“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” EXECUTIVE SUMMERY The project title is “Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” completed in Riddhi Siddhi Gluco Biols Limited, Gokak. The project was to understand the working of the marketing and logistic department of the company. Riddhi Siddhi Gluco Biols Limited, is a manufacturer of maize based starch industry. It is the largest wet milling plant of the Indian Sub Continent having the highest crushing capacity. It produces the starch of various types, liquid glucose, Dextrose Monohydrate , Malto Dextrin, Dextrose syrup, High Maltose Corn Syrup and the by products like Corn Gluten meal , Enriched fiber etc. The objectives of the project was to study the reasons for non delivery of goods of the company on time, for the month of May and June, and suggest the company the measures to improve the same. In this regard I collected the data from the sales software, the supported documents maintained by the company and from the company website and brochures. According to the study it was found that the main reasons for delay in sending the consignments on time, were lack sufficient transportation facilities and shortage of finished products due to increased demand for the products.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” FRAMEWORK OF STUDY PROBLEM STATEMENT Riddhi Siddhi Gluco Biols Limited is one of the major players in the corn wet milling industry, The company produces starch And other products which serves as the raw materials for many industries such as Food and confectionery industry, Pharmaceutical industries, Paper industry, Textile industries etc. But due to continuous increase in demand for the products, the company is facing difficulty in sending the consignments on time. Even though the company’s one of the objectives is to achieve the On Time Deliveries of the product, still the company is facing a problem in achieving it. To know the reasons for the above problem & suggest remedies for the same, this project has been undertaken.
OBJECTIVES OF THE STUDY. The following are the objectives of the study with which the above project has been undertaken:1) To Study the on time delivery of RSGBL products. 2) Finding the reasons for non delivery of products on time 3) Suggesting the measures of reducing the customer complaints on non delivery of goods on time.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” Sources of data:The following are the tools which are used in the course of the study. • Sales invoices for the month of May and June. • Dispatch instruction register • Schedule files. • Daily report file. • Transporters register. Methodology:The following are the steps followed for studying the On Time Delivery of the products. • First
the sales information for the month of May and June was
downloaded from the software maintained by the company. • Then the required information was copied into the On time delivery table, which consists of details of invoice number, invoice date, name of the party, quantity sold, name of the transporter and the vehicle number. • From the invoice number we will get dispatch instruction slip number. • Form the dispatch instruction slip number, we will come to know the schedule to be refered, which consists of details of name of the party, quantity demanded, date for sending the consignments and specifications of the product etc.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” • Then the difference between the invoice date and the actual date of sending the consignment is calculated and the number of days delated for sending the consignments is found. • Then all details of the products used by the company for domestic use, sale of scrape, products sent on daily basis and products sent on on time are erased. • Then referring to the daily report and transporters register the reasons for the delays is found.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
THE INDUSTRY PROFILE The wet milling industry also known as the “corn refining industry” began over 150 years ago with the production of starch for the laundry business. The industry grew rapidly as corn sweeteners, corn oil and corn gluten feed were developed. Today new product development and technical innovations are still driving industry growth. Actually starch and its bi products can also be produced using wheat, tapioca, potatoes and sweet potatoes. But all most all the companies use maize as their raw material because, only maize has got maximum amount of starch content (i.e. 65%) compared to other products. Wet milling is a complex process. The larger producers process approximately100, 000 bushels daily and primary product is starch and starch derived chemicals, Oil, bran and even protein also is obtained in wet milling. Oil is further processed to produce various salad oils and similar products. Protein and bran are used primarily as feed ingredients. Additional processing produces modified starch, Malto dextrines (slightly degraded starch), sweeteners, alcohol and chemicals/pharmaceuticals derived from fermentations. One hundred pounds of dry corn produces 67 pounds of starch and sweeteners, 3.6 pounds of oil, and 29.4 pounds of byproducts or co products.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
Cleaning The raw material for wet milling is shelled dent corn delivered in bulk. The corn is inspected and cob, dust, chaff and foreign material are removed. The cleaning is normally done twice before wet processing. After the second cleaning the corn is divided into portions by weight and intermediately stored in hoppers. From a hopper
it
is
hydraulically
transported
to
the
steeps.
Steeping A proper steeping is essential for high yields and high starch quality. The steeping is carried out in a continuous counter-current process. The cleaned corn is filled into a battery of large steeping tanks (steeps), where the corn is soaked in hot water for up to fifty hours. The steeping is actually a controlled fermentation and the addition of sulphur dioxide to the steep water helps control that fermentation. Steeping with sulphur dioxide improves the fermentation by enhancing growth of favourable microorganisms, preferably lactobacillus, while suppressing detrimental bacteria, moulds, fungi and yeast. Solubles are extracted Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� and the kernel softens. The kernel swells to more than double size and increases its moisture content from about 15% to 45%.
