Group D - Icecream Factory

8/2/2019 Group D - Icecream Factory

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Group Members:Syeda Sana 8916Sidra Shahid 8989Suneel Emmanuel 9317

Sadiq Saleem 8605

ICE CREAM FACTORY




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Project Scope Management:




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•Stakeholder

Register:Main

1. Collecting Requirements:



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Requirements Documentation:

Requirements documentation describes

how individual requirements meet thebusiness need for the project.

Consumers require healthy, tasty withsome form Basically the governmentneeds income through taxes, employeeswants their due share, creditors wants the

return on money. So, proper functioning of factory will provide all of them their due



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GAP: Current demand for ice cream isaround 160 million liters while its productionfrom documented sector is around 60 millionliters that means there is a huge marketavailable though their need is satisfied bysmall producers but with good brandawareness this market can be captured.With

these estimates and calculation we get Gapof around 100 million liters in Pakistan and60 million liters for Punjab.




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.

Expert

Judgement

2.Define Scope:



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ProjectScope

Statement:



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Project deliverablesincludes the types of

ice creamKulfa (2 lit)

Kulfa (1 lit)

Kulfa (cup)




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3. Create WBS:



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Tools & Techniques:

The Decomposition technique is used

for the purpose of having WBS.



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WBS Diagram:

Starting upmanufacturi

ng

RawMaterialPurchase

TestingPhase

Machinery

Installation

Transportation

Packaging

Recruitment

- Tendernotice –quotationanalysis

- Finaldecision

BuyingMachinery

Constructionof factory

Availabilityof utilities

MarketAppraisal

Land buyingLicense formanufacturi

ng




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InspectionInspection includes activities such as

measuring, examining, and verifying todetermine whether work anddeliverables meet requirements andproduct acceptance criteria.

4. Verify Scope:



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Change Requests

Not only unbranded products




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Variancecontrol to

5. Control Scope:




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PROJECT TIME MANAGEMENT




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The tool used is decomposition whichinvolves subdividing the work packagesinto smaller, manageable components

called activities.

1. Define Activities



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Activity List & Activity Attributes:

The activities are as follows:•Market Appraisal:

The following analysis will be done regardingice cream`s:overview of industry especially local industry

market sizedemand and supply statusavailability of raw materialstrends of consumerssegments analysis

•License for manufacturing:



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•Constructing of a Factorystructure:

It involves the mapping,tender notice, analysis of quotations that is accepting& rejecting quotations.

•

Recruitment:Giving an add for hiring theengineers, technitian &other official staff.

•Buying machinery:Involves the tender process.Basically the following unitsare required which includes:

freezing units



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•Install / deploy machinery:Involves the creation of foundation, setting up of

units and connection of units

• Testing phaseMajor phase which may consume time if there

came a problem in machine.

•Raw Material purchaseWill seek in for Lowest possible price with bestquality material.

Required raw materials are:1.Milk2.Butter3.Sugar

4.Eggs5.Dry Fruits



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Manufacturing Process

Raw material delivery & storage

Blending the mixture

Pasteurizing

Homogenizing

Cooling

Adding flavor

Continuous Freezing

Adding extra Fruits and chunks

Packaging



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Ice cream produce flow chart

Source:



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k. Transportation of final product.

Milestone List:

• To get the licence,•Avail resources,•Buying machinery•End product manufacturing.




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TOOLs & Technique: The tool used for network diagram

is Project Diagramming Method(PDM).

2. Sequence Activities:



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Activity Prior Activity

1 None

2 1

3 2

4 3

5 3

6 3

7 3

8 5

9 8

10 9

11 10

12 11

13 12

OUTPUT



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Project deliverablesincludes the types of

ice creamKulfa (2 lit)

Kulfa (1 lit)

Kulfa (cup)




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PROJECT TIME MANAGEMENT




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The tool used is decomposition whichinvolves subdividing the work packagesinto smaller, manageable components

called activities.

1. Define Activities



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•Constructing of a Factorystructure:

It involves the mapping,tender notice, analysis of quotations that is accepting& rejecting quotations.

•

Recruitment:Giving an add for hiring theengineers, technitian &other official staff.

•Buying machinery:Involves the tender process.Basically the following unitsare required which includes:

freezing units



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•Install / deploy machinery:Involves the creation of foundation, setting up of

units and connection of units

• Testing phaseMajor phase which may consume time if there

came a problem in machine.

•Raw Material purchaseWill seek in for Lowest possible price with bestquality material.

