OBJECTIVE OF INDUSTRY VISIT

We visited the Bisleri plant at Andheri (E) on the 29th of September. The main objective of this visit was to observe and understand the overall Operations and Production Process of Bisleri Packaged Drinking Water. From this visit, we understood the following things :1) The important factors which influence the location as well as the layout of the plant. 2) The different stages involved in the production process ie. right from the basic inputs of raw materials to conversion subsystems to the final finished output. 3) The functioning of the different departments in the Plant. 4) The different types of Machinery used in the Bisleri Plant. 5) How to manage the overall Operations of a Packaged Drinking Water Factory.

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PROCEDURE

The Procedure of our Study mainly involved visiting the Bisleri Plant and gaining knowledge First Hand. The main information regarding Operations and Production Process, Plant Location and Layout, Planning involved in Production, Knowledge about the different Departments and the Distribution Network was obtained by visiting the Plant. Also certain information such as About Bisleri and the Packaged Drinking Water industry was obtained from the website.

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‘DEMAND OF WATER WOULD NEVER GO DOWN… & WATER WOULD NEVER BE OUT OF BUSINESS’

Packaged Drinking Water Industry
Water everywhere, not a CLEAN drop to drink! Who would have thought that there will be a day when sanitation of available water would be more of a concern than availability of water itself? Hygiene is of great concern to everyone today, and this is evident with the surging rise in the consumption of packaged/bottled water. India has 16 percent of the world's population, 2.5 percent of the land mass and 4 percent of the world's water resources. These limited water resources are depleting rapidly while the demands on them are increasing. Drinking water supplies in many parts of India are intermittent. Transmission and distribution networks for water are generally old and badly maintained, and as a result, are deteriorating. India is one of the biggest and most attractive water markets in the world. The boom time for Indian bottled water industry is to continue- more so because the economics are sound, the bottom line is attractive and the Indian government hasn’t planned well for utilization of the nation's water resources. Corporate control over water and water distribution in India is growing rapidly: the packaged water business is worth $250 million. Around 1,200 bottling plants and 100 brands of packaged water across the country are battling over the market. Most multi-national (MNC) companies view India as the next big market with a lot of potential and growth possibility. Several MNCs are waiting in the wings to expand a $ 287 billion global water market into India. There is a huge market being exploited by the packaged water industry, and it's growing at 40% per annum. With over a thousand bottled water producers, the Indian bottled water industry is big by even international standards. There are more than 200 brands, nearly 80 per cent of which are local. Most of the small-scale producers sell non-branded products and serve small markets.

From being confined to the uppermost echelons of society, packaged water has now become a commonplace commodity and almost a necessity in metros. After witnessing historic growth in recent years, it has become a Rs 3,000-crore industry, one that is slated to only post healthy growth rates to become a Rs 10,000-crore business in just three years, The bulk water industry, or water in 12-, 20- and 25-litre packages, has also witnessed a parallel growth of Rs 700-1,000 crore. Basically, the market can be divided into two segments — the retail consumer market where the pack sizes are 500 ml, one litre, 1.2/1.5/2-litre and five-liter, and the household and 3|Page institutional market, where the pack size is usually are 20- or 25-litre. The Bureau of Indian Standards (BIS) is the governing authority on all quality and production regulations related to natural mineral water as well as packaged drinking water.

Future Growth Prospects for the Industry:
The industry’s phenomenal growth in recent years can be attributed to rising incidence of waterborne diseases, improper municipal supplies, and evolved health consciousness of people as well as globalization, which has brought in tremendous tourist inflow. The industry growth rate is 40-50 per cent a year, but India is still behind countries such as Indonesia, Malaysia and Singapore, where the industry is already worth Rs 15,000-20,000 crore. These countries have much smaller population but similar climatic conditions. If we consider these data as a base for future potential, then the growth prospects of Packaged Drinking Water in India is high. The Indian market currently has more than 2,000 players, the main brands controlling the market are Bisleri International Pvt. Ltd., Himalaya Mountain Water, Pepsi’s Aquafina, Coke’s Kinley, Kingfisher, SAB Miller’s Royal Challenge, besides local players such as Sabol. With better knowledge of packaged drinking water, brands such as Bisleri Mountain Water, Evian of France, Himalayan of North India and Blue Mont from the South are trying to create a niche in the premium water segment of “mountain spring water,” which comes under the natural mineral water specifications of BIS.