Germs Separation The soften kernels are broken up in attrition mills to loosen the hull and break the bonds between germ and endosperm. Water is added to assist the wet milling. A good steeping ensures that the germ will be freely released intact from the kernel by a gentle milling operation with no free oil. Oil constitutes half the weight of the germ at this stage, and the germ is easy to separate by centrifugal force. The lightweight germs are separated from the ground slurry by hydro cyclones to remove the prime germ. To complete the separation the product stream with remaining germs is reground by a second milling operation followed by a second hydro cyclone separation, which effectively removes residual germ the secondary germ. The germs are washed repeatedly counter-currently on a three-stage screen to remove starch. Process wash water is added at the last stage. Fine Grinding & Screening After germ separation the mill flow is finely ground in impact or attrition mills to release starch and gluten from the endosperm cell walls (fibers). The degerminated mill starch leaving the fine mill is pumped to the first stage of a fiber washing system, where starch and gluten is screened off. The overs, hull and larger fibers, are washed free from adhering starch and gluten (insoluble protein) on screens in counter-current with process wash water added at the last stage. The last fiber washing stage has a slightly courser screen for predewatering the fiber prior to a tapered screw press. The throughs (fine fiber) of that
screen
are
separately
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dewatered
on
a
rotating
screen.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� Starch & Gluten Separation Crude starch milk from the dewatering screen ahead of the fine mill and from the first stage fiber washing is combined. The crude starch milk contains starch, gluten, and solubles. It is fed to a primary separator via a safety strainer and a de-gritting cyclone. The difference in density makes it possible to use centrifugal force for continuous separation. Gluten enters into the overflow and starch enters the underflow.
Starch Refining Washing with fresh clean water refines the crude starch milk. With hydro cyclones it is feasible to reduce fiber and solubles including soluble protein to low levels with a minimum of fresh water. To save water the wash is done counter currently, i.e. the incoming fresh water is used on the very last step and the overflow is reused for dilution on the previous step, and so on.
By using multi stage hydro cyclones all soluble materials and fine cell residues are removed in a water saving process. Increasing the number of hydro cyclone refining steps may accomplish considerable water savings; which is one of the advantages of using hydro cyclones. The refined starch milk contains an almost 100% pure starch slurred in pure water. The overflow of the first washing stage contains mainly protein, some starch and other impurities, which
are
recycled
to
the
primary
separator.
In the strong gravitational fields of a hydro cyclone and a centrifuge, the starch settles quickly. Refining is based on the differences in weight density between water, fibers and starch. Although some impurities go with the starch in the underflow, there is - by means of a sieve - a last chance to remove the larger particles. Impurities not removed this way are not removable by any known technique. Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
COMPANY PROFILE INTRODUCTION:
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” Riddhi Siddhi Gluco Biols Ltd is the starch and glucose manufacturing plant of the Riddhi Siddhi Group. It was started on 26 th January, 1996. It is the largest wet milling plant of the Indian Sub Continent having the highest crushing capacity with mills located at prime locations – Gokak (Karnataka), Viramgam (Ahmedabad) and Pondicherry. It has a distribution throughout the country. The company has been promoted by a team of starch professionals with experience of more than 5 decades in the starch industry. The company has also the largest capacity in India for manufacture of maize based starches industry. Riddhi Siddhi Group has always focused on having the best quality manpower both by attracting outside talent as well as by training and retraining its personnel. This has enabled the company in continuously focus on satisfying customer’s needs by constantly improving the quality of products and services. With personnel having rich expertise in the field of production and quality of service, products of international standards are produced and are supplied to all major institutions in the country. This underlines the organizations ongoing commitment and quest for quality products and services.
Riddhi Siddhi stands as the largest manufacturing plant. It produces the starch of various types, liquid glucose, dextrose Monohydrate , Malto Dextrin, Dextrose syrup, High Maltose Corn Syrup and the by products like Corn Gluten meal and Enriched fiber which are used in various applications catering to different industries of Food, Textile, paper, Pharmaceuticals, Confectionaries and many more. They have a proven track record of fully understanding customers’ requirements so that their team can tailor various products to suit their needs. With adequate capacity for manufacture of all finished goods and by products, the company has vast potentials to export goods to all the neighboring countries like middle east, South East, Bangladesh, Srilanka, Nepal to name a few.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
MISSION Riddhi Siddhi Gluco Biols ltd is dedicated to providing its products that combine quality performance and customer satisfaction. We wish to establish a successful partnership with our customers, our employees, and our suppliers that respects the interests and goals of each party.
QUALITY OBJECTIVES. The following are the objectives of the company:• To reduce non conformities in process. • To reduce customer complaints. • To enhance customer satisfaction. • To achieve on time deliveries. • To achieve zero breakdown.
OPERATIONS RSGBL has three manufacturing units viz, a) Ahmedabad b) Gokak c) Pondicherry
a) Ahmedabad unit :The first manufacturing unit of the company is in Ahmedabad, which is one of the industrialized cities of the country. Ahmedabad is the Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” commercial capital of State of Gujarat with all infrastructure facilities for Rail, Road & Air Travel. The International Airport is also well connected to all important domestic cities. This unit was strted in 1994 with an initial capacity of 15469 tpa at a total project cost of Rs.649 lacs During the year 1995 the company implemented forward integration programme to manufacture 8550 of value added derivative at a project cost of Rs.428 lacs. This is also the registered office of the company.
b) Gokak unit:It is uniquely placed with the advantage of being in the heart of the maize growing region. The Gokak unit is located 75 kilometers from the District Headquarter town of Belgaum. This location is considered to be ideal being close to the river Ghataprabha for the water requirement and only 2 kilometers from Gokak town for availing of infrastructure facilities so it is located in an ideal location from raw materials, manpower, transportation and environmental conditions point of view. This unit has crushing capacity of 800 tonnes of maize per day which is the highest among the other 2 units. The monthly average turnover is Rs. 4 crore.
c) Pondicherry unit:This is the third unit of the company. It has been acquired by the company recently. This unit manufactures only the Modified Starch.
State
of
Art
of
technology:
Riddhi Siddhi Gluco Biols Ltd has adopted a contemporary state – of – the – art technology for the entire plant. Equipments are procured from world renowned manufacturers in Europe and U.S.A. Process control is PLC based with online instruments. Appropriate steps have Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” been taken for energy conservation measures. With good process control and uninterrupted operation – consistentancy of good quality of the product is ensured.
