INTERNATIONAL UNIVERSITY

DEPARTMENT OF INDUSTRIAL &

SYSTEMS ENGINEERING

[ INTERNSHIP 1 REPORT ]

Pham Tuan Phat

IEIEIU17021

August 2019
AJINOMOTO
I. Introduction:
Originated from the aspiration of Dr. Kikunae Ikeda to contribute to the improvement of
human life’s quality through food nutrition, Ajinomoto Group was established in Japan in
1909 with the first Umami Seasoning AJI-NO-MOTO. The great ambition of Dr.
Kikunae Ikeda has been developed into the corporate message “Eat Well, Live Well.”,
For more than 100 years, Ajinomoto Group has been continually expanding to become a
global company in a wide range of business domain including Food Products and Amino
Science.
As a member of Ajinomoto Group, Ajinomoto Vietnam was established in 1991 with a
100% Japanese investment capital up to 70 million US Dollars. The company has 3
Distribution Centers in Long Thanh, Hai Duong, Da Nang along with more than 60 sales
depots and nearly 290 sales teams nationwide. There are more than 2,300 employees
working at Ajinomoto Vietnam Company.

Ajinomoto Vietnam Company now has two offices in HCMC and Hanoi and two
factories: The Bien Hoa Ajinomoto Factory operated since 1991 and the Ajinomoto Long
Thanh Factory operated since 2008.

Ajnomoto Bien Hoa ( Produce Factory )

Ajinomoto Long Thanh ( Distribution Center )

 II. Processing of Production:
Sugar cane, a healthy, all natural food is harvested. The cane is transported to the factory
where its juice is extracted. Sugar is separated from molasses. A thick, dark syrup is then
fermented. Fermentation is the same process which is used to produce iru, daddawa,
soya, vinegar, etc. The fermentation process converts the molasses into glutamic acid.
Crytals are formed during a heating and evaporation process. This mixture is then
liquefied so that it can be neutralized and decolorized. Further heating and evaporation
produces the pure
white monosodium Glutamate ( or MSG) crystals. After it’s separated and dried, it’s put
into the famous red and white AJI-NO-MOTO package under hygienic condition
III. Supply Chain:
1. Planning and Development
Product planning and R&D based on the needs of each country.
2. Raw Material Procurement
Ensure the safety and stable procurement of raw materials.
3. Manufacturing
Production of safe and high-quality products.
4. Logistics
 The anchor to deliver the highest quality products to customers.
5. Sales
Information transmission to ensure consumers can purchase products with peace of
mind.
6. Customer Feedback
Improvement of products and services based on customer feedback.

IV. Quality Management:

Established in 1997, ASQUA is the Ajinomoto Group's own quality assurance system. It
is based on ISO 9001, the international quality management system standard, as well as
manufacturing management standards like Hazard Analysis and Critical Control Points
(HACCP), a food hygiene management standard, and good manufacturing practices
(GMPs).The system also incorporates the Group Shared Policy on Quality, Ajinomoto
Quality Assurance Regulations, Regulation for Quality Assurance, Quality Standards,
and other rules and requirements established by the Group or each internal organization.
With ASQUA, the Group carries out painstaking quality assurance activities worldwide,
from the procurement of raw materials to the sale of products, always pursuing even
higher quality manufacturing. Customer requests and expectations are also promptly
utilized to improve products, services and business operations.
ASQUA components
V. Conclusion and Suggestion:
 ACECOOK
I. Introduction:
Since its establishment on December 15th 1993 and official inauguration in 1995,
Acecook Vietnam Joint Stock Company has been constantly developing and becomes a
leading manufacturer of foodstuffs in Vietnam. Acecook Vietnam has attained a strong
position in the market while providing instant processed products with high quality and
nutritional values.

II. Processing of Production:

1. Ingredients
Noodles are mainly made from wheat flour whilst yellow color formed by turmeric
extract.

Ingredients of the seasoning sachets consist of dried vegetables, spices, and refined oil.
Instant cup noodles contain other dried ingredients such as eggs, shrimp, chicken, pork,
etc.
Packets, cups, bowls, and trays are made of materials which are safe for human health in
accordance with Vietnamese and international regulations.

100% of ingredients are strictly inspected, tested and meet the quality standards before
being put into production.