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The company is planning to set up four more plants. Presently Bisleri has 8 plants & 11 franchisees all over India. In 1969 & started bottling Mineral water in glass bottles under the brand name 'Bisleri'. Overwhelming popularity of 'Bisleri' & the fact that it has pioneered bottled water in India. 6|Page .ABOUT BISLERI: Mineral Water under the name 'Bisleri' was first launched in Mumbai in glass bottles in two varieties . Parle bought over Bisleri (India) Ltd. Since 1995 Mr.. This company was started by Signor Felice Bisleri who first brought the idea of selling bottled water in India. Later Parle switched over to PVC non-returnable bottles & finally advanced to PET containers. Their presence covers the entire span of India. When you think of bottled water.bubbly & still in 1965 by Bisleri Ltd. Bisleri commands a 65% market share of the organized market. has made it synonymous to Mineral water and has made it a household name. a company of Italian origin. . you think Bisleri. Ramesh J. Chauhan has started expanding Bisleri operations substantially and the turnover has multiplied more than 20 times over a period of 10 years and the average growth rate has been around 40% over this period.

water from the foothills of the mountains situated in Himachal Pradesh & Uttarakhand.5L 2L Returnable Packs— • • 5L 20L Recently Bisleri Natural Mountain Water was introduced .Product Range Bisleri is packaged in: Non-Returnable Packs-• • • • • • 250ml cups 250ml bottles 500ml 1L 1. Hence the product range now comprises of two variants: Bisleri with added minerals & Bisleri Mountain Water. Bisleri also has a marginal share in the Soda segment. 7|Page .

SO WHAT IS AN IDEAL PLANT LOCATION? There are many factors to be considered while deciding the location. LLDPE for the production of caps and PET for the production of bottles. The polymer manufacturing companies i.e. It plays a vital role in deciding the efficiency and smooth running of the factory.PLANT LOCATION Location is the most important factor to be considered while setting up any manufacturing plant. The granules of these are easily available. It varies from plant to plant depending on the sort of unit they are manufacturing. The factors which Bisleri took into consideration are :- 1) Availability of Raw Material :a) The main raw material for any bottling plant is water. 8|Page . CHEMCO and SNJ HYDERABAD have distributors in Mumbai. Hence any company attaches a lot of importance to selection of an ideal plant location depending on its line of business. On the other hand. However there are certain universal guidelines which have to be taken into consideration. a bad plant location may create many obstacles in the manufacturing process. b) The other raw material it requires is HDPE. Hence the company does not rely much on BMC for its water. The location that has been selected has 8 bore wells on site which is enough to supply water for the whole year.

Ltd. gets high rainfall which is essential for the year round supply of water. is located in an industrial area therefore there is abundant power available. Therefore. 3) Availability of power :Bisleri International Pvt. semi-skilled and manual or unskilled labour. Bisleri International Pvt. The factory is located right next to the western express highway therefore making it easier for it to transport the finished goods to the different parts of the city as well as out station. 5) Suitability of Climate :Bisleri is located in Mumbai which is in the temperate zone.a metropolitan city. Ltd. 4) Transport facility :Bisleri has a significant number of trucks (about 10) to meet the delivery needs of the company. 6) Availability of labor :Bisleri International Pvt.2) Nearness to the market :Mumbai is one of the biggest cities in India and the market in Mumbai is very large due to the fact that people here are more hygiene conscious. they have provided a substation to meet the needs of the factory. BISLERI PLANT LAYOUT 9|Page . It has abundant skilled. gets its power from TATA Power. is located in the city of Mumbai. They also hire Eicher trucks in order to transport the finished goods and semi – finished goods within the city as well as out of the state. the temperature is moderate and this area being near the coast. Ltd.

1Litre.Samant Road Dispatching Vehicles Space Administration Office Main Entrance Security Cabin Western Express Highway Laboratory Garden Blowing Wing Stocking and Storage of the Finished Products i. 500ml.e.. 20 Liters Bottles Disinfection of the 20 Liters Jars G Filling Wing Capping Wing Bore well Water Treatment Plant 10 | P a g e .

 The warehouse where the finished goods are stored is located right next to the vehicle pool in order to reduce the time wasted in transporting to the trucks. Therefore sloped entrance and exits are provided.  In order to facilitate the transporting of the boxes from one plant to another there are medium trolleys which have to be manually pushed.ANALYSIS OF THE LAYOUT  The factory has wide doors leading to a raised platform. They are then stored in an accessible place so that they can be taken for further processing. 11 | P a g e . There are small cranes which are used to pick up the lot of raw materials such as pre-forms and caps which are brought by trucks.

A Continuous industry is an industry that manufactures a product of a standard size. 12 | P a g e .INFLUENCE OF CERTAIN FACTORS ON PLANT LAYOUT 1) TYPE OF INDUSTRY:The unique manufacturing processes and the type of industry have a significant influence on the layout of the plant. in this case water. Each of the above industries can be further classified into:1) Intermittent industry 2) Continuous industry Bisleri falls under the category of a Continuous industry. 2) SIZE AND TERRAIN :The size and the terrain of the site determine the types of buildings which in turn. influence the layout of the plant. A Conditioning industry is an industry which is involved in the change of form or the physical properties of a substance. The different types of industries are as follows:1) Synthetic 2) Analytical 3) Conditioning 4) Extractive Bisleri falls under the category of Conditioning industry.

