavors to Cool milk Fruit and flavors are added at different steps
depending on the type of yogurt. set yogurt the
Flavors is added in the bottom of the cup and
then the inoculated yogurt is poured on top and
the yogurt is fermented in the cup.
L Place the empty cups on 2 persons are sat near the convey belt and
machine convey belt careful place the empty yogurt cups on the
belt at the correct position.
M Add milk in to the cups in Done by the machine.4 cups at once.
yogurt packing machine (4
cups for one set)

N Fix lid on the cup Done by the machine.4 cups at once.

O Send cups to date printing Done by the machine. It should be given

machine and print date the correct expire date and Manufacture
(Expire date, Manufacture date to print.
date)
P Send yogurt cups to cool to Carry the yogurt cups to the cooling room
4oC and keep it cooled to 4oC.And keep it until
it gets loaded for the delivery
Q Pack the set yogurt cups in to There are boxes which can pack 36 or 60
boxes yogurt cups. Carefully pack without
damaging
R load the yogurt packed Boxes Loading is done by the 2,3 workers in the
in to the delivery Vehicle and facotory.And careful loading to the delivery
arrive to the shop and meet Vehicle is important.
shop owner

S Ask for the Required Amount Arrive to the shop meet the shop owner
and record and ask for the requirement. Also check
the refrigerator and get the count of
existing and get the expired yogurt to
replace.
T Count and unload the required Hand written bill is provided and the
amount of Yogurt Cups and amount for the return is reduced from the
provide the bill total.

U Receive the Pavement for the Get the cash or check pavement
provided amount of sent
yogurt
8. Optimum Resource Allocation

Men (M1) Machines and Equip (M2) Materials and Service.(M3)

Labors(a1, a2, a3, a4 ) Pipes (f) Milk (p)

Workers(b1, b2, b3, b4, b5) Filter(g) Flavors(q)
Operators(c1, c2 , c3) VAT 1(h) Empty yogurt Cups(r)
Rep ( d) Boiler(i) Cup Lid (s)
Helper (e) Containers(J1,J2, J3, J4, J5 ) Ink (t)
Homogenizer(k) Boxes(u)
Cooling tank(l) Bill book(v)
Balance(m)
Yogurt filling and packing
machine ( n)
Delivery Vehicle(o)

Task Recourses
M1 M2 M3
Fill Raw milk in to Storage tank a1,a2 f p
Filtration of Raw milk in Filter a3 g p
Adjust milk composition b1 h P
Sending adjusted milk to boiler b2 j1 p2
Pasteurize milk to 95oc c1 i p2
Weight Sugar and Gelatin according to the requirement c, e,f,g K
Add Sugar and gelatin b3 j2,j3 p3
Send the Milk to Homogenizer and start mixing c2 k p4
Send Milk to Cooling tank and set 450c c1 l1
Weight the flavors according to requirement b1 j4
Add Flavors to Cool milk b2 m,j5 q
Place the empty cups on machine convey belt b4,b5 n r
Add milk in to the cups in yogurt packing machine (4 cups c1 n,e,f
for one set)
Fix lid on the cup c3 n s
Send cups to date printing machine and print date b3 n,o t
(Expire date, Manufacture date)
Send yogurt cups to cool to 4oC a1,c1 L
Pack the set yogurt cups in to boxes a2,a3
load the yogurt packed Boxes in to the delivery Vehicle a2,a3
and arrive to the shop and meet shop owner
Ask for the Required Amount and record d,e
Count and unload the required amount of Yogurt Cups d,e v
and provide the bill
Receive the Pavement for the provided amount of sent d
yogurt
9. Expected Time Plan

Activity Time
1. Fill Raw milk in to Storage tank 10 minutes
2. Filtration of Raw milk in Filter 10 minutes
3. Adjust milk composition 5 minutes
4. Sending adjusted milk to boiler 5 minutes
5. Pasteurize milk to 95oc 25 minutes
6. Weight Sugar and Gelatin according to the requirement 5 minutes
7. Add Sugar and Gelatin 5 minutes

