Garnier Color Natural

Process Flow
Product Specification

 Product Name: Natural Medium Blond

 Color Shade: 6
 Color Batch Size = 300 kg
 Developer Batch Size = 1000 kg
 CN Sachet Batch Size = 1000 kg
Overview of Process
 Batch Production card is generated by production for receiving of raw materials
 Dispensing of required raw materials by RM team according to BOM.
 After confirming the quantities by QC, dispensing materials are handed over to production.
 Production confirms the quantities before receiving.
 Batch production takes place.
 After batch production, quality of batch is checked by QC.
 After QC release, batch is utilized for tube filling.
 A batch card is generated by production for packing materials.
 Tube filling takes place until the batch completion.
 Semi finished FG goes to WIP(Work in Progress).
 Packing takes place for finished good. FG is transferred to FGS by generating STT.
 QC tests the final quality. After release by QC, FG is dispatched.
 A DC is generated for dispatched goods.
Dispensing of RM for Color/Developer/CN Sachet

Batch card
generated by Dispensing of RM Quantities
production for according to BOM confirmed by QC
RM

Dispensed RM Production Dispensed RM

moved to officer confirms handed over to
production area the quantities Production
 Color Batch Production

Addition of
Water Drain Addition of RM Heating 80 ˚C Addition of RM
Water

Addition of Addition of Cooling up to

Addition of RM Addition of RM
Ammonia Dyes 52 ˚C

Final Mixture
QC Report of Color Shade 6

Tests Performed Specifications Results

Aspect, color and odor Almost white to off white Conforms
color, smooth viscous
cream having
characteristic odor
Relative density 0.96-1.02 0.982
Viscosity cream 27-65 UD 48.6 UD
Viscosity mixture 10.545 – 11.6555 16.7 UD
Dying power Must conform to the Conforms
reference
Developer Batch Production

Addition of Heating up to
Water Drain Addition of RM
Water 80 ˚C

Addition of
Addition of Addition of Cooling up to
Hydrogen
Water Water 50-52 ˚C
Peroxide

Final Mixture
 QC Report of Developer

Tests Performed Specifications Results

Aspect, color and odor White color, smooth Conforms
viscous cream having
characteristic odor
pH 2.0-2.4 2.19
Viscosity 30-50 UD 39.1 UD
Percentage of Hydrogen 5.76-6.24 % 6.11 %
Peroxide
Specific gravity 0.90-1.00 0.961
Filling of 40 ml Color Tubes

Filling Line speed = 40-42 tubes/minute

= 2400 tubes/hour
Filling of 60 ml Developer Bottle

Filling Line speed = 30 bottles per minute

= 1800 bottles per hour
Issuance of Packing Materials

 A batch card is generated by Production for packing.

 Packing materials are issued according to BOM with 2% extra material.
 The packing materials required are:
 Leaflets
 Gloves
 40 ml tubes
 60 ml developer bottles
 12 ml CN sachet
 Shippers for FG packing
FG to Dispatch

 The FG shippers are moved to finished goods store by generating stock

transfer ticket(STT).
 The FG is dispatched after released by QC.
 A DC is formed for dispatched items.
Tubes Wastage Data

 Filled tubes = 7260

 Filled damaged tubes = 10
 Empty damaged tubes from machines = 30
 Empty damaged tubes from store = 40
 QA/QC samples = 17
 Total tubes count in wastage = 97
 Total tubes = 7260 + 97 = 7357
 %age of tubes wastage = 1.31%
Bulk Wastage Data

 0.982 x 40 = 39.28 ml
 39.28 x 10 = 392.8 ml = 0.3928 kg
 300000/39.28 = 7,637 tubes can be filled with 300 kg batch
 Tubes filled = 7260
 Difference = 7637-7260 = 377
 Bulk wastage = 377 x 39.28 = 14,808 ml/1000 = 14.81 kg
 %age of bulk wastage = 4.93 %