3) The Washrooms for men and women workers are also conveniently located are kept in hygienic conditions 13 | P a g e . 3) There is enough maneuverability for the workers to move about the machines and work comfortably. i. the workers have the following facilities:1) The plant is on the Western Express Highway and is also very close to the Andheri Station. 2) The Canteen for the workers is conveniently located and provides hygienic food. the following factors were taken into consideration while installing the machinery :1) There is enough space for the repair and maintenance of the machinery. This helps in the transportation of semi-finished products to the filler. The terrain of that plot is in the Step Form. The fixed and stationary parts of the machines should also be taken into consideration while designing the plant layout.The Bisleri Plant is located on a large plot. In the Bisleri factory. 2) The machines are placed in such a way that there is enough place for moving and relocation of the machines. Also the fact whether the employees have a job which requires them to sit in one place or move about should be taken into consideration. the full plot is not at the same level.e. In Bisleri. This makes it very convenient for the workers to commune. 3) MACHINERY :The size and type of the machinery to be installed also influences the plant layout. 4) Workers :The layout of the plant should be such that it fulfills the requirements of the workers.

They are as follows :1) The principle of minimum travel 2) The principle of sequence 3) The principle of usage. Along with these factors. This saves time and cost for Bisleri. 14 | P a g e . there are certain Principles which act as guidelines for the layout engineer while designing the plant layout. The Bisleri Plant has installed its Machines in such a way that right from the stage of raw materials to the final finished product there is very little distance for a unit to travel. 4) The principle of compactness 5) The principle of safety and satisfaction 6) The principle of flexibility 7) The principle of minimum investment Out of these the Bisleri Plant follows 2 Principles: The Principle Of Minimum Travel :This Principle states that there should be minimum distance for labor and materials to travel between operations so as to minimize the cost of Materials Handling.PRINCIPLES OF PLANT LAYOUT We have seen that certain factors influence the layout of the plant.

15 | P a g e . all the machines are arranged in a sequence therefore saving time and cost on material handling equipment. The Principle Of Sequence :Machinery and operations should be arranged in a sequential order. In the Bisleri plant right from producing the caps and bottles pre-forms to treating the water to making the bottles and filling and capping it. and efforts should be made to have it adopted in the process layout. This principle is best achieved in product layout.

Materials can account for almost 80% of the output. This starts right from the designing of the plant to the actual production. The Materials which are required by Bisleri are : Untreated Water  HDPE  LLDPE  PET  Recycled PET Granules  Cartons  Stickers 2) Procedure :This step involves designing the most compatible process of production with a given set of circumstances and facilities.PLANNING INVOLVED IN PRODUCTION PROCESS 1) Material :There is no output possible without the basic Raw Materials. 16 | P a g e . Hence Matrials are very important in planning for any production.

assembly.  Moulding machines for making the bottles according to the required size and shape. finishing. The price is printed through a spray gun. 3) Machines and Equipment:The Machinery that is used for production has to be carefully selected as it can result in higher and more efficient output at a lower cost. After the bottle is filled to the desired level.  Automatic fillers for the purpose cleaning and efficient filling of the bottles with least amount of rejection. 17 | P a g e . 4) Routing :The determination of where each operation on a component part. the bottle is automatically capped and then stickers are put on the bottle. The following are the methods of acquiring the machinery:1) Equipments can be purchased fresh or second hand 2) Equipment can be leased or rented 3) Equipment can be fabricated within the plant Machines used in Bisleri are as follows : Injection moulding machines for the production of pre-forms and caps. After that the semi finished products are transported from the cap and pre-forms division to the filling division. A generalized routing can be determined depending upon the size of the building and is established by departments such as machine shop. subassembly or assembly is to be performed results in a route for the movement of a manufacturing lot through the factory.The method for producing packaged drinking water starts with the production of bottles and caps. Then it is visually inspected and after that put into cartons ready for delivery. where the caps are added to the filling machines and the preforms to the corresponding size of the bottle. These bottles are then added to the conveyor belt to complete the process of filling the bottle automatically.