HISTORY
The history of Riddhi Siddhi Gluco Biols Ltd. (RSGBL) is the one, of innovation and adventure of risks taken and bold decisions made. The seeds of this successful corporate conglomerate were sown in 1990 in the name of Riddhi Siddhi Chemicals Pvt Ltd. In March 1992 the name was changed to Riddhi Siddhi Starch Chemicals Ltd. on the day of March 1992. What followed was an Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” unmatched
series
of
innovations,
achievements
and
accolades.
K.G.Gluco Biols Limited (KGGBL) was incorporated in 1987 being promoted in joint sector by Glaxo India ltd and Karnataka State Industrial Investment and Development Corporation (KSIIDC) for setting up an integrated maize processing unit at Gokak in Belgaum district which comes in ‘B’ category backward area. The project was initially appraised in 1987 with an estimated cost of Rs. 23,000 lakhs. It was estimated that the project would commence by January 1, 1989. But the project suffered time and cost overturn due to inadequate project planning and implementation. The project was reappraised in August, 1990 and the cost was estimated to be Rs.3, 101 lakhs. It was estimated that its processing capacity would be 50,000 t.p.a (tonnes per annum) (i.e. processing of maize into its derivatives.) But in actual the plant could only process about 23,000 t.p.a. Thus due to delay in project implementation, cost overturn, cash losses and industrial bottlenecks KGGBL’s project had been over capitalized and became unviable and the company could not stabilize its plant capacities on account of technical problems, as a result, its capacity utilization was below its break even level which resulted in continuous cash losses and the company was closed. KGGBL made a reference to the board for determination of measures to be adopted in respect of the said company. After enquiry it was held that the company had become a sick sick industry according to section 3(1) of Sick Industrial Companies act and ICICI was appointed as an Operating Agency.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� The Operating Agency was therefore directed to advertise in the news paper for locating an alternate promoter. In response to the advertisement, three proposals were received by the Agency. Out of which Riddhi Siddhi Starch and Chemicals Ltd (RSSCL) was considered the best. The major milestones in the history of RSGBL, At a Glance
1993- 94 Commenced manufacturing operations at Viramgam (Ahmedabad).
1994- 95 Liquid Glucose Plant at Viramgam (Ahmedabad).
1995- 96 Acquired K.G Gluco Biols Ltd., Gokak. (Glaxo KSIIDC)
1996- 97 Addition of Starch Drying facility at Gokak.
1997- 98 Stabilization and balancing of Operations at Gokak.
1998- 99 Increase in capacity of Maltodextrine at Gokak.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
1999- 00 Addition of Dextrose Syrup and increase in capacity of Dextrose Monohydrate and Liquid Glucose.
2001- 02 Implementation of 6.2 MW Captive Co-generation Power Plant.
2002- 03 Expanded Crushing Capacity of Gokak plant to make it India's largest Corn Wet Milling Plant.
2003- 04 Addition of High Maltose Corn Syrup plant at Viramgam (Ahmedabad)
2004- 05 Capacity enhancement of Liquid Glucose plant at Gokak.
2005- 06 Acquisition of Biopolymer Division from Hindustan Lever Ltd at Pondicherry. Further expanded crushing capacity of Gokak Plant from 500 Tpd To 750 Tpd Roped
in
Roquette
Freres
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of
France
As
the
strategic
investor.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” In march the company received most prestigious ISO 9001-2000 certification.
The company got One Star Export house accredition.
DEPARTMENTAL STUDY Riddhi Siddhi Gluco Biols Limited Gokak unit is a spread over the area of 105 acres and is very well managed unit. In all there are totally 12 departments:• Personnel department. • Purchase department. (Chemical). • Purchase department. (Maize). • Production department. • Quality Assurance & Quality Control department. • Accounts/ Finance department. • Marketing & Logistics department. • Stores
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” • Maintenance mechanical. • Maintenance electrical. • Effluent Treatment Plant. (E.T.P). • Water Treatment Plant. (W.T.P).
1) PERSONNEL DEPARTMENT The department which is considered as heart of the organization is the personnel & administration department. This department is headed by Mr. U. S. Bhatt. Function: 1. The personnel affairs and services of the company are conducted by an adequate with authority & responsibility delegated as necessary to stimulate
maximum
performance
and
individual
initiative
&
development. 2. Special assignments from the executive director or general manager are carried out and necessary actions are taken or specific recommendations and complete the assignment in time. 3. Collective bargaining and labour contract administration develop a mutually advantageous relationship with employees along with wage and benefit, cost and labour management practices which compare favourably with the industry. Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
4. Office services, maintaining personnel records of the employees. 5. Salary and benefit administration. 6. Induction of new employees. 7. Represent the company union or government officials or local VIP’s. 8. Framing new or revised personnel policies if necessary. 9. Handling of personnel problems and grievences. 10. Administration
of
Disciplinary
action
against
misconduct
and
absenteeism. 11. Maintains statutory records & registers, preparing monthly attendance report. 12. Supervising of security arrangements. 13. Arrangement of contract labourers. 14. Administration of welfare activities, farm and garden developments. 15. Distribution of stationary materials to all the departments whenever necessary. 16. Administration of recruitment.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� 17. To improve employee morale & inter personnel relation. 18. To develop performance appraisal system. 19. To develop competent work force. 20. Handling industrial disputes like labour unrest, conciliation strikes, lockouts etc.
