Factory Story: Eclairs, Toffee, and Candy Production in Sangli
The toffee and candy factory in Sangli operates at a modest 30% plant capacity, producing 5 tons of eclairs and
15 tons of toffee daily. The factory is staffed by 170 employees, with 6 people managing both candy and eclair
production on the first floor. For packaging, 10 women work at each of the **10 tables.
Key Operational Insights:
Production Breakdown:
o Eclairs: The factory produces 5 tons of eclairs every day to meet market demand.
o Toffee: The toffee production line is much more active, producing 15 tons daily, but it involves a
more complex, space-intensive process.
o Candy Cooking: Candy is cooked continuously, with the factory using 4.5 tons per day of raw
materials to ensure a steady production output.
Batch Processing: Toffee production follows a batch size of 80 kgs per cycle. The process includes
several stages:
1. Toffee Sheet Creation
2. Cooling
3. Manual Labor for Separation & Rolling
4. Post-Cooking Processing (Cutting & Wrapping)
5. Storage: After wrapping, the toffees are stored in 7 racks, each holding 12 kg per stack.
Space and Process Optimization Issues:
o The factory is facing significant space constraints, especially in terms of production and storage.
The manual labor needed to separate and roll toffee sheets occupies considerable floor space
and hinders the overall process flow.
o Cooling space is limited, which delays the toffee production process. Several steps, such as
rolling and cutting, require manual labor, reducing efficiency and plant capacity utilization.
o Packaging and Storage are also impacted by space inefficiencies. Toffees are stored in trays on
racks, leading to disorganization and slower movement of goods.
o Batch Processing in the candy section results in downtime between cooking and cooling phases,
affecting overall output.
Production Process Breakdown:
o Eclairs are produced efficiently, but manual labor is heavily relied upon in packaging.
o Toffee production involves multiple manual processes that slow down the overall production
speed.
o Candy Cooking is continuous, but still uses up significant space and resources.
Challenges and Areas for Improvement:
1. Space Utilization:
o The factory struggles to optimize space, particularly in cooling and storage. Limited space
results in a slowdown in production and storage inefficiencies.
o The layout on the first floor is congested, with both candy and eclair production sharing tight
space, leading to workflow disruptions.
2. Process Bottlenecks:
o Manual labor-intensive processes (separating, rolling, cutting, and wrapping) slow down
production, contributing to low capacity utilization (currently 30%).
o Batch sizes of 80 kgs result in frequent pauses and downtime, reducing production efficiency.
3. Packaging Efficiency:
o Packaging workflows are inefficient due to the limited space and the large volume of products
to be packaged. This reliance on manual labor results in slow throughput.
o An automated or more efficient packaging system could significantly improve this process.
4. Capacity Utilization:
o With only 30% capacity utilization, the factory is underperforming. Optimizing space and
processes could boost production without major new investments.
Solution Possibilities:
Space Optimization: A complete redesign of the layout would help separate the candy, eclair, and toffee
production areas, improving flow and reducing congestion. More automated cooling systems could help
speed up the toffee-making process.
Process Automation: Automation of manual processes, like toffee sheet separation, rolling, cutting, and
wrapping, would reduce labor costs and increase output.
Improved Packaging Systems: Adopting automated packaging solutions could streamline the wrapping
process, increasing efficiency and reducing reliance on manual labor.
Batch Size Adjustment: Increasing the batch size or refining production cycles to reduce downtime
could help improve throughput and reduce bottlenecks.
Need for Detailed Inspection:
In order to fully address these issues and implement the most effective solutions, a more detailed, on-site
inspection of the factory is necessary. This will allow for a deeper understanding of the production floor layout,
process flows, space constraints, and potential areas for improvement. By visiting the factory and observing the
operations firsthand, we can develop a more tailored and practical approach to optimizing space and processes,
ultimately boosting capacity utilization and improving operational efficiency.
Conclusion:
This factory in Sangli has great potential for growth, but it faces significant challenges with space utilization
and process optimization. By redesigning the layout, automating key processes, and optimizing storage, the
factory could significantly improve production capacity, reduce operational costs, and enhance overall
efficiency.