finally ready for delivery.inspection and so on. First comes the semi finished product then it is blown. filled and sealed. Hence. 6) Loading and Scheduling : Bisleri uses both scheduling and loading help in production planning. The plant layout is in such a way that it is easy to transport the semi-finished product. A detailed routing indicates the specific work station or machine to be used for each operation. According to the schedule of the delivery. The route of the production process is designed in such a way that in process. Predicting what a unit of a product will cost is very difficult to do. the trucks are loaded to be sent to wholesalers and retailers. Loading refers to the time gap for various work loads booked in advance for different products. Thus. amount to be delivered and the place they are to be delivered. 18 | P a g e . scheduling guarantees the observation of delivery times and loading guarantees the maximum utilization of the available facilities. Bisleri being an old company is able to estimate the demand because of past experience. They take the help of Market Surveys and past trends to determine the production requirements. transportation is at a minimum. Scheduling refers to the preparation of a time table for various operations covering the beginning and finishing times of various operations. 5) Estimating :Estimating is a special type of Forecasting. many companies have Pre-planning departments to estimate the cost of the products and the demand as well.

100 m. PET.. Mldg. 25 Resources Primary litres and low price Material: - Transportation Exchange Water from bore wells HDPE. Services Wholesaler Refill Other Private Services Personnel: - Plastics Engineering. Kinley etc.l. m/c. auto blow mldg. Market Bisleri Bottles Physical Manufacturing Locational Services Competition with Aquafina.. FDA. Quality Control 19 | P a g e . LLDPE. m/c. Utility Capital Assets: Auto Filling Machine.INPUTS CONVERSION SUBSYSTEM OUTPUT Environment Legal FDA. Production Managers. Blow moulding machine. BIS. BMC Technological automatic inj. recycling machine Control Sub-system Sealed bottle.l. Customer Desire 50 m.

2) Technological : - Bisleri International Pvt. This is the reason Bisleri has automatic Injection Moulding Machine in order to increase their production capacity 3 folds. Ltd believes in keeping up with times and they are trying constantly to increase their market share. Market 1) Competition : - Bisleri International Pvt. 20 | P a g e . comes under the FDA. Recently however. It also follows the standards of BIS. Ltd being a company involved in selling water which is fit for consumption. Therefore it maintains its quality and public perceive the image of being 100% safe. companies like Pepsi and Coco cola have entered the market to give tough competition to Bisleri by introducing brands like kinley and Aquafina.BISLERI’S PRODUCTION SYSTEM MODEL INPUTS Environment 1) Legal : - Bisleri International Pvt. Bisleri already has 2 automatic Blow Moulding Machines. Ltd 1992 at that time Bisleri enjoyed almost a complete monopoly.

3) More options: - Bisleri was the first company in India to increase its products in packaged drinking water ranging from 500ml to 20 litres.2) Customer desire:- Bisleri has become a household name to the extent that people instead of calling it packaged water are calling it Bisleri. The skilled labourers include production and plastic engineers. Conversion Subsystem 21 | P a g e . It has also got 2 plants located side by side for production purposes. 2) Personnel: Bisleri requires mostly skilled and semi skilled labourers. The bottles are made from polymers such as HDPE. 2 automatic blow moulding machines and 4 semi automatic blow moulding machines. Primary resources: 1) Material: The raw water is obtained from bore wells. LLDPE and PET. 3) Capital assets: Bisleri has got 14 injection moulding machines.

1) Physical: Bisleri International Pvt. Quality Control and Quality Standards 22 | P a g e . 2) Exchange services: The distribution network of Bisleri is maintained by its distributors and wholesalers. 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. Ltd is considered to be a manufacturing unit as it manufactures the semi finished product i. To supply to big corporates they have their own distribution network. bottles and caps and also produces the finished products.e.

Acceptance of Scheme of Testing and Inspection (STI) 6. No. follows and conforms to the standards set by the Bureau of Indian Standards (BIS). 8). Tests prescribed by the BIS are conducted daily and weekly on the Bisleri premises while quarterly. Copy of the appointment letter. Undertaking for getting the samples tested as per STI frequency from BIS approved/NABL accredited outside lab. qualification certificates for Chemist and Microbiologist 11. No Objection Certificate (NOC) from the concerned office of Central Ground Water Authority (if applicable in the state). Guidelines for assessment of Hygienic conditions with Explanatory notes for guidance 7. GENERAL REQUIREMENTS General requirements for grant of BIS License B. 10. 4. Containers (including lids/caps) 3. List of BIS approved outside lab for the Product Water.Bisleri International Pvt. List of Indian Standards which a Packaged Drinking Water Industry must have in original 8. Glass wares & Chemicals 2. Sr. REQUIREMENTS TO BE COMPLIED WITH BY THE APPLICANT OF PACKAGED DRINKING WATER FOR GRANT OF BIS LICENCE ACCORDING TO IS 14543:2004 A. Acceptance of Marking Fee 5. Ltd. Details of samples of the product/containers to be drawn during BIS visits. PRODUCT SPECIFIC REQUIREMENTS (FOR PACKAGED DRINKING WATER) 1. 23 | P a g e . List of Test Equipments. Consent letter from concerned outside lab for testing of sample (Ref. half-yearly and even yearly tests are conducted in a separate laboratory. 9.