2. Mixing powder
Via an enclosed pipe system, wheat flour and mixture fluid are pumped into the mixer
from the stainless steel container and mixed evenly by automatic equipment.

3. Rolling
After being mixed, the dough is transferred to the roller via the conveyor system. The
noodle belt is pressed gradually by pairs of rough and fined rollers until it reaches the
required elasticity and thickness according to the specification of each type of product.

4. Slittering
The noodle belt is slitted into large, small, round, flat shapes with different sizes and the
typical wavy-shape is formed by the slitter system.

5. Steaming
The noodles are gelatinized and cooked in a sealed steam chamber. The source of heat is
generated from a modern heating system combined with standard pressure setting and
automatic adjustment.

6. Cutting and molding

Passing through the conveyor to the cutter and cutting board, the noodles are cut into
certain length and drop down to the feeder and put into the mold to form the shape for the
noodles. Depending on the types of product, noodles are formed in a square shape, round
shape, or other shapes for cups, bowls, trays, etc.

7. Drying
After being steamed, the noodles are conveyed through a modern drying system to reduce
the moisture of the noodles to the lowest level and to help preserving the product for five
or six months.

There are two drying methods:

1. Hot air drying: for non-fried noodles

2. Oil-frying: for fried noodles

• The oil is heated indirectly by steam (similar to cooking in bain-marie) before being put
into sealed pans system
 • New oil is added continuously with an automatic system

• Oxidation index of the oil is always controlled in accordance with TCVN (Vietnamese
standards) and Codex to ensure that the oil is always fresh.

8. Cooling
With the automatic cooling system utilizing fresh air from the natural environment which
is filtered with modern devices, the temperature of noodles after being dried quickly
becomes normal for packing.

9. Adding seasoning packets

After cooling, seasoning packets of different flavors will be added to the noodle block by
an automatic system.

10. Packing
After adding sufficiently seasoning packets for each product, the noodle block is packed
in films to make a finished noodle packet. The expiry date is printed on the package
during the packing process.

11. Checking quality of product: Weight checking, detecting metal and abnormal
objects
After packing, finished noodle packs shall go in turn through the detectors and weighing
instrument to check for metal and abnormal object and standard weight. Unqualified
packs will be removed from the line.

12. Casing
Finished products are packed in cases in accordance with the requirements of each
product. The case will be printed with manufacture date, stored, and inspected by Quality
Assurance Department before being distributed to the market.

III. Supply Chain:

 Since April 2014, ACV ( Acecook Vietnam ) has applied the SCM software package (L-
Series) named as “Business support system” by NTT Data Company (including the
system for warehouse management, order management, sales support for distributors and
sales staff). Next, the goods coordination information system will be used to collect the
data on means of transportation, vehicle operating information to make the base for
enhancing the good coordination operation. Besides, the capture of work progress
situations as well as making effective vehicle coordination plans shall help to improve the
effectiveness of goods loading and reduce no-load runtime, through which Logistic costs
can be reduced.

IV. Quality Management:

The production process is controlled to meet the criteria of national and international
norms and standards on food safety and hygiene.

1. HACCP food safety and hygiene (Recertified every three years)

2. BRC Global Standard for Food Safety (Recertified every year)
3. IFS Food standard for food quality and safety assessment (Recertified every year)
4. ISO 9001 for quality management system (Recertified every three years)
5. ISO 17025 and standard for laboratory capacity (Recertified every three years)

V. Conclusion and Suggestion:

YAKULT
 I. Introduction:
Yakult Vietnam was established on June 26, 2006, with a total investment of over VND
400 billion due to the contribution of Yakult Honsha of Japan (80%) and the Danone
Group of France (20%). Yakult Vietnam started its business in August 2007. With
Yakult's philosophy of "contributing to the healthy life of people all over the world",
Yakult believes that protecting the earth's environment is the most important aspect of
production operations in harmony with life and society.

II. Processing of Production:

1. Dissolving Tank
The skim milk powder is dissolved in hot water of 50-55° C in the dissolving tank to
make a milky solution.

2. Culture Tank
From the dissolving tank, the milky solution is transferred to the culture tank and
sterilised. It will then be cooled to 37° C. The culture starter, L. casei strain Shirota from
the seed tank will be added into the tank to ferment the solution until the number of L.
casei strain Shirota reaches at an ideal concentration and the solution will change into
curd form known as culture base.