Welfare facilities 1. Canteen facilities: The company provides food and tiffin to its employees at subsidized prices. The employees get free tea thrice in the day. The company charges Rs.12 for food to visitors. 2. uniforms & shoes: The company provides uniforms & shoes to every employee once in a year. It also provides washing allowances. 1. functions : The company arranges functions on national holidays and festivals. It conducts sports on these days. The winner gets rewards as books, home appliances & certificates. 2. ESI and PF : The company provides ESI benefits under ESI Act. The company also provides PF to all its employees. 3. Safety facilities : Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� Te company provides fire extinguishers, safety masks, safety belts and fire buckets. All over the pipelines are fixed in such a way as to avoid fire hazards. The first aid facilities are also provided by the company. 4. Others : Company provides other facilities such as rest rooms and guests house. News papers and magazines are kept in the rest rooms.
PURCHASE DEPARTMENT (CHEMICAL) In RSGBL there is a exclusively separate department for the purchase of all the raw materials except maize and stationary materials. This department is entrusted with the work of purchase of all the other raw materials such as chemicals and also all the stationery materials required for the office staff such as paper, files, folders etc. This department place order for the materials at the beginning of every month. PURCHASE DEPARTMENT (MAIZE). The main raw material for any corn wet milling industry is maize/ corn, so in RSGBL utmost importance is given while purchasing maize. For this purpose there is a exclusively separate department for the purchase of maize. RSGBL has got a very good network and contacts for the supply of maize, so they never face the problem of shortage of raw materials. Functions 1. The main function of this department is place order for the maize as per the monthly requirement after consulting the production department. Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
2. Entering annual agreement with the sellers, traders and the farmers for the supply of maize. 3. Checking the quality of the maize once it is brought to the factory. 4. Supervising the unloading and proper storage of the maize.
PRODUCTION DEPARTMENT As the name suggests this department is entrusted with the work of converting raw maize into variety of finished products and various derivatives. There are two sections, one is starch section and the other is derivatives section. Starch section converts raw maize to starch slurry as main product and other bi products. The second section takes starch slurry and converts it into finished products namely DMH, MD, LG, Glucose-D etc. The company produces the products customers’ specifications. The following is the maximum production capacity per day of main products:PRODUCT
DAILY PRODUCTION CAPACITY
STARCH LG MD DMH
(TONNES) 330 120 45 50
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
QUALITY CONTROL AND QUALITY ASSURANCE DEPARTMENT The company produces the industrial products i.e. the products which are not the finished products to the final consumers. These products are used in food industry and pharma industry so it becomes very important to maintain the quality of products.
So this work is looked into by the quality control and
quality assurance department along with marketing department after getting specification from the customers. There are three labs under this department. One is for testing of raw maize and starch, second is for derivatives. These two are for process control. the third is for quality assurance and microbiological lab. Functions: 1. To check all incoming raw materials and chemicals. 2. Checking of Online control parameters at a regular interval of one hour. 3. Taking care so that the below standard products do not reach the customers. 4. Taking necessary measures to improve the standard of quality of the Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� finished products. 5. If the quality of the product is lowering, different steps are taken to check the deviation using different chemical treatment. 6. To suggest methods and means of reducing manufacturing faults. FINANCE DEPARTMENT Finance is the life blood of any organization, as it is required for all the activities. The following are some of the functions of this department. 1. Collection of funds from the parties as on the due date. 2. Proper utilization and allocation of funds. 3. Making payments to the parties from whom the raw materials, stationary and other materials are purchased. 4. Maintaining an account of salary of all the employees. 5. Preparation of report of all those customers from whom the amount is due. 6. Providing advance to the transporters. 7. Providing traveling expenses to all those staff/ marketing executives who represent the organization in any business meetings or deals. 8. Preparing the excise report of all the abroad sales. Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
9. Preparing the daily sales report.
MARKETING DEPARTMAENT The marketing and logistics department is headed by Mr. R.S.Srinivasan. But the Gokak unit is headed by Mr. S.G. Joshi (DGM Marketing). The company has its marketing offices in Ahmadabad, Banglore, Delhi, Mumbai, Pondicherry and Chennai from where the regional marketing executives send orders to both the manufacturing units. The marketing executives in each office are assigned with certain area and certain specific parties. So it is the responsibility of these executives to get the orders from the parties. There is a specific format of sending the dispatch instruction, in which all the specifications of the customers is filled in and it is sent through mail or fax. These dispatch instructions are then given to the production department with the instruction of keeping them ready on a specific date. Then on the scheduled date the Transport officer makes arrangement for the dispatching of the consignment to the parties. The fixing of freight as per the market conditions is also the responsibility of the Transport officer. When the marketing department gets the approval of the Quality assurance department as to the quality of the product then y\the vehicle is sent to the loading point. Here the product is loaded under the presence of dispatch staff and Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” it is covered with tarpaulin sheets. Then the weighment is made at Weigh Bridge. Then the 4 copies of invoice are prepared. Out of which original is parties’ copy one is for accounts department the third one is a excise copy and last one for the marketing department.
