INTERNSHIP REPORT

On
Punjab Beverage Pvt. Ltd.

By
JABIR SULTAN
Roll. No. 47
Semester 6th BBA(Hon)

Internship Report submitted in partial fulfillment of

The requirements for the degree of
BBA (Hon)

DEPARTMENT OF MANAGEMENT SCEINCE

GC UNIVERSITY, FAISALABAD (LAYYAH CAMPUS).

JUNE, 2016.
PEPSI LOGO.
 Certificate by the Internship Supervisor

I certify that the contents and form of internship report submitted by JABIR SULTAN, Roll No

47 has been found satisfactory and according to the prescribed format. I recommend it be

processed for evaluation by the External Examiner for the award of the degree.

Signature…………………..

Name: ………………………

Stamp……………………….

Chairperson/Coordinator

Dean,
Faculty of Management Sciences,
GC University, (Layyah Campus).
 Executive Summary

This report is based on the activities performed during my internship at Punjab Beverages
Company (Pvt.) Ltd. Internship duration was 8 weeks and it provides me practical knowledge of
working in professional environment. I join Punjab Beverages Company (Pvt.) Ltd on 6 June,
2016 as Management Trainee to do internship for completion of BBA Hon Degree (Management
Science).

In the first part, there is some introductory detail about the company. The history and present
growth of the company has explained. The organization structure and the details of its
management along with its organizational chart are also discussed in the second part. I have
discussed the important departments of the company and some business operations in the third
part.

In fourth part I describe my own working at Punjab Beverages Company (Pvt.) Ltd. The SWOT
Analysis has given in fifth part. At the end there are some suggestions according to my
knowledge about organization. I worked as an internee mainly in Production, Quality Control &
Quality Assurance department and Marketing Department
 Acknowledgement
On the very beginning of this page I want to admit that it was possible for me to complete my
studies with the help of Allah Almighty and name of Hazrat Mohammad (S.A.W).
All praises and thanks for Almighty Allah who is entire source of all kinds of wisdom and
knowledge, who gave me health, chances, teachers, and helping hands.
I pay my humblest thanks to Holy Prophet Hazrat Muhammad (S.A.W), who are forever a
model of kindness and knowledge for humanility, the most perfect among ever born on the
surface of earth.
I would like to extend my sincere thanks to the Syed IBN UL HASSAN, Coordinator
Department of BBA HON, and Management Science. He gives me the opportunity to increase
my practical knowledge in my interest of management area. I am also thankful to all the
professors of the department for their very good support.
I am incredibly thankful to my supervisor Mam Mehvish Javid and all of my teachers for their
sympathetic behavior, reward less help, precious suggestions, constant encouragement, personal
interest and precise guidelines that enable me to complete this task.
I want to say special thanks to the Production and Quality Control & Assurance department in
Punjab Beverages Co Pvt. Ltd. for offering me lot of opportunities to learn the technical skills
and learn how to apply my theoretical knowledge in practical work. I am very thankful to;
Mr. Sarfraz Assistant Manager Payroll Dept.
Mr. Shokat ALi General Manger Production Dept,
Mr. Rana Athar Senior production manager
Mr. Tariq SAP Financial Coordinator
Mr. Saffyan Manager Earth System
 Mr. Sajid Ali Food Technologist
They also guided me on each and every step, helped me in developing communication skills and
as well as kept me on right track with their best. I appreciate all those instructors who managed
to deliver lectures even they were crowded by the workload; I will not forget to pay regards to
those entire people who helped me in learning.

Finally I will pay my heartiest and wishful thanks to my affectionate and loving parents whose
spiritual inspiration and mystical guidance are always with me & whose prayers made me
everything that I am.

JABIR SULTAN
 Dedication
I dedicate all my effort to my father who gives me strength in all walks of life throughout my
childhood to present, who raise hands for me in darkness of night when I sleep with sweet
dreams, who teach me working hard with commitment, who bear all the pain for my gain and to
my mother who take care of me more than any other person in this world, who feel and fulfill my
requirements before I say a single word, who encourage me in every event of my life, who
educate me the loyalty, tolerance and forgiveness, and to my brothers and sisters who contribute
all their resources for my success, who give me guidance, love and respect.

JABIR SULTAN
Chapter # 1
Introduction and Background
Our Mission
Our mission is to be the world's premier consumer Products Company focused on
convenient foods and beverages. We seek to produce financial rewards to investors as we
provide opportunities for growth and enrichment to our employees, our business partners
and the communities in which we operate. And in everything we do, we strive for
honesty, fairness and integrity.

Our Vision
"PepsiCo's responsibility is to continually improve all aspects of the world in which we
operate - environment, social, economic - creating a better tomorrow than today." Our
vision is put into action through programs and a focus on environmental stewardship,
activities to benefit society, and a commitment to build shareholder value by making
PepsiCo a truly sustainable company.

Pepsi Cola International Values and Philosophy

Our Values and Philosophy are a reflection of the socially and environmentally
responsible company we aspire to be. They are the foundation for every business decision
we make.

Punjab Beverages Company (Pvt) Ltd Values

 Integrity
 Excellence
 Team work
  HSE (health, safety, environment)
 Cost consciousness
 One family

Our Commitment
We are committed to delivering sustained growth through empowered people acting
responsibly and building trust.
Objective

The major objective of the company is to produce and supply of highest quality, which
confirms to both the national and international quality standards. The company is
committed to provide maximum level of customer satisfaction.

Food Safety Policy

No matter what we are producing, quality and integrity of our product is our single
highest responsibility. The Punjab Beverages Co. (Pvt.) Ltd, Acknowledges is
responsibility to produce and deliver safe products to its consumers.
3 Colors uses in PBC
Red Wash Room
Blue Production Area / Labs
Yellow Offices / Storage
History of Pepsi cola in Pakistan
Pepsi Cola International brands is being formed and consumed in 48 countries in world
including Pakistan. In Pakistan, Pepsi cola is no 1 in term of sales wise and market share.
It is the market leader. But overall the world coca cola is no 1. In Pakistan there are 9
territories where the franchised unit produce and sale Pepsi brands.
Some of these territories are:
1. Lahore
2. Karachi
3. Rawalpindi
4. Peshawar
5. Multan
 6. Gujranwala
7. Faisalabad
8. Sakhar
9. Baluchistan