Detailed Manufacturing process indicating treatment for disinfection along with Process Flow Chart.2 of IS 14543:2004 specifies various processes for manufacturing Packaged Drinking Water for guidance only 13.). using a sampling formula. Details about the arrangements of pest control treatment such as an agreement/contract with the agency.12. IS 14543:2004 and clause 7. RAW MATERIAL ARRIVES SAMPLING FORMULA USED QUALITY CHECK DONE 24 | P a g e CONSIGNMENT ACCEPTED/REJECTED MANUFACTURING DEPT. Clause 3.2 of IS Quality Control Measures at the Inventory level When the raw material like performs are ordered and are subsequently delivered to the plant. Declaration of Shelf-life of the product separately for each type of container (e. Copies of Medical Examination Reports of the employees engaged in washing/filling of the product for any communicable/skin diseases and fitness to work in a food industry. DECIDES . 16. to ensure the quality of the goods delivered. a Quality check is done physically. 20 litre etc. from BARC before submitting the application and test report received from BARC is to be submitted along with the application form.g. otherwise it is rejected and is returned back to the supplier. If they conform to the Quality Standards prescribed. Undertaking Regarding clause 6 (Packing) of 14543:2004 (Labelling Prohibitions) 17. 1littre. 14. Obtain request letter from BIS for getting the sample tested for Radio Active Residues. Also details of Cleaning in Place (CIP) 15. 2 litre. then the manufacturing department gives the ‘go ahead’ and the raw material consignment is accepted.

Preforms Rs. it has consideration levels for rejection of damaged items during the production and manufacturing process. Labels Rs. preforms and bottles rejected in the process. 89. 10.91. Ltd. the cost of rejections calculated in monetary terms for the 8 hour shift was Rs.159.Other Quality Control Measures Leakages in the System : Bisleri International Pvt. For instance a count is kept for the number of caps. 290. Bottles Rs.8% to 0. has standards for leakages in the system.357 Standards for reuse/recycling of bottles : The 20 litre bottles are cleansed and then reused. Caps Rs. i.9% leakages in the system are tolerated. 10. On the day prior to the plant visit.357 broken up as Cartons Rs.e. Approximately 0. Bisleri has certain standards for the reuse of these bottles. If this count goes above a particular level. For instance the bottles are first 25 | P a g e . Total Rs. then the machinery is considered faulty and is immediately serviced / repaired. 9728.

• Overall productivity for a day is maintained at 80% to 85%. • Bisleri maintains a regular sanitation and maintenance record.externally cleansed. Other Methods : • The packed cartons are not placed directly on the floor of the plant. Then ‘jet pressure’ of above 1 kg is used to wash the bottles internally. Also trolleys and carts are used to transfer the cartons within the plant. Ltd. (For the day prior to the plant visit it was 82% productivity) Bisleri International Pvt. If a bottle is unnecessarily touched by human hand. has the following Quality Policy : 26 | P a g e . • There are at least two people appointed to remove defective or damaged pieces from the assembly line • Water wasted during the bottling process is recycled and put to use. • An expiry date is decided for the product so that the desired quality can be maintained. the product is discarded to maintain adequate quality. • Minimal human intervention is involved during the production process. • The mineral water is ozone treated before packaging. However if the bottles do not match the parameters for reuse. then they are rejected and crushed. first with added disinfectant of the desired ppm level and then the bottles are rinsed with plain water. • Workers in the plant are required to wear head masks to avoid contamination of the product. • Daily pest control is undertaken to maintain a clean environment for manufacturing. lest they get damaged and consequently degrade the quality of the product. A record is kept of these bottles.

The quality policy is implemented uniformly across all manufacturing units. The head is accountable for implementation of the quality policy and guidance. The “corporate quality Assurance” will provide necessary support and guidance for up gradation of the procedures and standards. We are committed to implement good manufacturing practices and to achieve continuous improvement in the plant. We will strive to train all our people and develop an obsession for qualtity in all aspects of work in an organization. process and didtribution chain. We ensure full compliance to all government regulatory norms and strictly adhere to the internal standards of quality and hygiene.Quality policy Bisleri commits itself to produce and market a world class product to satisfy the present and future needs. Each and everyone in the organization is responsible for quality. Production System Mass production: - 27 | P a g e .