FUNCTIONS:1. To analyse the demand for the product. 2. To take all necessary sales promotional activities. 3. To make arrangements for transport. 4. To maintain good and cordial relation with the transporters. 5. To get the orders from the customers. 6. To send the samples of the products to the customers. 7. To prepare the loading slip, invoices and LR. 8. To enter into periodical agreements with the transporters. 9. To help the accounts department in preparing excise report. 10. To help the transporters in getting advance from the accounts department. 11. Getting the schedules from the marketing executives daily for sending the Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� consignments. 12. Addressing the complaints of the customers if any. 13. Keeping an account of specifications of products given by different parties, and instructing the Production department to keep that product ready for dispatching on time. STORES DEPARTMENT There are totally three stores in the company. One is for storing of purchased goods i.e. stationery materials electrical goods etc. second is for storing of finished goods (main products). Third is for storing of derivatives. Sometimes the company also takes help of local warehouse for storing of its materials. MAINTENANCE MECHANICAL As the name suggests the work of this department is to supervise the working of all the mechanical devices and looking after the repairs of all the devices. It is also the duty of this department to see that the machines are not overloaded and they do not break down. The oiling and greasing of all the devices is also done by this department only. MAINTENANCE ELECTRICAL As the name suggests the work of this department is to ensure that all the electrical devices are properly maintained. And even the periodical inspection of all the electrical devices is made by this department and if necessary replacement of devices is also done.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� EFFLUENT TREATMENT PLANT. (E.T.P). Riddhi Siddhi Gluco Biols Limited is very committed towards protection of environment. It is their constant endeavor to improve and sustain the natural environment around them. For the same reason the company has kept a separate department. This department monitors and ensures that it does not go beyond statutory limits. For this purpose they have installed electro static precipitator to control air pollution. They also have a well established Laboratory which routinely monitors the pollutants and control measures. They check domestic effluents on weekly basis. WATER TREATMENT PLANT:Water and wastewater management is given utmost importance by the management. So they have a separate department. This department takes care that all treated water from Effluent Treatment Plant is used within their process and further the treated water is also used for tree.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
The products: RSGBL stands as the highest starch producing company in India. It is facing stiff competition from many companies some of them are Anil Products Ltd, Maize products, Gujrat Ambuja Exports Ltd, Sayaji industries Ltd, Shubham Starch Chem Pvt Ltd, Sukhji Starch Chemicals Ltd & Universal Starch Chem Allied Ltd. The company manufactures nearly 14 products out of which 6 are main products and 8 are bi products.
Main products:• Dextro Mono Hydrate. (DMH). • Dextro Syrup. (Dex-S). • Glucose D. (Gl-D). • Liquid Glucose. (LG). • Malto Dextrine. (MD). • Maize Starch Powder. (MSP).
Bi products:• Corn Steep Liquor. (CSL). • Dust. • Fine Fiber. (FF). • Enriched Fiber. (Fiber (E)). Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
• Germ. • Gluten. • High Maltose corn Syrup. (HMS). • Maize Husk Wet.
Product flow diagram:-
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
Liquid Glucose & High Maltose Corn Syrup Liquid Glucose is a mixture of Glucose, Maltose and Maltodextrin and Oligosaccharides. It is a colorless, odorless, viscous sweet syrup, mainly used in confectionery and pharmaceuticals industry as a sweetener and bonding agent. It is a combination of mono, di, tri, penta and higher saccharides. High Maltose Corn Syrup is a specially prepared acid-enzyme converted corn syrup which contains maltose as its major carbohydrate constituent. This high maltose syrup improves flavor, body, and texture at high sucrose replacement levels while imparting resistance to color formation, moisture absorption, and crystallization in finished products such as hard candies. It produces finished products which have exceptional stability, clarity, and brilliance.
Maltodextrin Maltodextrin is a starch hydrolysis product ranging up to 20 DE. The main characteristic of this carbohydrate is that it provides body to a food product without appreciably increasing the sweetness while retaining the calorific value. Another characteristic of Maltodextrin subject to medical confirmation is that this carbohydrate is more easily digested and more easily tolerated by the diabetic persons. It is aloes used as base in preparation of food products such as health drinking, soups Milk shakes etc.
Dextrose
monohydrate
Dextrose Monohydrate is commercially produced by enzymatic hydrolysis of starch. It is a white free flowing crystalline powder. DMH find applications mainly in the manufacture of instant energy drinks and Pharmaceuticals Fermentation stage of manufacturing of anti-biotic its uses are many and varied. From the food industry to the pharmaceutical industry and from cattle/poultry feed to industrial applications.
Glucose-D Glucose-D is manufactured by blending Dextrose Monohydrate with tricalcium phosphate, di-calcium phosphate and vitamin D3. Glucose-D is used as instant energy beverage.
Dextrose Syrup Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� Dextrose syrup is commercially produced by hydrolysis of starch and through enzymatic process. Dextrose Syrup is extensively used in breweries and fermentation process (fermentation process is widely used in pharmaceuticals industries for manufacturing antibiotic drugs and penicillin).
Maize Starch Starch is a carbohydrate which occurs in all vegetable matter and is found in commercially recoverable quantities in Maize, Tapioca, Potato, Wheat, and Rice. MAIZE STARCH is a white or creamy powder having various direct and indirect applications in industries. Starch can be modified to suit individual requirement of the users and such starches are known as chemical starches/Dextrin. The maize starch finds application in different industries as a binder, stabilizers, yarn sizing, thickening and suspending agent, viz. textile, paints, detergent, paper, ceramics, pharmaceuticals etc. besides such direct industrial application of starch, it is also converted into a range of starch derivatives, viz. Liquid Glucose, Dextrose Monohydrate, Dextrose Anhydrous, Maltodextrin, Sorbitol etc., all of which find application in the food processing and pharmaceuticals industries.
Native Starch This grade of Native Starch is processed and recovered from selected hybrid corn varieties available in plenty in the proximity of this plant. Choosing right corn variety and quality ensures the finished product namely Native Starch with low ash content and high brightness desirable for the users in the food, pharmacy, paper industries, etc.