Introduction of Punjab Beverages Company

Punjab Beverages Co. (Pvt.) Limited is a leading bottler of Pepsi Cola International,
having the Highest Market Share in world. The Company is situated over an area above
100 Canals of land at Samundri Road (About 150 Kilometer away from Lahore). The
operations of the company were initially started with one Bredbi branded filling machine
of foreign origin in September 1976 with a CSD (Carbonated Soft Drinks) production
capacity of 2000 crates of 250 ml RB per day having 20 spouts. However at later stages
the machinery and the other production facilities were expanded and modernized by
installing new state-of-the-art machinery which were imported from Italy, USA,
Germany, Australia, France, Belgium, Austria, Canada and Switzerland.
Pepsi Beverages Company (PBC) is Pepsi Co's beverage manufacturing, sales and
distribution operating unit in the Punjab. Its diverse portfolio includes some of the
world's most widely recognized beverage brands, including Pepsi, Mountain Dew,
TEEM, Sting, Miranda, 7up, Aquafina. The operating unit is headquartered in Faisalabad
employs approximately 2,200 people.
Brands of Pepsi
The product line of PBC is
 Pepsi
 Diet Pepsi
 Mountain Dew
 Miranda
 7UP
 TEEM
 Aquafina
  Sting (red, yellow)

Future Planning
The company operates through well knowledgeable, loyal and hardworking employees
exceeding 2200. The first and the most basic plan it to train them according to the
changing technology and computerized environment and satisfying their needs and
requirements.. The company is planning to increase its sales force and development in its
infrastructure in the coming time period.
Hierarchy of the Punjab Beverage Company (Pvt.) Company.

Chief Executive

Director

Departments

Production H.R Finance Security Operation S&D

CSD Non CSD Personal

Internal
External
1
Water Treatment Recruitment

MSD Supply Chain

Accounts
Cost & Budget

Audit Sales Accounts

PBC Factory Faisalabad
Google Earth View
Pepsi is situated at 5 km Samundri road, Faisalabad Google earth view of PBC factory is
The Layout of the Factory
Company’s Profile
 Name: Punjab Beverages Company

Logo:

Established in: 1975

Geographical Location: Faisalabad- Pakistan

Industry: Food & Beverages

Major Units: Injection Molding, Blow Molding, CSD

Number of Employees: 2,000 to 2,200 Employees

Business Based: Manufacturing to customer

Brand of PBC Pepsi, 7up, Sting, Mountain Dew, Teem, Miranda,

Aquafina

Distribution Area T.T Singh, Okara, Jhung, Sargodha, Johra Abad

Company Offices Faisalabad Pakistan

PCI Ranking Sep, 2011. In Asia 1st position & all worlds 2nd position

Certifications: ISO 9001, Moody, UKAS Quality Management

Address: P–1590 Samundri Road, Nisar Colony,

Faisalabad, Pakistan

Contact Information: 041 - 2660270

041 - 2660370

Organization culture
The culture of PBC is differentiated with the other Beverage Companies on the basis of
following key characteristics.
1. Innovation & risk taking
The PBC focus on creativity & innovation and risk taking is higher than
the competitors and due to this characteristic increasing by all other Pepsi Cola
Franchisees the PCI has got 1st  position in the year 2011 in Asia and overall the
world 2 n d position that has been published by a very well renowned Magazine “
2. Fortune attention to detail
The company’s employees display accuracy, investigation, and interest to detail. Due
these qualities, the overall performance of the organization is respected and well managed.
3. Outcome orientation
The management of PBC focuses on outcomes rather than on the strategies and
processes used to achieve these results.
4. People orientation

The decisions made by the management of PBC take into consideration the
effect of result on people within the company. The employees working under
different Managers are treated by the self-motivated approach to get the maximum
effectiveness from them.
5. Team orientation
The working behavior in PBC is planned about teams rather than individuals.
Abbreviation of TEAM
T Together
E Everyone
A Achieves
M More
6. Aggressiveness
The employees of PBC are always willing to adopt the challenges and
criticality to achieve the tasks assigned and aggressive rather than easy going.

7. Stability
 In working place, to maintain the relationships among employees are kept in status quo in
contrast to growth like socialization.

Location

Location has important effect on company’s capability to compete and on its experience to
threat from outside factors. In a innovative market the company may enlarge, add or change
place new facilities. Location decisions are important due to following reasons.

 Competition.

 Quality

 Product differentiation

 Cost.

 Hidden effects.

Factors that effect the location decisions are

 Raw material

 Availability of energy utilities

 Skills and availability of labor (experience + raw handed employees)

 Market related factors.

 Tangible & intangible Cost factors.

 Transportation (Logistic Management )

 Water availability and costs.

  Construction and site cost.

 Technical expertise (equipment, electrical, mechanical, knowledge workers)

 Support services (community, culture)

 Environmental issues and regulation at local & federal level

 Taxes.

 Weather

 Proximity to customer

Management Structure of PBC

Managerial structure Non- Managerial Structure

 General Manager  Departmental supervisor
 Deputy General Manager  Assistant supervisor
 Sr. Production Manager  Skilled operator
 Deputy Production Managers  Semi skilled operator
 Assistant Production Managers  Driver
 Sr. Officer  Loader
 Officer
 Management Trainee

PEST Analysis
The macro environment consists of the larger societal forces that affect the
microenvironment. The external factors are not under the control of the strategists; they
can just observe them and make strategies in light of these factors. Some of these factors
are given below:

Political and Legal Factors

  Political Stability

Whenever the government is considered to be stable, the business will increase. If there is
political stability in the country the policies and strategies made by Pepsi can be
consistent to be implemented. Foreign companies are also keen to invest in those
countries which are politically stable where they have no fear of decline in their market
share or shut down due to sudden change of government.

 Mixed Economy

In mixed economy government and private sector both plays their role in developing the
economy of the country. Investment by foreign companies like Pepsi is more likely to
flourish in mixed economy.

 Laws Formulation

Government has given copy rights to Pepsi so that another company cannot sell their
product by the name of Pepsi. The countries where laws are formulated, the strategies and
activities of the company are different.

 Social Responsibility

Pepsi’s social responsibility is to provide its customers with clean and hygienic product
so to do this they have increased the use of disposable bottles.

Economic Factors

 Income and Income per Capita

If the income level or per capita income of the people increases, it will have a positive
effect on the consumption of Pepsi.

 Inflation

If the country faces inflationary trend in the market, the price of the Pepsi will ultimately
increase which will lower its demand.

 Consumption Behavior
Pakistan is a consumption oriented society. Due to demonstration effect the people are
more inclined towards consumption than saving. So the people of Pakistan spent heavily
on food items. Hence Pepsi has a good market share in the present circumstances.

 Income Distribution

It means how much is in the hands of rich and poor class. In Pakistan 10% rich people
posses 93% of wealth and 90% people posses 7% of wealth. If there is balanced
distribution of income in the country, the consumption of the people will increase hence
increasing the sales of beverages as well.