3. Storage Tank
The culture base will pass through a homogeniser (a high pressure machine) to make it
into fine texture before it is transferred to the storage tank. In the storage tank, the
sterilised sugar syrup is added to the culture base to form the concentrated Yakult and the
tank will be chilled at the temperature of 5° C.

4. Mixing Tank
The concentrated Yakult will be transferred to the mixing tank and diluted with sterilised
water. Natural flavours and permitted colouring will be added at this stage for flavoured
Yakult and the diluted mixture will then be transferred to the filling tank.

5. Bottle Moulding Machine

The plastic bottles are produced by the moulding machine at the speed of 7000 bottles per
hour. These bottles that are made of polystyrene are then transported by a clean air
blower through a duct to the storage tank.
 6. Selector Machine
From the storage tank, the empty bottles will be transferred to the selector machine which
will arrange them in an upright position before they are sent to the printing machine.

7. Printing Machine
The printing machine will print Yakult logo, the ingredients used etc on the empty bottles
using instant dry red ink.

8. Filling, Capping & Sealing Machine

From the printing machine, the printed bottles will be sent to the filling machine which
has the capacity to fill 30,000 bottles with Yakult per hour. At this stage, the bottles are
capped and sealed with an aluminium foil that has the date print, “Use-by-date”.

9. Packaging Machine
The finished Yakult will be sorted in single bottles or in a pack of 5 bottles that is shrink-
wrapped in polypropylene. The single bottles are packed into a crate of 100 bottles of
the same flavour. As for the 5-bottle pack Yakult, it will either be wrapped into single
flavour or mixed flavours. These 5-bottle pack Yakult will also be loaded into a crate.
All crates containing the Yakult will be transported to the cold room by the conveyor
belt.

10.Cold room
In the cold room, the finished products are kept refrigerated at a temperature of 5° C so
that they will always remain at the best condition before distribution.

11.Distribution
Yakult stored in the cold room will now be ready for delivery by refrigerated trucks for
distribution to the following sources.

Direct Sales – which consists of the distribution channels: supermarkets, retail and
convenience stores, vending machines, schools and exports to Brunei.

Home Delivery – which is a door-to-door delivery mostly in the public housing estates
and supported by the Yakult lady agents.

III. Supply Chain:

1. Research and Development
We develop products that contribute to the health of customers and provide these at
prices anyone can afford.
2. Procurement
We procure raw materials that are safe and offer peace of mind through fair transactions.
3. Production
We use environmentally conscious methods to produce safe, high-quality products that
offer peace of mind.
4. Logistics
We deliver products using methods that consider both safety and the environment.
5. Sales
We contribute to the healthy lives of our customers through the delivery of our products.
6. Community
We contribute to the creation of a healthy, sound and secure society.

IV. Quality Management:

Yakult maintains a comprehensive quality assurance program in order to ensure that our
product is of the highest quality. For this reason, samples are collected for laboratory
analysis throughout the production process to confirm that the quality assurance measures
in place have been effective.

Our testing involves more than 150 samples per production run, upon which a total of
more than 200 tests are conducted. These determine Lactobacillus casei numbers, check
for potential contaminants, microbiological quality, composition, acidity, physical
attributes and taste. In addition, each bottle is inspected for undesirable markings and
incorrect printing.

Quality assurance measures are in place to maintain standards for personnel and factory
hygiene, equipment cleaning, processing methods and parameters, and product handling.
Yakult's quality assurance utilizes a system called "Hazard Analysis and Critical Control
Points" (HACCP). The principles of HACCP are internationally recognised as an
excellent method for assuring stringently high standards.

V. Conclusion and Suggestion:

 HEINEKEN
I. Introduction:
HEINEKEN Vietnam is a subsidiary of HEINEKEN, the number one brewer in Europe
and the number two brewer in the world. Originated in the Netherlands, this family-
owned business with a history of over 150 years. HEINEKEN Vietnam makes a
significant annual economic contribution to Vietnam, amounting to approximately 0.88%
of the nation’s total GDP. HEINEKEN has six factories across Vietnam, in Hanoi, Da
Nang, Quang Nam, Ho Chi Minh City – District 12, Vung Tau and Tien Giang. In 2017,
HEINEKEN Vietnam was recognized as the most sustainable company in Vietnam by the
Vietnam Chamber of Commerce and Industry (VCCI) based on the annual Corporate
Sustainability Index.
II. Processing of Production:

1. Raw Materials Storage

Beer is an alcoholic drink made from malted barley, several
adjuncts and water through fermentation by yeast. The basic raw
materials of beer are Pilsener malt, hops, maize grits, coloring
malt, rice and caramel malt. Malt is made from barley by malting,
that is by steeping, germinating and kilning the grains. Last but not
least, water is also an essential raw material. The raw materials storage provides the plant
with sufficient quantity and quality base materials for brewing.