Modified Starch The company has a range of Modified Starches, either they are chemically modified and or physically modified. In the range of chemically modified starches the company has various grades of Thin Boiling Starches, Etherified Starches, Cationic Starches, etc, finding customer specific applications in the textile and paper industries.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
Co – Products Corn Germ / Oil Corn germ is a byproduct of the industrial processing of corn, with excellent properties as a cooking media. From corn germ which is rich in oil (45 - 50 %), corn oil of high quality is extracted. Investigations have shown that the use of corn oil decreases the level of coronary diseases. Corn oil can also be used in the production of margarine. CORN GERM/OIL CAKE is used as an additive in cattle feed where it specifically increases the productiveness of animals.
Corn Gluten In corn, the protein content generally ranges between 60 and 70 %, and these are mainly readily digestible proteins which make CORN GLUTEN a valuable ingredient in poultry feed. Besides in vitamins (xanthophylls and carotene), CORN GLUTEN is also rich in essential amino acids, playing thus a significant role in growing poultry. It can also be used in the foodstuffs industry
Corn Fibre CORN FIBRE is mainly rich in cellulose, but also in mineral matters, vitamins and fats, being thus a valuable ingredient in cattle feed, particularly for the animals with the shorter digestive tract.
Corn Steep Liquor The 48-50% of dry substance content in CORN STEEP after evaporation is corn steep liquor. This product is rich in soluble proteins, vitamins and lactic acid, which make it valuable. It is used as a culture medium in the production of antibiotics, vitamin B-12, lysine, yeast (for bakery, brewery, cattle). It is a high quality additive to cattle feed.
APPLICATIONS
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” Riddhi Siddhi Gluco Biols Ltd has a unique advantage of multi-location unit and with Corn as the single raw material they are into manufacturing of a variety of products having a wide application in various industries. PRODUCT APPLICATION CHART.
The following are the areas where the RSGBL products are used.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
Paper
Food
Industry
Industry Textile
Other
Pharmaceutical
Industry Industry
PAPER INDUSTRY
Maize Starch is widely used in surface sizing to enhance appearance and has the ability to increase paper strength and stiffness. Both native and modified starches like Thin Boiling Starch, Oxidised and Esterified starches have multiple applications in the Paper Industry.
TEXTILE INDUSTRY
Maize starch is of paramount importancein the area of sizing, finishing and printing in the textile industry. It gives strength to the yarns minimizing breakage and increasing weaving efficiency. It also Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� imparts stiffness to the fabrics. Modified starch is also used as a printing thickener in yhe textile industry. It also ensures smoothness and consistency to the cloth. It is stable in alkaline conditions hence helpful in preparing rapidogen dyes.
FOOD INDUSTRY Maize Starch It is a cereal starch with
optimum
viscosity and hence is widely used in various food industries. basically thickening
It
is
used
for
sauces,
pudding and gravies. It is also used in bakeries
and
for
preparing ice cream cones.
Liquid Glucose & High Maltose Corn Syrup LG & HMS not only prevent sucrose crystallization but also imparts a smooth texture and hence is used in ice cream by replacing cane sugar which is susceptible to crystallization. Large amounts of liquid glucose are used in commercial bakeries for pie and cream filling. Here, liquid glucose provides body bulk sweetness and also helps keep the finished products soft. Liquid glucose acts as a base or principal ingredient for a number of house hold syrup
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� like products, for e.g. honey. Besides being used as a sweetener in confectionery products, Liquid glucose also helps control crystallisation and improves the texture. Various grades of high maltose corn syrup find special applications in making deposit candies or brewer syrup. Dextrose Monohydrate It is used in jams and jellies to preserve and control sucrose crystallization, body appearance and osmotic pressure. Use of DMH in ice creams is preferred as it provides better 'melt down' characteristics, improves body and 'mouth feel' and provides a balanced sweetness. It is also used in the manufacturing of syrups as it is an effective replacement for non-fat milk solids. Moreover, DMH also increases the shelf life of canned food products. Maltodextrin It is used as a starch replacement in baby foods as it digests more easily. In infant cases having impaired carbohydrate digestion, it is used in place of lactose to adjust the carbohydrate content of diluted cow's milk to match that of human milk. It also has a application in the manufacture of deictic foods, ice creams, frozen fast foods and many other food processing industries. Maltodextrin also acts as a baking agent and viscosity modifier to control moisture and therefore increase storage stability of processed foods.
PHARMACEUTICAL INDUSTRY Pharmaceutical starch It is used in the tablet coating and drug formulation amongst other applications in the pharmaceutical industry. Liquid Glucose Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” It is a mixture of glucose, maltose and maltodextrine. Liquid glucose is an essential ingridient in the manufacture of variety of syrups, antacid suspensions and other mixtures as it has an unique property of balanced sweetness while imparting body and consistency.
Dextrose Monohydrate (DMH) It works wonders as a source of energy because unlike cane sugar, DMH easily assimilates without inversion. This special property allows for its use as an effective tablet binder and in the manufacture of intravenous injections. DMH is also widely used in antibiotics. Corn Steep Liquor It plays a vital role in the pharmaceutical industry in the manufacture of antibiotics like Penicillin G, Aureomycin or Inositol due to the essential ingredient – phytin. In some medicines this product acts as a lipotropic agent. Dextrose Syrup It is widely used in the manufacture of antibiotic drugs and Penicillin.
OTHER INDUSTRY
Other products like Maize Germ are a rich source of corn oil; a popular cooking medium. Gluten is a rich source of protein and is used in Poultry feed as it contains 65% protein. Dextrose Monohydrate is useful in cattle and poultry
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” feeds as it activates weight increase in animals and table birds. Liquid glucose is used as anticaking agent in shoe polish. It also gives softness and weight to leather.