Required raw materials are:1.Milk2.Butter3.Sugar4.Eggs5.Dry Fruits



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Manufacturing Process

Raw material delivery & storageBlending the mixture

Pasteurizing

Homogenizing

Cooling

Adding flavor

Continuous Freezing

Adding extra Fruits and chunks

Packaging



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Ice cream produce flow chart

Source:



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k. Transportation of final product.

Milestone List:

• To get the licence,•Avail resources,•Buying machinery•End product manufacturing.




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TOOLs & Technique: The tool used for network diagram

is Project Diagramming Method(PDM).

2. Sequence Activities:



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Activity Prior Activity

1 None

2 1

3 2

4 3

5 3

6 3

7 3

8 5

9 8

10 9

11 10

12 11

13 12

OUTPUT



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4

2

6

7

9

1 1

1 3

3

1

5

8

1 0

1 2

PDM



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3. Estimate Activity Resources

Tools & Technique:

We will use the tool of Expert judgement andalternative analysis.



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Activity Resource Requirements:

Manpower Resource requirements can bebifurcated intoHRExecutive officialsEngineers

Technical staff Blue colar staff

Raw Material s required for initiatingproduction are as follows:•Milk•Sugar•

Butter•Fruit pulps•Dry fruitsProject Document Updates:

The documents are updated with theinformation contained in this section.




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• Tools & Techniques used:

Expert JudgementAnalogous Method

•15% probability of exceeding 1 month& 85 % probability of completion in thegiven time.

4. Estimate ActivityDuration:




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Tools & Techniques:

Gantt chart

5. Develop Schedule:



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OUTPUT: GANTT CHART




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6. Control Schedule:



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Tools and techniques:

We basically focus on two tools:

Performance Reviews

Performance reviews will be done tomeasure, compare, and analyze scheduleperformance such as actual start and fi

nish dates, percent complete, andremaining duration for work in progress.

Variance Analysis



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Work Performance measurements:

The values for SV and SPI will be

calculated.

Organizational Process Assets Updates

Organizational process assets that maybe updated includes the following:

• Causes of variances,

• Corrective action chosen and the



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Plan quality Quality assurance Quality control• Raw materials delivery • Suitable and perfect



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Raw materials delivery& storage

Suitable and perfectenvironment

• Mixing units• Storage units• Freezing units• Homogenizer• Brine tank • Surface cooler• Filling and Packaging

line• Blending • Milk eggs, sugar,

• Refrigerated tanker

trucks• Stainless steel blenders.

• 36°F (2°C)• 1,000 gal (3,7851)

stainless steel blende• Blended for eight to te

minutes.

• Pasteurizing • To kill the bacteria.• Pasteurization machine• Thin stainless steel

plates.

• 182°F (83°C) flows onthe one side of theplates

• 180°F (82°C) water tokill bacteria.

• Homogenizing • High-pressure pistonpumps;

• Breaks down the fatparticles

• Air pressure of 2,000pounds per square inc(141 kg per sq cm)

• Cooling • The process of homogenizing will be

• Cold water 34°F (1°C),• Mixture: 36°F (2° C)•

Plan quality Quality assurance Quality control



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• Adding flavors • Flavorings are thenpiped into the vatsand will be blendedthoroughly

• 300 gal (1,136 1) of mixture

• Continuous freezing • Liquid ammonia will beusing as a freezingagent.

• Soft-serve ice cream.

• 700 gal (2,650 1) perhour.

• Temp insiderefrigerator: -40°F (-40°C),

• Adding extra fruitsand chunks

• Fruit feeder:strawberry or cookiechunks are evenlydistributed.

• Star wheel in pre-

measured amounts

• Packaging • Automatic fillingmachines

• Cardboard cartons• Lids• Expiration date• Production code• Plastic shrink

wrapping.

• Premeasured amountsof ice cream at therate of 70-90 cartonsper hour.

• Hardening • The cartons moveslowly back and forththrough the tunnel for

two to three hoursuntil the contents are

• -10°F (-23°C).

a qua y Qua y assu a ce Qua y co o



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ESTIMATE COST



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(Rs in (000)

SNO DESCRIPTION TOTAL COST

1 land 175235

2 building 57798

3 machinery local 570

4 machinery imported 44719.398

5 inland charges 20

6 erection & installation charges 200

7 contingencies 5000

8 furniture & fixture 5000

9 vehicles 12500

10 reproduction expenses 1000

11 interest during construction 27528

TOTAL FIXED COST 329570.398

INITIAL WORKING CAPITAL 50628

TOTAL COST OF PROJECT 380198.398

ESTIMATE COST

ESTIMATE BUDGET



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DESCRIPTION VARIABLE COST FIXED COST TOTAL COST

raw material 572140 0 572140

labor 37194 0 37195.2

manufacturing

overheads

37406 171700 209106

depreciation 0 8315 8315

administration &

general expenses

0 3876 3876

selling expenses 28 0 28

interest 0 37534 37534

amortization of

preproduction

expenses

0 333 333

TOTAL 646769 221757 868526

sales value of

production

1114649

Breakeven point [221757 / 1114649 -

646769]