8. Send the Milk to Homogenizer and start mixing 30 minutes

9. Send Milk to Cooling tank and set 450c 10 minutes

10. Weight the flavors according to requirement 10 minutes

11. Add Flavors to cooled milk 5 minutes

12. Place the empty cups on machine convey belt 1minutes
13. Add milk to the cups in yogurt packing machine (4 cups for one 1 minutes
set)
14. Fix lid on the cup 1 minutes
15. Send cups to date printing machine and print date 1 minute
(Expire date, Manufacture date)
16. Send yogurt cups to cool to 4oC 10 minutes
17. Pack the set yogurt cups in to boxes 20 minutes
18. load the yogurt packed Boxes in to the delivery Vehicle and arrive 10 minutes
to the shop and meet shop owner
19. Ask for the Required Amount and record 2 minutes

20. Count and unload the required amount of Yogurt Cups and 10 minutes
provide the bill
21. Receive the Pavement for the provided amount of sent yogurt 5 minutes
12. Add more Resources to Critical activities and crash the Programme

Crash programming tries to reduce the total completion time of the process. To reduce
the total time of the process, it can be used,

 Add more labours, workers to the critical activites.can get the human resource
from the parallel activities and move them to the critical activities.
 Current system can produce only 4 cups at once. The machine can be
developing or can hire a machine which can produce more number of cups

13.Use Appropriate technology and Reengineer the Project Process

 Milk is being transported between some activities by manual transporting using

containers(Baskets). A good pipe line system can be implemented and it can
reduce the number of human resource and the containers(baskets). Also the
process will be speed up and the time will reduce.
 Borrowing a new machine which can fill milk and packing more than 4 cups
at once. Producing more cup at one increases the production.
 Borrowing cooling tanks and boilers which will automatically stops when
it reaches to the required temperature. This will reduce the human resource
which is use for checking the temperature.
 Introduce a new data base to identify the number of expired items in each
shop and there for can know how much return items for a day before reaching
to the shop. It reduces the time spend in the shop.
 Mobile application or a software program can be used to know the
requirement for the hole sale buyers. If they can order the required amount
through internet it will reduce the time waiting in the shop.
 Through the software if we know the requirement of the hole sale buyer, we can
print the bill at the factory and can send to the shop owner. Also online
payment methods can be done.
14. Check actual QQT and Desired QQT

Activity Desired Actual

Quality Quantity Time Quality Quantity Time
(minutes) (minutes)
Raw milk should One 10 Raw milk One 10
be checked for sample checked for sample
A wholesomeness, from bacteria only. from
bacteriological, 500 l 1000 l
and chemical
quality.
Check should be Sample 5 No testing for No 5
done for for cheek particles sample
B particles present testing present. Visual
in the raw milk examination
after filtration
Milk composition For 500 l 3 Milk For 500 l 5
should be composition
C adjusted should be
adjusted
adjusted milk For 500 l 5 adjusted milk For 500 l 5
should be send are sending to
D to boiler in clean boiler in clean
containers containers
95oC should be 500 l 20 95oC should be 500 l 25
E for pasteurized for pasteurized
milk milk
Weight should - 5 Weigting is - 5
F be taken done but no
correctly and records
should recorded
Gelatine and Sugar – 3 Gelatine and Sugar – 5
G Sugar should be 5 kg Sugar are add 5 kg
add in correct Gelatine in correct Gelatine
amounts – 5 kg amounts – 5 kg
 Milk – Milk –
500 l 500 l
Mixing should be 500 l 35 Well mixed 500 l 30
H done in well
Weight should 5 Weigting is 5
J be taken done but no
correctly and records
should record
Flavors should Correct 5 Correct Sugar – 3
K be add in correct amounts amounts 5 kg
amounts Gelatine
– 5 kg
Milk –
500 l
Cups should be 4 cups 1 Cups are place 4 cups 1
L place at right For the at right time For the
time and right machine and right place machine
place
Amount added 80 ml 1 Amount is 80 ml 1
M should be adjusted
adjusted.
Should Heat the 1 lid for 1 Should Heat 1 lid for 1
N cup in correct one cup the cup in one cup
heat to fix the lid (4 at correct heat to (4 at
with high quality once) fix the lid with once)
high quality
Expire and - 1 Expire and - 1
O manufacture manufacture
date should be date are print
print corectly corectly