 Payment Mod

As the use of plastic money is increasing the consumption pattern of the people are
increasing. Although it will have a low affect on the consumption of Pepsi.

 Employment Opportunities

As employment opportunities increase the living standard of the people increase and the
people consume more.

 Aggregate Demand

In case of Pepsi, aggregate demand of the product increases in the season of summer as
the hot weather makes the consumers want to drink more.

 Aggregate Supply

In summer season to cope up with the increasing demand they have to increase the
aggregate supply of their product.

 Economic Policies

Some of the economic policies which can affect the market of Pepsi are discussed below:

 Fiscal Policy

It is the policy of taxes. If heavy tax is levied on Pepsi then its price will rise having
negative effect on its consumption.

 Monetary Policy
 Monetary policy is made to restrict or increase the supply of money in the market. If
policies are made to restrict the flow of money in the market, inflation can be controlled
hence increasing the real income of the people which will ultimately affect the
consumption of Pepsi.

 Price Policy

If price of Pepsi is increased its demand will decrease and vice versa.

 Income Policy

If income of the people will increase their purchasing power will increase and hence
increasing the market share of Pepsi.

Social and Cultural Factors

 Psychographic

It is a combination of demographic and psychological factors. Psychological attributes mean

how you perceive things. The company will focus on the behavior of consumers and make
different changes in their product quantity or quality and in promoting their product so that
they can attract the customers. Keeping in view that the behavior of different consumers is
not alike they have to make their marketing strategies in accordance with their requirements
so that they are convinced to buy the product.

 Religious

Religious factors can influence the market sales of Pepsi as it happened in 2003 when the
U.S-led attack on Iraq, wide sections of society in Pakistan has banned American
multinationals Coke and Pepsi.

 Social Status

Pepsi is a well renowned brand. People who are brand conscious will not drink beverages of
lesser known brands such as Amrat cola. They will try to show their status by drinking Pepsi
which is known to all as a quality drink.
  Media

It is a very important factor for marketing. Media these days is a very effective way of
inspiring people to buy a specific product. A good promotion can boast up sales to a great
extent.

Technological Factors

 Research and Development

Through research and development quality of the product can be improved or better
techniques or machinery can be developed which can increase the production. When
technology is advance the supply of the product increase hence the company experiences
growth in their business.

Chapter No: 2 Hierarchy of Production Department

CEO

G.M G.M Supply G.M G.M Sale G.M G.M SAP G.M
Shipping Chain Finance Marketing Procurement Production
Management

Deputy
G.M

Instrument Mechanical Electrical Quality Quality Sr. Manager

Manager Manager Manager Assurance Control Production
Manager Manager

Deputy
Manager

Assistant
Manager

Sr. Officer
 Officer

Incharge

Supervisor

Inline Head

Operators /
Production Department drivers /
loaders
Basic production process involves the main six plants’ that further leads to production process.
At initial, there is so much complexities that must be handled and controlled well so that to safe
the mishap in further stages of production.
Now production main and basic plants are:
1) Syrup plant
2) Clean in process
3) Water Treatment Plant

Production management functions are being effectively implemented by top management. A

brief summary of operations functions studied by this group are described below.

 Product Planning

At present new product assessment is taken by the upper management. Demand for new product
& services are investigated by production general manager- terms of raw material, equipment
function, and quality. For this point he can get direction from constructions. Finance department
evaluates financial capability. Sample production is conducted. Response from buyer in terms of
satisfaction and company’s ability to meet the requirement helps in deciding to produce new
product.

 Process Design

In the company process is continuous supply of concentrate is critical but process can be
automated. Production process is flexible and process can be changed within 45 minutes to one
hour. Production is of large scale and covers a wide area for the distribution of the product.

 Facility Design and Layout

Physical layout & design of plant and supporting facilities and building is provided by the parent
company that is PEPSI COLA International. A transportation or logistics cost with the plant is
minimum. Physical layout provides maximum utilization of technology, labor and available
space by optimizing costs.

 Inventory

Company is using the qualitative & quantitative methods for calculating EOQ, carrying cost,
safety stock, reorder point, and annual inventory cost. The company does not give importance to
control inventory cost. Lead time is usually 2 days and in an exceptional case it can be up to 4-5
days. This also one reason that EOQ, FIFO, lead time are calculated using qualitative techniques,
by estimates of experienced managers of different fields.

 Inventory Management

Inventory is very significant to many organizations because it helps the organization take action
quickly to customer demand, which is a main element of competitive approach. Inventories of
raw material processed goods can help a organization complete the production cycle in a much
shorter time then would otherwise be possible. The more affective a company inventory’s
system, the better able it is to manage its resources and to compete efficiently & effectively.

An inventory system is collection of people, machinery and procedures that function to maintain
quantity of each item in inventory and to determine which item should buy or produce in what
quantities and at what time. Some inventory systems require transaction reporting to keep track
of every instance in which units are added or taken from the existing inventory at PBC can be
classified into five categories.

 General items.

 Lubrication items.

 Stationary items.

 Electric items.

 Part items.

 Issuance of Different Items

When production department need a particular thing from inventory, they fill the demand slip.
One copy is kept at the store and a carbon copy is kept by the production department. This
demand slip includes the quantity issued, stock register page number, item code, this demand slip
is signed by the production manager. Inventory items are issued on these slip.

Control of Inventory

At the end of each month, store prepares a monthly utilization report. This report includes the
detail of all the inventory items which were consumed by the production department of PBC
during the month

.Material Requirement Planning

Company produces beverages and uses Sugar, Carbon Dioxide, Ammonia and concentrate as
raw material. Soft drink is a seasonal product. Most of the sale is done during summer season.
Concentrate is bought from the franchiser Pepsi Co. Sugar is bought directly from the sugar
manufacturers of the area. CO2 is prepared within the organization, which is enough for the full
capacity of two plants. When during 6 plants are in working, CO2 is purchased from the outside
suppliers.

Quality Department

”Standard achieved by process controlling to render defects free product to customer”.

Quality standard is maintained at each and every stage. Punjab Beverages & CO. has won best
quality award for many times by Pepsi Cola International competing all the Asian countries.
Quality control labs are fully equipped. Quality controllers/ chemist are at home in their jobs.
That’s why the quality control efforts are recognized by the international management of Pepsi
cola. They are focus on quality “ the poor quality is equal to zero”

 Quality Control

“Quality control system implement in process to achieve the above quality standard”.

The quality control should

 Define exact product and service quality level necessities.

 To establish the relationship of facility design and process uniqueness to

productivity and process related requirements.

 To determine tools & technique for measuring quality.