ANALYSIS TABLE NO. 1 OVERALL PERFORMANCE ON TIME DELAYED CONSIGNMENTS CONSIGNMENTS MAY 915 (71%) 381 (29%)
TOTAL CONSIGNMENTS 1296
JUNE
1092
780 (72%)
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312 (28%)
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
From Table no.1 we can come to know that the total number of consignments sent by the company during May is 1296 and during June is 1092. The main cause for decrease in the number of consignments during June is rain. Due to heavy rain during some of the days in June the company could not load the goods. But still when we see percentage wise, there is little improvement during June despite of rain.
TABLE NO.2 ANALYSIS OF NORMAL V/S ABNORMAL DELAYS TABLE OF NORMAL V/S ABNORMAL DELAYS ABNORMAL NORMAL DELAY DELAYS MAY 116 (31%) 265 (69%)
TOTAL 381
JUNE
312
70(22.5%)
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242 (77.5%)
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
The Table no. 2 shows the comparison between normal delay and abnormal delays. Here normal delays refer those delays where in the consignments are delayed by 1-2 days. Such delay is considered as normal because it is an accepted level of delay. It can be improved. And abnormal delays refer to those delays where the consignments were delayed by more than 2 days, this can not be taken as acceptable delays. The main reason for normal delays is , receiving the schedule within a short notice of time. From this table it is also clear that during the month of June the abnormal delays were more than that of May, the main reason for that is rain and another reason is that, during the month of June there was a huge demand for DMH & LG due to which the company could not send the some consignments. TABLE NO. 3 ANALYSIS OF REASONS FOR DELAY REASONS FOR DELAY MATERIAL
MAY 152(40% )
JUNE 130 (42%)
VEHICLE
212(56% )
154 (49%)
MANAGEMENT TOTAL
17(4%) 381
28 (9%) 312
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
By referring to the Table no.3 we can understand that there are mainly 3 reasons for delay in sending the consignments on time, viz, • Material • Vehicle • Management
1) Material Delay due to material refers to:A) Non availability of finished goods. B) Non availability of finished goods of specified details. C) Receiving of excess DIs in relation to daily plant capacity. 2) Transport:Delay due to transport refers to:A) The company is not having its own transportation facility. So company has to completely depend on outside transport companies. B) 0Non availability of vehicles for going to specific place. Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� C) Shortage of vehicles during month end. D) Shortage of vehicles during market days. E) Non availability of vehicles due to some reasons such as hike in diesel prices, transporters were demanded higher prices during May& June. 3) Management:Delay due to management refers to:A) Usually company enters into agreement with the parties to send the materials only after getting the payment, and if the party fails to send the payment then there will be delay in supplying the materials. B) Delay in delivering the materials due to failure in loading the materials. due to rain. C) Due to some other managerial reasons.
REASONS:A) The main reason for delay in sending the consignments in both the months is transport (which is 56 & 49% respectively); this is because due to sudden hike in diesel prices during May there was a problem in getting vehicles. And during June the vehicles could not be loaded due to heavy rain. B) The next reason for delay is material which is 40 & 42 % respectively in both the months, because there was a sudden increase in the demand of DMH & LG during these two months.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.” C) There is an increase in the percentage of delay due to managerial reasons during the month of June (i.e. from 4 & 9 %), As the management has not provided infrastructural facilities.
TABLE NO. 4 DETAILS OF OVERALL DELAYS OVREALL DELAY IN DAYS 3 to 5 6 to10 >2days days days 49 MAY 116(31%) 71 (19%) (13%) 70(22.5% 58 JUNE ) 63 (20%) (19%)
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11 to 15 16 to 20 More than days days 20days 29(7%) 45(14.5% )
total
31 (8%)
85 (22%)
381
23 (7%)
53 (17%)
312
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
The above table no. 4 shows the overall delays taken place insending the consignments on time, the main reasons for the same are:• Non availability of proper infrastructural facilities. • Non sufficiency of vehicles on time. • Sudden increase in the demand for products like DMH and LG. • Hike in the prices diesel.
PRODUCTWISE ANALYSIS:TABLE NO.5 DEXTRO MONO HYDRATE DELAY FOR DMH IN DAYS 3 to 5 6 to10 >2days days days 5(11% MAY ) 4(8.5%) 10(22%) 9(17% 10(19% JUNE ) ) 9(17%) Babasabpatilfreepptmba.com
11 to 15 16 to 20 more than days days 20 Total 4(8.5%)
5(11%)
18(39%)
46
7(14%)
7(14%)
10(19%)
52
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
By referring to the Table no. 5 we come to know that there is an increase in the overall percentage of abnormal delays during both the months, this is because of sudden increase in the demand for DMH. This is because in addition to their normal applications, DMH was also used in fermentation industry due to increase in the prices of sugar cane. So the company faced the problem of sending the consignments on time.
TABLE NO. 6 DEXTRO SYRUP DELAY FOR DEX-S 3 to 5 >2days days 6(60% MAY ) 2(20%) 2(18% JUNE ) 2(18%)
6 to10 11 to 15 16 to 20 more than days days days 20 total 2(20%)
0
0
0
10
2(18%)
0
1(9%)
4(37%)
11
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
By referring to Table no. 6 we can say that there is not much change in the performance of Dexto syrup as per as the delivery schedule is concerned.
TABLE NO. 7 LIQUID GLUCOSE LG DELAYS (%) >2 3 TO 5 6 TO 10 11 TO 15 16 TO 20 MORE DAYS DAYS DAYS DAYS DAYS THAN 20 Babasabpatilfreepptmba.com
TOTAL Page 47
“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� MAY 17(31%) 16(29%)
7(13%)
3(5%)
2(4%)
10(18%)
55
JUNE 13(29%) 6(13%)
10(22%)
5(11%)
2(5%)
9(20%)
45
By referring to the Table no. 7 we come to know that there is an increase in the overall percentage of normal delays during both the months. During these two months there was sudden increase in the demand for LG, This is because in addition to their normal applications, LG was also used in fermentation industry due to increase in the prices of sugar cane. So the company faced the problem of sending the consignments on time.