0.47

ESTIMATE BUDGET

CONTROL COSTS:



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CONTROL COSTS:Set up time After the cleaning, pipes used for making closed-loopcleaning are disconnected andnozzles are installed back to theirplace

Product change over time change the running flavor by anotherflavor of Ice Cream.

size and replace it by the mold of anothersize

Holding cost holding one unit of product over a unit of time (oneweek in theselected case)

Inventory balance constraint inventory, forecast and production.Itsimply states that inventory level at the end of any given periodmust be equal to the inventory level atthe end of the previousperiod plus planned level of production less the forecasted salesduring this same given period.

No shortage constraint products should always be available to the




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Project HR management



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Human Resource Plan

Environmental Factors

it need to be noted that hazardous factors should be not beneglected during the different phases of development andtechnological use

Society of the area should be timely informed regarding theconstruction

Organizational Process Assets

The different assets of the organization should be usedappropriately

Resource Requirement ResponsibilityInfrastructure Staff

Asset Management administration

equipment Administration manager

Food Administration

Project Office Administration



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Roles and responsibilities The role and responsibilities of the projectcoordinator is to be accountable at every phase of development of the ice-cream factory



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Acquire Project Team

T he project manager or project management teamshould effectively negotiate and influence others whoare in a position to provide the required humanresources for the project

hence an experienced person should be hired who has

worked on the pervious related project and should work asa leader to carry out the initiative

Environmental factors

I f the human resources are not available due toconstraints, economic factors, or previous assignmentsto other projects, the project manager or project teammay be required to assign alternative resources, perhapswith lower competencies, provided there is no violation

of legal, regulatory, mandatory, or other specific c



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Develop Project Team

Teamwork is a critical factor for project success, and developingeffective project teams is one of the primary responsibilities of the project manager

Project managers should create an environment that facilitatesteamwork.

Project managers should continually motivate their team by

providing challenges and opportunities, by providing timelyfeedback and support as needed, and by recognizing andrewarding good performance

High team performance can be achieved by using open andeffective communication, developing trust among team



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Manage Project Team

Managing the project team requires a variety of management skills for fostering teamwork andintegrating the efforts of team members to create high-performance team

Team management will involve emphasis on

Ø CommunicationØ conflict management

Ø negotiation

Ø and leadership



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Project communication

Program Communication



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Program Communicationand governance

Program Meetings•Program Kick Off Meeting – ProgramLead

•Bimonthly meeting( once in two months)

with the Program

Communication Frequency Audience



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Communication Frequency Audience

Program Steering Committee

Meeting

Bi-monthly Sponsor, Key stakeholders,Program

Lead and Program Managers

Program Working group Monthly Program Lead, ProgramManagers,



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PROJECT PROCUREMENT



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The procurement process

Hydrogenated coconut oil, palm oilMilk Powder (Skimmed/Full Cream)

Ice Cream Stick

Emulsifier and Stabilizer

Food Colouring

Flavours

Glucose

Quar Gum

Chocolate Coating/filling



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Procurement of machinery

Continuous Freezer 5Homogenizer (1000lt/hr) 1

Homogenizer (500lt/hr) 1

PHE Chiller (1000 lt/hr) 1

PHE Chiller (500 lt/hr) 1

Cold Room 2

Ammonia Compressors KC-21) 2



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Contd..

Ammonia Compressors (5/5) 1Pasteurizer (1200Ltr) 1

Ageing Vat 5

Candy Making Machine 2

Pad Tanks 2

Ice Bank (30000Ltr) 1

Hot water generator 1

Automatic Cup /cone filling machine 1

Food Feeder 1



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PROJECT RISK MANAGEMENT



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Risk mananagement

.There are a couple of possible hazards,which could be associated with ice cream.Some of the basic bacteria according toHACCP in ice cream manufacturing are:

Bacillus cereus

Listeria monocytogenes

Salmonella

Allergen



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Critical control points in risk



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Critical control points in riskmanagementRaw materialsPasterization

Hardening, storage and transportation

aging



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Group D - Icecream Factory

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