 Check & control the quality record

 To take Corrective action about processes when actual quality various from the
acceptable quality.

Quality requirement is part of product design activity, and culminate in the quality specifications
and design sub system to assure the quality with standard.

 Quality Specifications and Design Subsystem

The actions of the subsystem are the internal part of product design, its objectives are clearly
established that new design.

 To meet the customer’s needs

 Properly operate under end use term & condition

 Product is produced given the organization capabilities

 Determine the purpose with specific level of dependability in conditions of least amount
means time between failures.

 To efficiently & effectively utilization of organization resources to maintained working

hours and material operating cost.

 Can be mandatory within a convinced time frame.

 Quality Assurance

“Quality assurance preventive defects that clear product to give customer”.

“Preventive actions to take avoid the any quality defects”.

Quality Assurance Rules

 Punctuality

 Quick learning

 Loyalty

 Hard working

 Positive attitude

Responsibility of quality assurance person

  Monitor the quality control system

 Evaluate by audit, inline & finishing inspection.

 Assure the quality with standard

How to identify defects & corrective action

CLCA (close loop corrective action)

 Product inspection

 Identify defects

 Roots cause of defects

 Corrective action

The quality assurance system is the combined quality management system. It interfaces with
other general management system performing similar functions relative to the organizations
financial personnel facilities and marketing policies

 Process Quality Planning & Control Subsystem

This subsystem concerns the what, where, when, who, why, and how of quality control during
operations. It frequently involves major expenditure for personnel, equipment, inspection and
testing activity.

The objectives of the subsystem

o Determine the process and characteristics

o Determine the method of inspection and develop the instruction about process.
  3.determine the personnel according to requirement, select, train and give task to
implement the quality standard

o Analysis of quality issues and record on system in term of no of defects and

causes of defects.

o To take corrective action about procedures to control situation

o Define the dispositions of quality deficiencies.

 Support Facilities

Support facilities that are directly and directly related to operations function. Support facilities
are important for production. Some of departments to be considered in layout are

 Inventories, material and suppliers.

 Considerations for inventory layout are considerable.

 Inspection and quality control.

 First aid.

 Safety and security.

 Emergency situation analysis.

 Transformer.

 Clerical and bookkeeping.

 Equipment for work shop.

 Air conditioning plant.

  Tool room.

 Repair & Maintenance.

 Tube well.

 Air conditioning plant.

 Canteen.

 Medical facility.

 Bailing press.

 Parking facility.

 Considerations for inventory layout are considerable.

Chapter 3

Water Treatment Process

• WATER FROM
TURBINES

• STORAGE TANK

• COAGULATION TANK

• SAND FILTER

• CARBON PURIFIER

• POLISHERS

• BEFORE R.O TANK

 • MEDIA FILTER R.O

• POLISHERS

• AFTER R.O TANK

• CARBON PURIFIER

• POLISHERS

• UV LIGHT

• TREATED WATER
DISTRIBUTION

SYRUP
SEND TO
BOILER
CSD
Process of Water Treatment
 Water is collected from turbines is stored in the storage tank.
Coagulation Tank
Water from storage tank is forced to coagulation tank by means of pumps. In coagulation
tank water is treated with chlorine, Ferrous Sulfate and lime.
 Chlorine Function
1. To kill m.os.(micro scale)
 Lime Function
i. PH rise.
ii. To reduce the alkalinity.
 Sand Filter

After the coagulation tank water passing from sand filter.

Filtration is a process of removing small particles of suspended matter from water by
passing the water through a porous medium. It removes collect particles or other
suspended matter which may have been carried over from the retention tank.
Carbon Filter
After sand filter water passes from carbon purifier. The purpose of carbon purifier to
removes:
 To remove the chlorine
 Absorbs the odor
 Absorb the residues comes from the sand filter.

Polishers
Then water passes from polishers. Polishers are used is 5 micron spools means the poor
size of polishers is 5-micron.The filter remove small particles of rust material that have
been picked up in processing the water. It removes the micro particles of foreign matter
from the water that make the water crystal clear.
Before R.O Tank
The water is stored in before R.O tank that water should be free of chlorine and T.O.A.

Media Filter R.O

 R.O purpose to reduce
 Reduce T.D.S.
 Reduce Alkalinity.
 Reduce total hardness.

After R.O Tank

Then water is stored in after R.O tank. We add 6-10ppm chlorine. T.D.S should be
<500. Then goes to carbon purifier for further purification .carbon nil the chlorine and clear
T.O.A. Then goes to polishers for further purification. Water is passed from UV light to kill m.os
and that water should be prepared for final beverages. AT this stage check the required
parameters.

Chapter No: 4
Syrup Room
In syrup room, the syrup for the final beverage is prepared with the help of water and
sugar. Some heat exchangers and filters are also used. The description of the processes,
being used in syrup room is mentioned as:

Purpose
To upgrade the quality of refined sugar by the treatment of with activated carbon at the
elevated temperature to kill bacteria and, especially pathogenic bacteria and de-coloring
of syrup.
Principles of Operation
Heating the simple syrup solution helps the activated carbon to remove impurities and
also kill the yeast, mold and many bacteria and it also lower the viscosity of the syrup,
thereby increasing the filtration flow rate.

Flow diagram of Syrup Room

• SUGAR BUNKER
 • RECURPERATION TANK

• DISSOLVING TANK

• REACTION TANK

• DOSING TANK

• FILTERS

• BAG FILTERS

• HEAT EXCHANGER

• SIMPLE SYRUP

Sugar Bunker
 Sugar is added in sugar bunker continuously. Sugar bunker having vertical and horizontal
conveyor. The sugar goes into the dissolving tank by horizontal conveyor. It is continuous
process.
Recuperation Tank
Treated water is stored in the recuperation tank. Treated water suck by the pump and pass
from the heat exchanger .The temperature of the water should rise to 850C.
Dissolving Tank
In dissolving tank sugar and water is added. Crystallization is also take place. Syrup is passed
from crystallizer. Crystallizer having four filters. The purpose of crystallizers to recycle the sugar
that are not dissolved. Then syrup is passed from A.C tank.
Activated Carbon Tank
The syrup is passed to activated carbon tank. The correct amount of activated carbon is added to
the solution and syrup is agitated, so the carbon is contact with syrup. Then syrup is passed to
reaction tank.
Reaction Tank
The purpose of reaction tank to
 To operate like antigens.
 To filter foreign particles.