TABLE NO. 8 MALTO DEXTRINE DELAY FOR MD 3 to >2days days
5 6 to10 11 to 15 16 to 20 more than days days days 20 total
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� 6(13% MAY ) 7(16% JUNE )
8(18%)
8(18%)
6(13%)
5(11%)
12(27%)
45
10(23%)
7(16%)
7(16%)
2(4%)
11(25%)
44
By referring to Table no. 8 we can say that there is not much change in the performance of Malto Dextrine. Even though this one of the main products, still the demand for this product is not much. During both the months as the demand for DMH and LG was very high, the company gave utmost importance to sending the consignments of those two products, so the delivery of MD went on delaying.
TABLE NO. 9 MAIZE STARCH POWDER
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
DELAY FOR MSP 3 to 5 >2days days 75(50% MAY ) 31(21%) 34(33% JUNE ) 20(19%)
6 to10 11 to 15 16 to 20 more than days days days 20 Total 17(11%) 16(15.5% )
9(6%) 16(15.5% )
6(4%)
12(8%)
150
6(6%)
11(11%)
103
By referring to the Table no. 9 we can say that during the month of May the delay in sending the consignments is more when compared to that of June, this is mainly due to non availability of sufficient vehicles, as the transporters were demanding for higher freights, due to hike in prices of diesel. So while negotiating with the transporters, there was a delay in sending the consignments by 1-2 days that is why the percentage of normal delays is more than that of abnormal delays.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
TABLE NO. 10 BI PRODUCTS DELAY FOR BI PRODUCTS 3 to 5 6 to10 >2days days days 8(11% MAY ) 10(13%) 5(7%) 7(12% JUNE ) 15(26%) 14(25%)
11 to 15 16 to 20 more than days days 20 total 5(7%)
13(17%)
34(45%)
75
10(18%)
3(5%)
8(14%)
57
The Table no.10 shows the overall delay taken place in bi products taken all together. The company usually concentrates much on main products, so these delays, does not make much difference for the performance of the company.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.”
IMPORTANT NOTES:• The above analysis includes the total number of consignments sent and not the total vehicles sent. (In some cases when the quantity demanded by the parties is more, then more than one vehicle is sent). • In the above analysis the consignments of products like fine fiber, gunny bags etc is not considered because they are sent on daily basis. • In the above analysis the scrap transported is not taken into consideration. • Some of the products are used by the company for its domestic products, such consumption is not taken into consideration.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
CONCLUSIONS AND SUGGESTIONS FINDINGS After going through all the above tables, graph and analysis, and during the tenure of the project, as per the observations made the findings are:1. The company is not having its own transportation facilities, so company has completely depended on outside transporters, and the company has entered into agreement with the transporters. 2. The company is not having proper infrastructural facilities for loading the products during the rainy season. 3. Recently the company expanded its production capacity to 750 tonnes per day which was earlier 500 tonnes per day due to increasing demand for their products. But still then the company is not producing to the full capacity as the management has decided to increase the daily production step by step so as to prevent the breakdown of machines. 4. Sometimes when the materials specified by some party is rejected by the quality control department for not bearing some specifications, then, if that product is having specification asked by some other party then it is sold to them. Otherwise the marketing department tries to sell that product to parties at some discounted rates.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� 5. Suppose if any transporter fails to provide the vehicles when required, then the company hires the vehicles of local transporters at market rates and any surplus amount paid by the company to the local transporters is debited to the account of that transporter who has not provided the vehicle. 6. The company evaluates the performance of all the transporters as per the guidelines provided by the ISO. And then decides whether to renew the contract with the transporters or not. 7. During the month ends and market days i.e. Thursday usually the company faces the problem of shortage of vehicles. So the company hires the vehicles from local transporters. 8. Even though the marketing department tries to send the consignments throughout the month but sometimes the company faces problem of overburden of work during last days of the month.
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.�
SUGGESTIONS:After going through all the above analysis, the following recommendations are given:1. The main cause for delays is transportation. The main reason for transportation as the company is not having its own transportation facilities. So it is recommended for the company to have their own arrangements for transportation and not to depend on outside transporters too much or they can outsource the transportation facilities to a well reputed transport undertaking. 2. Even though the efforts are made to get the schedules for dispatch, evenly throughout the month, It was found that, they get cramped during the month end. So the efforts should be made to get the schedules regularly. So all the marketing executives should be instructed to get orders regularly. 3. During the month of June, the company could not send some of the consignments on time. The reason for such delay was that the vehicles were not loaded because there was no proper loading facility in the premises. Hence it is recommended that proper loading facilities should be developed. 4. Efforts should be made keep the orders ready anticipating the demand Babasabpatilfreepptmba.com
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“Study of On Time Delivery of Riddhi Siddhi Gluco Biols Limited, Products.� before hand. 5. Materials should be kept ready, in case of those parties who send schedules at the beginning of the month, so that there is no delay in sending those consignments. 6. The transporters should be informed before hand so that they can provide the vehicles on time. 7. The Pondicherry unit is currently producing only Modified Starch, so it is recommended that the company should start producing other products like Malto Dextrine, Dextro Mono Hydrate, Liquid Glucose, Dextro Syrup etc, in Pondicherry unit , so that the the burden of Ahmedabad and Gokak units gets shared, and even it would help the company to achieve on time delivery of the products.
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