and. Effects on the organization of work: The development of mass production transformed the organization of work in three important ways: 1. mass-produced goods are standardized by means of precisionmanufactured. in addition to a large distribution and sales force. or at least semiskilled workers. Blowing : 28 | P a g e . The major experiments that eventually led to mass production were first performed under the aegis of the military. the only large-scale demand for standardized. chemists. since much of the skill was built into the machine. although allowing lower prices. interchangeable parts. Mass production requires mass consumption. Until recently. Manufacturing concerns grew to such size that a large hierarchy of supervisors and managers became necessary.Mass Production is the name given to the method of producing goods in large quantities at low cost per unit. Mass production. uniform products came from military organizations. careful supervision of quality standards. Production Process 1. later. The increasing complexity of operations required employment of a large management staff of accountants. 3. Tasks were minutely subdivided and performed by unskilled workers. The mass production process is characterized by mechanization to achieve high volume. elaborate organization of materials flow through various stages of manufacturing. and minute division of labour. does not have to mean lowquality production. engineers. social psychologists. 2. Instead.

After draining.In the blowing department the performs. Bottle Sizes 1 ltr 500 ml 250 ml 1. rinsed and sprayed with ozonated water at 2 Bar pressure. Filling : Preform Sizes 21gms 17gms 15gms 32 gms 34 gms 75 gms 710 gms The filling department is situated in a closed and a controlled environment to maintain the hygiene. which means that every bottle is held by the neck automatically while being inverted.5 ltr 2 ltr 5 ltr 20 ltr 2. RFC equipment is neck run and it boasts of a mono block unit. obtained from the preforms department are blown to form bottles. Bottles are fed by an air conveyor from the blowing unit directly into the infeed of the RFC. At the filler these bottles are straightened up and gradually 29 | P a g e . There are a total of 2 fully automatic blowing machines which are directly connected to the filler. Preforms are available in various sizes according to the size of bottle. the bottles are re-inverted and transferred to the filler.

Since the water is ozonated all product contact parts are of 316L grade stainless steel and the rubber parts are of EPDM. Here ozonated-water rinsed caps are screwed on the bottle with uniform torque. The water dispenser fills the bottle till the desired level of water is filled which is checked by a sensor. after quality testing has been done. to the filling department. first the bottles are passed through UV light to kill the bacteria. then the bottles are filled to the desired quantity. The bottles are directly loaded onto the conveyor belt. 4. Capping : The bottles are passed to the capper from the filler through the conveyer belt. The caps that are produced are automatically packed into cartons. 3. 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 characteristic green colour of Bisleri. The bottles are passed to the capper from the filler through the conveyer belt. All Bisleri bottles are labeled on a hot melt reel feed BOPP labeling machine. Labelling: From the capping section the bottles are directly sent to the labeling section. This semi finished product is transported. then the bottles are cleaned by pure water. The caps are produced in the cap department.lifted to the filling valves which open only when a bottle is placed under them. This machine allows each individual bottles to be spaced out and fed to the labeling station where precisely 30 | P a g e . Filling is then done systematically through gravity.

5. The code exactly contains Date. These labels are fed into the machine in a roll form too. The sensor first senses the bottle and then the price. manufacturing date. Coding : The labeled bottles are then passed to the coder. thus reducing wastages and being environmentally friendly. then the bottles pass through a screen of white light where workers manually check all the bottles for any defects. Technology 31 | P a g e . get rolled around the bottle. 6. All the waste bottles are separated send to the recycling department for recycling where they are cleaned. grinded to a coarse powder which is again used in the manufacturing process. Time and Quality Checkers initials.cut labels with a strip of hot melt glue at the leading and trailing edge. batch number are printed by spraying machine on the bottle itself. Packaging : Lastly they are packed in cartons and stored in the warehouse ready for transportation to its destination.

 Spectrophometer – to check the standards for mineral levels in the water. odour and taste) 5) Visual appearance 6) Packaging 7) Level alignment 8) Torque test ( for capping pressure)  There is a bursting strength unit. It should be neutral.  There is thickness meter to check the bottle thickness. It is to check the carton acceptance capacity.02mg/l Zinc – Zn – 5mg/l Manganese – Mn – 0. • • • • Nitrate – NO3 – 45mg/l Nitrite – NO2 – 0. 6-8 is the normal bearing capacity. The capacity is checked on the meter.  Sample size for water treatment depends on the PH level. Carton is placed and the machine is started.1mg/l 32 | P a g e .8 to 7.Water testing There are 8 Physiochemistry tests performed on the water: 1) pH: This test is performed to check the hydrogen ion concentration in water.2 2) TDS (Total dissolved salts) 3) Turbidity 4) AOT ( Adherence. The pH limit which is accepted is 6.

• • • Calcium – Ca – 75mgl Magnesium – Mg – 30mg/l Sulphide – S .05mg/l All the different machines to the check whether bottles are blown properly or not are “BISLERI PATENTED” 33 | P a g e .0.

