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PROCESS MAP OF NABISCO BISCUIT

The process is conventional and easy. We can divide the process into four main categories.
Wheat flour along with other ingredients is mixed with water and dough is prepared. Then it is
kept at a normal room temperature for about couple of minutes to allow proper fermentation.
Then it is placed in biscuit molding trays and these trays are placed in oven for baking. After
requisite baking, trays are taken out, cooled and biscuits are packed manually. But we are
showing the whole process flow chart of Nabisco from bringing out the raw materials to ending
of the process.

Preparing of dough

Molding

Baking

Packaging

Figure: Four main category in biscuit


processing
Taking/Bringing out raw
materials from Nabisco Preparing the machine Putting warm water into
warehouse (flour, sugar, egg, (dough and raw material machine
flavor) mixing machine)

Putting flour at Adding Sugar in it Adding flavor Mixing all the


optimum level ingredients

Mixing all the raw


Adding egg in the materials in machine
mixer Completing
the dough in
certain
minutes

Switching Automatically cutting Starting of Waiting for 30


on the dough the dough rolling minutes
machine machine

Transforming the dough Cutting the sheets into


Putting the sheets different sizes & shapes
into long sheets Putting
in a cutting sheets
on oven

Bake Biscuits

Quality
Using isCream
certain
if if
End of Process
Bake Biscuits Yes Passing to the cream Checking
mixing machine quality

No
Yes
Passing to the
packaging
Coolin Packaging
department
g manually

Cartooning

No

Transferring into
Putting 36- 48
warehouse
packets of biscuit in
a carton & putting
cartons in case
sealing

Graph: Flow chart of biscuit


processing

DESCRIPTION OF PROCESS MAP


Firstly, the processing starts from taking out all the ingredients & raw materials for biscuits from
Nabisco warehouse to the production place. These ingredients include flour, sugar, egg & flavor.
Then, labor force make dough and raw material mixing machine ready. After that, they put
optimum level of warm water into the machine because the consistency of dough largely depends
on water. And, they add flour, sugar & eggs into the machine, starts proper mixing of all the raw
materials and make dough. Dough is the soft lump of mixture that is made by mixing the
ingredients before they are cut into shapes and cooked.
Now, Workers switch on the dough and mixing feed machine. Here, the feed machine cut down
dough into pieces and put the pieces into rolling process which is known as soft dough forming
machine. In the rolling process the dough is rolled down into thin sheets. It comes out as a
continuous strip of dough about a meter wide, carried on a conveyor belt to the biscuit cutting
machine. Dough pieces are rolled down for a number of times and delayed for 30 minutes.
And then, as the dough sheet moves along, it passes under a block of cutting molds which stand
20- 30 biscuits at each stroke. At the same time they stamp into the dough the name and design
of the biscuits. The shape and size of the cutters change with each sort of biscuit.
After that, the biscuits move onto a flat steel band or wire mesh conveyor that will carry them
through the ovens in a continuous process. They are passed through a tunnel oven and baked as
they move. The oven is long as 60-90 meters. Here, a decision process takes place, if the biscuits
are needed to mix with cream then it move to the cream mixing machine and then reach to the
quality control section. If the biscuits dont needed to be mixed with cream it directly move to
the quality control section.
Now, quality checking process decides whether the quality of the biscuits are up to the mark or
not. If the biscuits are not suitable for further processing then they stopped the process for those
biscuits. And after that, these baked biscuits are then passed on to cooling conveyors for natural
cooling prior to packaging. The temperatures are brought down to room temperatures. It should
between 35- 40C.
Finally, cooled biscuits move to the packaging department and workers packaged all the biscuits
manually. These packs are then put into secondary packaging like cartons to be transported to
warehouse again and further shipped to the retailers.
Recommendations
1. We want to recommend automation packaging system instead of manually doing it using labor
force. Nabisco. Ltd can use improved packaging and auto feed system like horizontal flow
wrapping machine where biscuits are packed and sealed fully
automatically.

Passing to the
packaging
Coolin department Packaging
g manually
Cartooning

Nabisco. Ltd can improve packaging system


which is marked by read color.

Recommended packaging system flow chart

Passing to the
packaging
Coolin Placing Delivered Fine Cutting
department
g on in feed to former sealing unit
conveyor area unit

Cartooning Discharge
area

Every wrapper has an in feed conveyor, a film feed assembly (back stand), a film forming area
(former), bottom seal (fin seal), a cutting head and a discharge area. Food and non-food products
created by processing equipment, are placed on the in feed conveyor of the flow wrapper. This
can be done by hand feeding or by using an automated feeding solution. As the in feed conveyor
delivers product to the forming area, film is drawn from the film feed assembly into the forming
area, where a film tube is formed around the product and a fin seal is created. The film tube and
the product are then delivered to the cutting head. The cutting head creates the end seals while it
cuts apart adjoining wrapped products into individual packages, and delivers the packages to the
discharge area. From the discharge area, the packages can be either cartooned at a packing
station or accumulated for packing at a later time.
Benefits of Automated Packaging Systems
Reduce Employment Costs: With these packaging systems, Nabisco needs fewer
workers. A single person can operate multiple machines at a single instant of time. Thus,
it reduces your employment costs.

Consistency: These packaging systems are consistent in performance as these dont get
tired and perform flawlessly at the end of the day as they did at the beginning of the day.

Improved Safety: With these packaging systems, the chances of causing an injury for
example, dangerous environments such as those with temperature extremes or radioactive
and toxic atmospheres to the person who is operating them are minimal. As these
machines are fully automated and a user has to do a limited amount of work. Increased
automation means an improved safety for individuals operating them.