Dosing Tank
In syrup room tank we add filter powder and dose them with syrup
Filters
A filter contains sieves. Filter powder remain on to the sieves that does not passed the A.C
remains on the sieves but syrup passes easily. It also removes other foreign matters.
Bag Filter
The purpose of bag filter is to completely remove A.C.
Heat Exchanger
Heat exchanger having three stages
1. First stage the temperature of syrup is 85oc.
2. 2nd stage temperature of syrup decreased in between 40-45oc.
3. 3rd stage the temperature of syrup is 25oc.
Then simple syrup is stored in storage tank.
Clean In Process (C.I.P)
The main purpose of clean in process (CIP) is to clean the syrup tanks when needed. It is
required because if market demand is more of Pepsi but changed to Dew, then tanks must
be washed through CIP to make, as different chemicals are used in different brands.
Steam is present in CIP system and through brushes and different rotators syrup tanks are
washed.
These three plants are very much closely related. They also live side by side. High steam
and brushed makes easy to wash tank automatically. This plant solution is also checked at
different levels be the chemists of quality control department.
Test Performed for Syrup
1) T.A TEST
2) INVERTED BRIX TEST
3) BRIX TEST
4) C.D TEST

1. T.A (TITRATABLE ACIDITY) Test

 Take 100 ml sample in beaker.
 T.P.C (tripotassium citrate) only for pepsi.bcz in Pepsi phosphoric acid in high
quantity. To reduce phosphoric acid in Pepsi sample we add 2ml T.P.C.
 Titrate with sodium hydroxide.
 Note the reading if it reading is 11.78 multiplied by factor 1.0.

2. INVERTED BRIX
1) Take a sample 30ml
2) Add1 drop of HCL.
3) Place into water bath at 90oc temp. for 45 mints
4) Cooled the sample.
5) Then check the brix on refractometer.

3. BRIX Test
1) Take 500ml simple syrup in cylinder
 2) Dip the hydrometer into cylinder.
3) Note the brix and temperature on the hydrometer
4) Note the reading.

4. C.D (Control Drink) Test

1) Take few O.Z for water into C.D flask.
2) Take 2 O.Z of finished syrup sample.
3) Add into C.D flask until reached 12 O.Z.
4) Shacked well.
5) And note the reading onto Rafractometer.
Chapter No: 5
Bottle Washing
Bottle Washing
We divide the empty bottle 2 categories
1) Glass bottle (250 ml, 1 ltr)

2) Pet bottle (0.5 ltr, 1 ltr, 1.5 ltr, 2.25 ltr)

We will understand the process of filling for both the bottles as there is slight difference in these
2 products:-
For Glass Bottles
Empty bottle is brought by the help of lifter and catcher brought these bottles to the conveyor
belts for further process

Then Bottle is brought to the washer and in washer. It is very important portion of the filling unit
and special attentions are concentrated on that process because whole quality of the product is
depending upon that portion. There are many stages of washing and bottle is washed by hot
water and caustic soda and clean water.

Then this clean bottle is brought to the filling machine

The bottle is being filled with beverage

After filling the bottle, capper is used for capping the filled bottles.

Then again, catcher is used for packaging the bottles to crates then by lifter it is transported
ET
B
G
FILA
R
V
N
D
S
P
M
U
C
H
O
K
Y
The complete chart of all the processes for Glass bottles is as
For PET Bottles
Empty bottle is brought from blow molding unit to the filling unit by the help of air conveyors.

The empty bottle is brought to the filling machine

The bottle is clamped with the help of clamping devices for further operations

This empty bottle is washed by treated water

The bottle is filled with beverage by filling machine

Capper is used for capping purpose

Then final product is wrapped with plastic sheet and packaging is done. So final product is trans
shipped for the sales
PACFILGBEKVRN
The complete chart of all processes for PET bottles is as
Process Flow
First of all the empty bottles are put on the running conveyor. Conveyor is in the moving
state with the help of pulley and gear system. Point to be noted that soap is put on
conveyor and boiled water below the conveyer melts the soap, creating its foam its foam
on conveyer thus bottles smoothly pass on it and not fall.
 In next step bottles pass from both side of the of light screen on light conveyor,
thus operator checks either is any breakage, is printed monogram on bottles, so
that pick those bottles and remaining bottles reach the table conveyer.
 Now machines put the bottles in tank no: 1 once at a time. There are pre-rinse jets
in first tank. It has treated with water coming from tank no: 4 through carry over
pump. Tank no: 1 has only soft water. The water is replaced on weekly basis.
 After initial washing bottles enter in 2nd tank which is big size than 1st tank. Pump
is attached with caustic tank which suck water (caustic mixed) from it and after
passing from filter this water falls on jets. Jets through water with pressure inside
the bottle for washing.
 Tank no: 3 which is big size than tank no: 2 and has caustic in it. It is used to clear
washing and appearance and also used to remove date from bottle. Its remove
impurities, straws, bees’ ets from water. It also has five jets.
 Now bottles enter into tank no: 4 which have only soft water in it. Temperature is
maintained from bottles coming in it and by the wall of 3rd tank at 45-55oc.no use
of steam pipe line for temperature. Here a pipe line is coming from R.O plant for
treated water. When bottles are near to come out from washer, treated water is
used to wash from inside at the end of process.
CHAPTER NO 6
Bottle Inspection
Bottle inspection
Bottle inspection is very necessary to meet quality of company products. During inspection we
see that that bottle is free from foreign matter, visible clear.
Rotation of inspectors
Rotate Inspectors between empty inspection and other duties at regular intervals in order to
maintain a high efficiency in rejecting dirty and defective bottles. Below rotation rules are being
followed.
Stages of Bottles Inspection
These are three stages of bottle inspection.
I. Pre inspection
II. Post inspection
III. Full good inspection.
I. Pre- Inspection
This is the stage before bottle washing.
During this stage we remove following bottles.
 Broken bottles
 Cracked bottles
 Chipped bottles
 Damaged bottles
 Fainted bottles
 Badly scuffed bottles
 Other bottles of the product
 Painted bottles
II. Post- Inspection
This is the stage after bottle washing.
At this stage we remove following bottles
Inadequate cleaned bottles include those with foreign objects or dirt inside bottle
 Rusty neck bottles
Damaged bottles during washing.
III. Full Goods Inspection
This is the stage after filling of bottles
The following types of bottles must be removed
 Low filled bottles
 High filled bottles
 Unsealed bottles
 Improper crown cork bottles
 Bottle without date code
 Containing any foreign matter
 Dirt inside the bottles
 Fainted bottle
 Damaged bottle
Chapter No: 7
Main LAB
Apparatus used in main LAB are
 CARBO QC & PFD APPARATUS
 TURQUE TESTER
 RAFRACTO METER
 T.A APPARATUS
 PH METER
 SECURE SEAL TESTER
 REAGENT BOTTLES
 GLASS WARE
 DEGASSING APPARATUS

 CARBO QC & PFD APPARATUS

A special type of device is used for gas volume ratio.