Water Treatment Process Diagram 34 | P a g e .

The Carbon Filter removes residual chlorine & odours.WATER TREATMENT Every drop of Bisleri water is purified as per international standards to ensure that Bisleri experience always remains pure and satisfying for longer. Reverse osmosis removes organic material. pressure and water flux rate . retaining the solute on one side and allowing the pure solvent to pass to the other side. The following is a brief understanding of the water treatment process: The Raw water is the Water taken from the 8 bore wells present at the Plant. Ozonization is a process where in Ozone gas is passed through water. Reverse osmosis is similar to the membrane filtration treatment process RO (Reverse Osmosis). 35 | P a g e . This is the reverse of the normal osmosis process. The water is then passed through a Silverization Chamber to give sparkle to the water. Chlorination kills micro organisms and removes organic matter. Controls total dissolved solids in the water.The Ultraviolet chamber helps to cure the bacteria and viruses present in water. which is the natural movement of solvent from an area of low solute concentration. to an area of high solute concentration when no external pressure is applied. through a membrane.It works by using pressure to force a solution through a membrane. however involves a diffusive mechanism so that separation efficiency is dependent on influent solute concentration. After that the water goes through the Sand Filter where the solid wastes are removed. It ensures water remains bacteria free for longer life.

Bisleri’s portfolio includes Bisleri with Added Minerals and Bisleri Himalyan water. 7am-3pm. while the number of trucks averages 300 and 250 in the Mumbai and Delhi market alone. Other plants across the country Bisleri has 52 bottling plants across India and uses state-of-the-art technology at all stages of its purification processes including double ozonisation.000 trucks on call for Bisleri. nearly 5.DISTRIBUTION NETWORK OF BISLERY Our observation of the Andheri Plant What we found from our analysis of the Mumbai plant is that Out of the 3 shifts the factory has i.e.000 retail outlets.500 distributors and nearly 600. 3pm-11pm and 11pm-3am. 2) Bisleri plans to overtake Himalayan. Everyday. the night shift 11pm-3am is used for loading of cartons which carries approximately 40. sweet drinking water to replenish the stocks of 2. at the top end of the market (mountain water) with its 36 | P a g e . . The distribution is done using 80 vehicles and is sent to the 20 distributors in the city who then sells it to the retailers.000 delivery vans drive out of these 52 strategically located Bisleri bottling plants carrying over 1 million units of pure. Future Objectives 1) Bisleri is targeting a 40 per cent growth this year and has outlined an aggressive market penetration strategy which is a dual distribution plan – penetrating newer markets – including townships and rural India which includes smaller and interior markets and aggressively looking at entering newer territories and increasing shelf presence in the metros and existing markets. On a national level. there are 2. It also plans to penetrate every possible segment of the market by introducing more pack sizes and establishing the brand strongly with trendy new packaging.000 litres of water.

UP. the company is expected to beef up its distribution significantly. At present. Karnataka. priced at Rs 20. the company has only one plant in Mumbai. Jammu & Kashmir. Europe. For which it is also investing heavily on vans. which was acquired by Tata Tea last September. A bottle of Himalayan sells at Rs 25 and with Tata Tea taking charge. For which Bisleri began operations at its new mountain spring at Rudrapur in Uttaranchal. since distribution is a key factor in the business and focusing strongly on marketing to key accounts. UAE and Japan by the end of October 2009 for which the water will be bottled at the plant in Himachal Pradesh. Jharkhand and North Bengal states. Tamil Nadu. Kerala. which caters to the city and surrounding markets like Pune. Himalayan. Himachal Pradesh. is the largest player in the natural mountain water category in India. UK. Bisleri is confident that its one-litre bottle. Future projects  The company is setting up dedicated channels for its 20L jars to ensure that every household and corporate gets service at their door step.75 million litres a day. will make an impact in an increasingly health-conscious market.  It is also planning to set up 25 new bottling plants across the country which will be located in states like Maharashtra.  Bislery plans to have six more plants in Mumbai.  The company will start exports to the US. Orissa. with a capacity of more than 0. 37 | P a g e .premium variant Natural Mountain water in six months.

To reduce inventory costs by reducing inventory levels To improve plant operating efficiency by better use of resources. In order to meet its MRP objectives. in the months of March. In other words the availability of dependant materials is managed in order to achieve maximum efficiency AGGREGATE PRODUCTION PLAN FORECAST DEMAND FIRM ORDERS BILL OF MATERIAL MRP INVENTORY TRANSCATION INVENTORY STATUS MRP System Structure 38 | P a g e . May. i. the summer season and October which is the vacation month there is a greater demand of mineral water bottles. April. For Example. the management of Bisleri has scheduling plans at yearly. monthly and weekly levels.. Depending upon the season or the requirement there is change in materials ordered.MRP Objectives of MRP for Bisleri are : • • • To improve customer service by meeting the delivery schedules promised and shortening delivery lead times .e. quarterly.