2. Brewhouse
The first important step of brewing, called mashing, takes place in
the brewhouse. Mash is made by mixing maize grits and crushed
malt with water. After that the liquid wort must be separated from
the spent grain and other solids. It is achieved by filtering, called
lautering. The last brewhouse process is the wort kettle operation,
that is heating the liquid after adding the hops. Hops are the spice of beer. Finally, in the
whirlpool coagulated substances should be removed from the hot wort.

3. Wort cooling
After the brewing, hot wort should be cooled down so that yeast
for fermentation can be safely added. The precise temperature also
depends on the type of beer.

4. Fermenter

Cold wort is pumped over into the fermenting vessels. In these tanks
the liquid is pitched (or injected) with brewing
yeast and air as required for fermentation. Yeast
is the heart of beer. 

5. Filter Equipment and Bright Beer Tanks

The fermented bright beer must be clear, free of taint or
contamination. For the filtering Kieselguhr is used as adsorbent.
Finished beer is then temporarily stored in the so-called ``bright beer tanks'' at a low
temperature for one or two days before pasteurization and packaging.

6. Filling and Packaging Plant

This is the last step of brewing when filtered finished beer is
pasteurised and filled into the packaging units, i.e. into tankers,
kegs, bottles or cans. 

 Bottle filler: 
The crates with the empty returnable bottles are first
transported to the bottle picker. The empty crates are then
moved on along the conveyor belt to the crate washer. The
 bottles from the crates go to the bottle washer, then on the conveyor belt to the
cleanness checker. The next steps are the filling and crowning equipment and the
labeling equipment. The last step for the labeled bottles is
the crate filler.

 KEG filler:
The returned empty kegs are moved on a one row conveyor
to the check point with a CCD camera. The kegs are then
turned around vertically 180 for the rest of the operation.
After filling the kegs are sealed with caps of appropriate
colour.

 Can filler:
Empty cans are fed into the system in packaged pallets. The
filler has 60 filler valves. After putting on the lids, the filled
cans are transported on a wide collecting line to the
packaging unit where they are packaged in cartons. The
cartons are then grouped into pallets and shrink-wrap is
applied.

7. Suspension Carrier Line

This state-of-the-art conveyor line feeds the plant with empties and
transports the packaged beer into the finished goods warehouse.

8. Warehouse
The storage capacity of the 7,000 square meter finished goods
warehouse is 14 million bottles.

 
9. Lab
Finished beer must comply with high quality requirements. The
extensive quality testing of the packaged beers takes place in the
lab. As well as the sensory examination of aroma and flavour.

III. Supply Chain

1. Farms
First process is getting raw materials. Heineken has farms in New Zealand from which a
machine picks Grains and hops.
2. Cans
Cans and bottles supply come from tiers or recycling centers.
3. Manufacturing
The grains and hops are then transferred to factory by delivery of trucks.
At the factory the grains and hops are synthesized and are getting ready for brewing.
4. Brewery
The grains and hops are transported to the brewery through trucks.
5. Distributor
 From the breweries the beer is transported worldwide to Heineken’s distributors.
 Once the purchase orders are placed to their specific distributor, the beers are shipped
once again by trucks.
6. Stores
 The stores put purchase orders to the distributor who then ships the product to them.
 The stores obviously are now responsible to sell the products to the final consumer
which is us.

IV. Quality Management

The manager of Quality & Sourcing will achieve excellence in ensuring quality assurance
of Heineken USA is updated and executed according to the most recent Heineken Rules,
Standards and Procedures, local legal framework and works closely with our supply
partners (source OPCO’s, 3PLs, Global Supply Chain) to provide the best in class quality
of all products of our portfolio. The role also includes the assessment of technical
capabilities and feasibility of new potential source breweries.
V. Conclusion and Suggestion