The CO2 content strongly influences the taste of alcoholic and non-alcoholic beverages.
For this reason, as well as for product safety, the precise measurement of the CO2 content
is an important task in the production and quality control of beverages. A new measuring
method that avoids the shortcomings of conventional methods of CO2 measurement has
been developed by Anton Par. This measuring method, incorporated into the Carbo QC
Beverage Carbonation Meter, is not influenced by other dissolved gases such as oxygen
and nitrogen, requires no sample flow during the measurement, is rapid, and needs only
minimum sample volume.
The Carbo QC beverage Carbonation Meter by Anton Par fulfils all these requirements!
The Multiple Volume Expansion Method implemented into Carbo QC is patented and
allows the fast and precise determination of the true CO2 content bottles. In combination
with a PFD Piercing and Filling Device, sample is transferred directly from bottles or
 cans to Carbo QC. A PFD Piercing Filling Device allows direct sample transfer from
corked bottles. It penetrates most kinds of corks –without any CO2 losses!

 TEMPERATURE TEST

Bottle is opened and temperature is checked with thermometer. Thermometer is shacked

inside the bottle and reading is taken.
 DEGASSING TEST
Bottle is taken in 500ml beaker and is placed under degasser. Degasser is a device in
which air is blowing out with pressure for 5 and 15 minutes. Due to Air blowing foaming
is produced and solution is degassed. Degassing is done to check the brix of the finished
product.
 BRIX TESTING

Funnel, vacuum pump, beaker 250ml, and refractometer

 Take the filled bottle from the production line and remove the crown and wash the
funnel using some beverage from the bottle.
 Close the funnel valve and fill it with 200ml beverage. Seal the funnel by cap of
vacuum pump.
 Switch on the pump and start the stop watch, slightly open the funnel valve to left
the air sucked by the pump.
 The vacuum sucked the co2 from the beverages or “decarboxination” is done for
10 mints app.
 Stop the stop watch and switch off the vacuum pump.
 Take the sample on spoon and put on the rafractometer.
 Note the brix
 CROWN TESTER
It is done by the crown cork tester. A sample crown is passed through this tester and is
observed that cork is passed or passed or not passed according to standards. If there is
fault then, it is advised to mechanical section to reduce this fault.
 TORQUE TEST
Torque is twisting force which measures the rotation around its centre axis.
For torque test torque tester instrument is used which show the tightness of closure.
1. Bottle is adjusted above the torque.
2. And when green signal show press ok.
3. Screen show zero value.
4. Value will appear on screen
5. That will be torque value.
6. The value of torque should be 9 to 17.
7. Torque is checked after 45 mints.
Chapter No: 8
Incoming Material Testing
Raw Material
1) Water
2) Sugar
3) Concentrate and Beverage base
4) CO2
Testing of PET Bottles
Sample collection
First of all check the sample and delivered quantity.
We should required (24 bottle per truck load and delivered to lab.
When delivered the lab.
We check different parameters
 Height
 Weight
 Shoulder diameter
 Label diameter
 Stress cracking
 Net content
 Burst test
 Drop impact test
Height
The height of the empty bottles is measured with the help of height gauge. The height of
the empty bottles should be according to PCI standards.
Weight
The weight of the empty bottles is measured with the help electric balance.
Shoulder Diameter
 The shoulder diameter of the bottles is measured with the help of dial caliper.
Label Diameter
The label diameter of the empty bottles is measured with the help of dial caliper.
Stress Cracking
Stress cracking test is performed to check any crack at the bottom of the bottle.
 Make 0.2% solution of caustic.
 Dip the bottom of the bottle in the solution
 If there is any crack the water is leak out from bottle. It is not ok bottle.
 If there is no leakage at bottom it is ok.
Drop Impact Test
In drop impact test we drop the bottle from different angle to check its strength.
Net Content by Weight
 Determine weight of the empty bottle with help of electric balance.
 Determine full good weight of the bottle (empty bottle + liquid)
 Beverage weight = full good weight of bottle – empty bottle weight
 Divided with temperature.
Burst Test
The burst test internally and increasingly pressurizes a package until an area of the
package seal around the perimeter "bursts" open in response to pressurization. By placing
the package within restraining plates during pressurization, the dimensional stability of
the package is maintained in a manner that results in stresses applied more uniformly
along the perimeter of the package, where seals are normally placed. This allows the test
to have a higher probability of detecting the weakest area of the seal and provide a
measurement of the pressure required to "burst" open the package.
Testing of Packaging Boxes and Trays
 The sampler draws 08 samples each a lot.
 Parameter.
Check the following parameters
 Length
 Width
  Height
 Color
 Label condition.

Testing of Crown
i. Take samples of 10 crown.
ii. Height is measured with venire caliper.
iii. Length is measured by venire caliper.
iv. Weight is measured with electric balance.
v. Observe the label condition.

Testing of Closure
 Take the sample of 10 closures.
 Height is measured by with venire caliper.
 Length is measured with venire caliper.
 Weight is measured with electric balance.

Beverage Based Testing

Check no. of delivered quantity.
Visually inspect containers and boxes for damage.
 Leakage during transport.
 Label
 Date of expiry.
 Sealing of container.
 Sealing of boxes.

Releasing Process

To releasing process when any incoming raw materials enter the industry quality give the

 Lot. No
 Item code
 Releasing date
 Receiving date
  No. of container
 Analyst name
 Expiry date