Human Resources and Customer Relationship Management . Financials. Supply Chain Management. Projects. The ERP system supports all of its business systems maintained in a single database.ERP Bisleri has implemented an Enterprise Resource Planning system called as ‘Navigen’ developed by Godrej which has automated all its functional business systems in terms of information management . the data needed for a variety of business functions such as Manufacturing. Enterprise Resource Planning 39 | P a g e .

Expansion: Bisleri at this particular plant has no space for further expansion. 2. Centralized location: Bisleri’s plant is centrally located & close to the railway station. High Automation: the process used by Bisleri to purify the water is highly automated. Commuting for employees is also easy. Packaged drinking water is synonymous with Bisleri. 7. This results in higher levels of hygiene. Well Known Brand/Goodwill: Bisleri in India has a strong brand value. The shift to the current green label & round bottle from the previous blue label & hexagonal bottle is an example of this. Its market share is 65%. WEAKNESS: 1. The company by continuously working on its brand positioning has capitalized on the first mover advantage. This makes supply of products easy. Due to this it enjoys a distinct identity.SWOT ANALYSIS STRENGTHS: 1. People have strong belief & trust in the purity of Bisleri hence the goodwill that Bisleri has is immense. 40 | P a g e . Bore wells on premises: The plant has 2 Borewells on the premises providing a definitive reduction in costs. 4. 3. was the first company in India to enter the packaged water segment. 6. First Mover Advantage: Bisleri International Pvt. Innovative Brand Positioning: Bisleri at regular intervals modifies its bottle shape & label graphics to counter imitation of the same. Ltd. Huge Market Share: Bisleri has a huge market share in the packaged water industry. 5.

Spring Water: after mountain water it can further diversify into the spring water segment. International standards: The level of hygiene at this plant falls short of anticipated international standards. High level of substitution: Bisleri water can easily be substituted by that of other brands. 3. 41 | P a g e . If water is not wasted in the first place retreatment costs can be avoided. According to surveys conducted the quality of water across the country for the same brand differs. Other competitors like Himalaya have a first mover advantage in this segment 2. Mountain water: Bisleri can try and capture more market share in the mountain water category.2. OPPORTUNITIES: 1. As also different department areas could have been demarcated. 4. This is a huge opportunity because overseas demand for spring water is high due to its medicinal properties. Unorganized Plant Layout: This particular plant of Bisleri could have been more organized. THREATS: 1. 5. 4. Higher Home Consumption: due to higher standard of living & higher health consciousness in India currently. As a long term plan it can also enter the aerated drinks segment. Wastage of water: during the automated process water gets wasted which is then retreated. 2. It can concentrate on expanding the same. Bisleri can try to increase home consumption. Non Homogeneity: The packaged water industry in India is unorganized & non homogenous. Late entry into the mountain water segment: Bisleri’s entry into the mountain water segment has been late and the distribution limited to a few areas. 3. Soda water: Bisleri has a marginal share in the Soda water segment.

Recommendations  Use of vertical space/overhead space for storage of finished goods  The location of raw material storage should be shifted near to the first production process  Ergonomics at the stage of preform being put in the machine for the blowing process  Have safety instructions on machinery  Proper storage of scrap  Should avoid keeping loose and unattended raw material near the machinery  Have mess facilities for workers as well as gaps between shifts  Have more systematic approach towards security of the plant  Workers should be provided with mouth pieces to ensure hygiene during production  Bring in automation in production process of 5 ltr and 20 ltr Limitations 42 | P a g e . 4. Threat from imitators/fakes: smaller players which imitate Bisleri labeling and packaging are a huge threat especially in non metros.3. Threat from smaller players: Smaller players have good sales in non metro & non cosmopolitan cities.

43 | P a g e . Ltd has helped us in understanding various concepts and applications related to Operations Management and its relevance to the organization. This extensive research. review and recommendations provided in the report was a great learning experience for us and we hope to reflect this learning in our future endeavors at work. sand and carbon filtration) relating to the production process  Not having an access to certain areas of the plant ( filling. reverse osmosis. production process of 5 ltr and 20 ltr bottles) where the production process was undertaken  Mismatch of information from the website and from what we gathered from our plant visit Conclusion The research report on Operations Management at Bisleri International Pvt. It also gave us a deep insight into the fact that all these aspects are crucial to the organization. interpretation. analysis. Understanding certain technical aspects (filling.

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