Chapter No: 9

AQUAFINA
Water is the necessity of our daily life, it’s so important for us that we need clean,
safe and sanitary water every day, and usually there’s a more strict inspection standard in
the more advanced country. There are two kinds of drinking water in the market. One is
the natural water, which is called mineral water. The other is processed water coming
from underground or from the pipe of water plant, which is called R.O. water, space
water or pure water. Mineral water comes from natural springs. It contains a lot of
various kinds of chemical goods such as potassium, magnesium and calcium, which are
healthy to our body. After the water is filtered and sterilized properly, it’s our first choice
to use it. However, the shortcoming is that the source of mineral water is limited. On the
other side, pure water doesn’t contain any nutrition, but it’s easy to be obtained and very
clean after being processed. It tastes good with PH value 5-7 that’s the reason why people
like it very much. Pure water is processed through different stages of a filter system such
as sand, carbon, and Reversed Osmosis System. The water is passed Page 49 from 5
micron through 1 to 0.2 micron filter. After that, pure water can be filtered to remove
harmful materials with an efficiency of 96%.
Method of Mineral Water Testing
Processing mineral water from underground water resource or other resources goes as
follows.
1) Motor pump is used to draw water from theses sources or source which is transported
to the source water reservoir. Coagulation chemical is added to remove the settled
colloidal and suspended materials contaminated in the water. Water is then sterilized
using oxidants like chlorine or other chemicals to kill harmful bacteria and
microorganism.
 2) Filtration is the next step. Using filtration system like Quartz Sand Filtration System
gives good purifying results. After purification water contains very little amount of
suspended solids.
3) For further purification, water is absorbed on the activated carbon which absorbs most
pollutants dissolved in water. This also helps in the removal of the odors and helps in
improving the flavor of the water.
4) After being purified water softening is done by passing water through the tank
containing sodium ion. The tank consist of resin pellets and the softening is done by ion
exchange method Water still contains small micro pollutants that are removed by passing
them through tanks that are meant for this purpose. Apart from this method reverse
osmosis process is also used for obtaining pure water. In this process water is purified by
using semi permeable membrane. Purified water is sterilized or disinfected and then
packed for market.
Process Description
 Natural springs or underground water drawn by the motor pumps is sent to the source
water reservoir. An agglomeration of colloidal and suspended materials contaminated
in the water settles and is removed through addition of coagulant chemicals. The
water is then processed by sterilization with chlorine or related chemicals so as to kill
a large portion of the bacteria and microorganisms in the water.
 The water is then filtered through layers of varying depth of uniformed Quartz Sand
Filtration System. This slow filtration gives good purifying results so that the water
will not contain any large quantity of suspended solids.
 The water is then absorbed on the activated carbon. It’s currently one of the safest
means for purifying drinking and mineral water. Activated carbon absorbs most
pollutants dissolved in water. Water containing a very small quantity of residual
pollutants can be removed. Water purified through the activated carbon process may
have odors removed and its flavor improved.
 The water passes through a salt tank full of Na+ ions where there are lots of resin
pellets in it. The purpose of using Na+ ions is to soften the water; most of the
different mineral goods are absorbed away from the water in the process.
  The water is then passed through the 1.45μand 1μfilter, which eliminates the micro
pollutants and micro toxic substances.
 The treated water is then discharged into a UV sterilizer system for sterilization. This
process destroys any disease-producing bacteria or microorganisms which might exist
in the mineral water, thus making it more sanitary and safe to drink.
 The final 0.2μfilter is then used as a final safety filter since the water must be
permanently free from any matter that might escape from the proceeding treatment.
After that, the treated water is stored in the pure sanitary grade water reservoir.
 The mineral water is then pumped into the filling machine. The high-speed machine
fills seals and dates the carton automatically.
 The sealed cartons of mineral water are then moved into a refrigerated warehouse by
a convey system where they remain until ready for shipping.
 As for pure water RO processing system, it starts the same processes with mineral
water for the beginning five stages, then
 Through a buffer reservoir, water is passed through the 5μand 1μfilter, which
eliminates the micro pollutants and micro toxic substances.
 Reversed Osmosis System is used to make sure that mineral goods are removed from
the water completely.
 An Ozone Producing Equipment is used to produce ozone; the treated water is then
mixed with ozone in the mixing tank for sterilization

Pre-Treatment Operations
After the completion of water treatment process, the pet bottle is filled is the water and nitrogen
gas is dozed into the bottle and after this cap is applied by capper machine. Plastic sheet is sealed
at the neck of the bottle to make it seal pack and ink coder is used for coding on the pet bottle

Capping of mineral water bottle Sealing pack the mineral water bottle
The final product is automatically and manually inspected, if any defect is found, the defected
piece is separated from the lot. Then product comes to the packaging line with the help of
conveyor belt and it is it is wrapped and packed with the plastic sheet and then to the lifter and
then for transportation.

Packaging of the product

Process of Mineral Water Treatment

Chapter No: 10
Blow Molding
Blow molding is a manufacturing process by which hollow plastic parts are formed. It is a
process used to produce hollow objects from thermoplastic.
The basic process has two fundamental phases. First, a pre form (or parison) of hot plastic resin
in a somewhat tubular shape is created. Second, a pressurized gas, usually air, is used to expand
the hot pre form and press it against a mold cavity. The pressure is held until the plastic cools.
This action identifies another common feature of blow molded articles. Part dimensional detail is
better controlled on the outside than on the inside, where material wall thickness can alter the
internal shape. Once the plastic has cooled and hardened the mold opens up and the part is
ejected.
Process description
Blow molding is a manufacturing process that is used to create hollow plastic parts by inflating a
heated plastic tube until it fills a mold and forms the desired shape. The raw material in this
process is a thermoplastic in the form of small pellets or granules, which is first melted and
formed into a hollow tube, called the parison. There are various ways of forming the parison, as
explained below. The parison is then clamped between two mold halves and inflated by
pressurized air until it conforms to the inner shape of the mold cavity. Typical pressures are 25 to
150 psi, far less than for injection molding. Lastly, after the part has cooled, the mold halves are
separated and the part is ejected.
Material for Blow Molding
Parts made from blow molding are plastic, hollow, and thin-walled, such as bottles
and containers that are available in a variety of shapes and sizes. Small products may include
bottles for water, liquid soap, shampoo, motor oil, and milk, while larger containers include
plastic drums, tubs, and storage tanks. Blow molded parts can be formed from a variety of
thermoplastic materials, including the following:
 Low Density Polyethylene (LDPE)
 High Density Polyethylene (HDPE)
 Polyethylene Terephtalate (PET)
 Polypropylene (PP)

Chart for the different steps involved in the blow molding process
 WORK DONE BY ME
I have been interning at production department, I was a team member of their production team.

INTERNSHIP SCHEDULE IN PRODUCTION DEPARTMENT

Description Period No of Days

Syrup Room Section 6. June. 2016 to 9. July. 2016 4
Water Treatment 10. June. 2016 to 12. July 2016 3
Quality Control 13. June. 2016 to 16. July. 2016 3
Line - 1 17 June. 2016 to 19. July. 2016 3
Line – 2 20. June. 2016 to 22. July. 2016 3
Line - 3 23. June. 2016 to 24. July. 2016 2
Line - 4 26. June. 2016 to 27. July. 2016 2
Line – 5 28. June. 2016 to 30. July. 2016 2
Line - 6 31. June. 2016 to 1. July. 2016 2
Blow Molding 3. July. 2016 to 4. July. 2016 2
Aquafina 5. July. 2016 to 6. July. 2016 2

Learning and Outcomes

My internship was a mixture of labor intensive work and practice of having good interaction with
employees. I learned to analyze employees behavior with in the production area, how a
process is complete, and how organizational structures & culture are built. I learned how I
should listen harsh words of employees about the incentives and bonuses and to respond to
their queries in an effective manner. I became skilled at satisfying employees and building good
relations with them to get more information about production process.

SWOT Analysis of Production Department in PBC

Strength

 High experience staff involves in production process.

 High motivated staff

 To provide customer high quality products to customer.

 Production department work on the behalf of customer requirements

 Production department is back bone of PBC

 To pay the operators on daily basis.

 Keno technology system of PBC is the competitive advantage in the market to reduce

time of production and improve quality

 Proper feedback to top management about the production issues.

 All departments (Factory) depend on the production department.

 Establish market linkage directly or indirectly with customers.

 Raw material is converting in finished products.

 Production department is ability to make customized products

 Traditional skill based with sufficient manpower resources

 Maintain the product consistency with the customer requirement

 Good working Coordination among top and lower worker level

 Control of quality in assembly line (example quality feedback, defects and root cause)

to share with upper management

 Working environment 5S + 1 implement in PBC

 Skilled labors will increase productivity

 Positive image of the PBC in the market

 Situated in an area where cheap labor is available

 Imported machinery use with in factory to improve efficiency

 High Financial Resources

 Management team is highly competent professional

 To become leader in beverages in domestic and Asian market and to achieve a highest

level of success

 To build the PBC on sound financial bases with better productivity, quality, and

improve production t stable cost by using latest technology

 The best profitable company by improving terms of quality, productivity, reliability, and

customer satisfaction

 Production department prepared many reports like (Daily production reports,

Efficiency reports, Faults reports, Inline reports, Packing reports)

Weakness

 De motivated employees

 No Promotional Activities because reference is prefer

 Not enjoying the Economies of large scale in the market

 Centralized decision making.

 High labor cost and power & fuel cost

 Working environment is like a funfair (music and hooting of seniors)

 Every employee have own a culture

 Lack of training in organizations for workers, supervisors and managers.

 Same salary of all production employees that result no concept in PBC about senior &

junior.

 Poor linkages between customers to jointly resolve their problems.

 Inadequate up gradation in terms of efficient repair technology

 Poor management skills to improve the daily targets

 Production department is not focus on quality

 Inadequate levels of cooperation and trust between top to bottom

 Production department is major deficiency to maintain the quality

 Some time Production department is not follow up the quality department requirements

 The upper management of production department is not properly utilized the authority

 Production department is not utilized weekend holiday due to extra work load.

 No system developed to motivate the employee

 There is weakness in the quality system because mostly worker don’t follow them
  Lack of team work at managerial level. Group tasks are not given to the employees rather

they are assigned individual work load.

 No reward system is given to operators and all reward is divide in the management

Opportunities

 Production department is direct communicate with buyer

 Scope for effectively exploiting markets with phase out quota rule effectively

 Scope for Technology up gradation on equipment front

 Availability of core material for necessary up gradation.

 Scope to work together on various departments to enhance cost and quality

competitiveness

 Scope to work together to some considerable cost reduction on the production

 Source from optimal sources in Pakistan and abroad and develop performance with

growth

 Scope to enhance efficiency, energy use and pollution issues by utilizing international

expertise

 Production department work on the behalf of buyer

 Production department can hire well educated and experience management staff to

improve efficiency

 Work efficiency increased

 Customer satisfaction

 Produced better quality products

Threats
  Filler Operator is not responsible for quality

 PBC is focused on production rather than quality

 Enhanced cost and quality competition from other competitor

 Inadequate direct information base on competitors as also local markets affecting

performance.

 Increasing cost of production when make defective products

SWOT Analysis of Quality Assurance Department in PBC

Strength
 High qualified and experience staff to check & assure the quality
 High motivated staff
 To provide customer defect free products
 To measure the organization quality system
 Proper feedback to top management about the beverages quality
 Control of quality in assembly line (example quality feedback, defects and root cause)
 Different action checklist to improve the quality
 Identify the fault and find out the root cause in production department
 Maintain the product consistency with the customer requirement
 Reduce the fault rate
 Checking the suitability of material, process, syrup room, water treatment and packing.
 Establish fault rate recording system
 To give the quality awareness training
  Implementation of quality standard 9001, Ukas Quality System, Moody
 Use the military standard 105 E, for random sampling criteria for acceptance or rejection
 Quick detection and correction of inferior quality
 Protection and preservation of product quality during filling, storage and delivery.
 Good working Coordination among top and lower worker level

Weakness
 Quality assurance department work on the behalf of customer requirements
 Quality assurance department not properly utilized the authority
 Quality department diagnosis the faults in raw material, process and finished product but
approved it to use.
 QA staff mostly time consume in labs that result many problems incurred in production
and enhance the organization cost.
 QA is not utilized weekend holiday due to extra work load.
 No system developed to motivate the employee
 QA team identify the fault but no action taken against that department during daily work
 Due to the shortage of QA staff it is very difficult to check the daily production issues
 No corrective and preventive action taken to improve the quality of product in work flow
 There is weakness in the quality system because mostly worker don’t follow them
 AQL and OQL technique used 20 to 30% audit fail
 Boredom Office Environment Lack of Culture of Intrinsic Reward
 Lack of team work at managerial level. Group tasks are not given to the employees rather
they are assigned individual work load.

Opportunity
 To help quality control and production department
 Direct communication with buyer
 QA department work on the behalf of buyer
 QA department can hire well educated and experience staff
 Internal auditors are opportunity to work on the behalf of buyer
  Work efficiency increased
 Produced better quality product
 Control excess damage
 Customer satisfaction

Threats
 Operator is not responsible for quality
 PBC is focused on production rather than quality
 Cost of poor quality is equal to zero if quality is not working actively

Suggestions
About Production and Quality Department
 In the production hall, very concerned person must use masks, gloves and safety glasses.
 Earplugs should be provided to the people working in the production hall.
 Proper sitting room should be provided to CO2 supervisor to keep the spare parts, tools
and documents safely.
 Labor should wear neat and clean uniform.
 Skilled manpower availability is less in PBC that reduces productivity.
 It can be improved the efficiency by giving training to employees.
 When change the plan, time is directly affect the production cost
 Manpower Availability of Skilled labors is only in the range of 35%.
 Proper arrangement should be for draining
 Many under 18 age boys are working in production
 Every problem is solved with systematic process like from the root of the problem
 Different training courses should be arrange for improving the quality of work for staff
about six sigma and lean manufacturing
 Internal auditors have opportunity to work on the behalf of buyer if auditor are certified
PCI.
 There is also a problem of work overload for the QA staff and it should be control
properly that employee have need motivated.