Introduction

Production management is one functional area of total business management. It is also called production function of management. Production is the creation of utilities for meeting human wants. Here, men, material and equipment are used for the creation of goods, which can be used for different purposes. In the production process, raw material and other inputs are converted into finished goods for actual use. Production is transformation of raw materials by factory methods into things wanted by people or users. There is creation of utilities through the process of production. Satisfaction of human wants is the guiding principle of all production activities. Thus, production is a process by which goods and services are manufactured or brought into existence. Production is a combined result of materials, machines and other factors in operation. Workers/employees play an important role in bringing such combination of resources.

Definition of Production Management: -

The term production management is difficult to define precisely as production management is not independent of other areas of business management such as marketing, finance and personnel. However, production management which deals with the transformation of resources into goods and/or services. In simple words production management may be defined as the planning, organizing, directing and controlling the activities of the production function which deals with the conversion of raw materials into finished products.

This simple clear and exhaustive definition speaks about the coverage of production management. Production management is a decision-making process relating to activities involved in the production process.

PRODUCTION PROCESS

TYPES OF PRODUCTION PROCESSES:

1. PROJECT PROCESS: A type of process used to make one product at a time. These processes are used when there is high customisation 2. BATCH PROCESS: This is the manufacture of a product in batches (small or large) or lots by a series of operations, each operation being carried out on the whole batch before any subsequent operation is taken

3. LINE PROCESS: It is used to produce a large volume of standardise products. With line process the product is produced with little or no customisation.

4. CONTINUOUS PROCESS: Here production is carried out continuously through uniform and standard sequence of operations using highly sophisticated and automatic machines.

MAD OVER DONUTS

INTRODUCTION

Mad over Donuts is specialty donut concept the very first of its kind in India, and has already managed to sweep Mumbai to be part of the donut revolution that has taken the world by storm, with people thronging the stores to get their hands on fresh, hot donuts.

It now has 20 stores in Mumbai and branches all over the country in cities like Pune, Bengaluru, and Delhi

The Manufacturing Process

I) Acquiring the ingredients

The company imports its ingredients from Singapore. It starts from the Mad Over Donuts manufacturing plant in Singapore, which produces proprietary mixes which are directly imported to India. Majority of the ingredients used in the donut recipe are imported particularly their secret donut mix which is produced at a state of the art laboratory in Singapore. The donuts are freshly made every day, throughout the day. That covers practically everything, from the dough to the toppings. The raw materials include two major ingredients 1) Dough(flour)

2) Toppings II) Mixing and kneading The flour mixture is then poured into a large mixing bowl put onto an mixer and the appropriate amount of wet ingredients are added depending on weight of the batch and type of doughnut in production. The dough includes water , salt ,flour,yeast and a premix from Singapore. The dough mixer then begins its work; a large dough hook first mixes and then simulates the human kneading process, pulling and stretching. The mix runs on an automatic timer and the entire mixture, including the softened yeast, is kneaded together for approximately 13 minutes.

III) Sheeting It is essential that yeast dough "rests" or simply sits for about 10 minutes after it is mechanically kneaded. At the end of this period, good-quality dough is spongy and

soft. The donuts are then gone to a automated sheeter. So on a sheeter the dough is rolled out and flattened. It is rolled out with a mechanised rolling pin.

IV) Cutting Here the doughs are cut with a mould into the desired shape. This is done manually with specially designed moulds. From here the donuts are picked up and put in a proofing tray.From here it is put on to a proofing tray. V) Proofing Proofing chamber (a warm, oven-like machine), which is a hot-air, temperaturecontrolled warm box set to approximately 125 F (51.6 C). Here, the thin doughnuts are slowly allowed to rise or proof as the yeast ferments under controlled conditions. Proofing renders the doughnuts light and airy. In a proofing chamber the donuts are kept at an ideal temperature which makes the donuts puff up and rise. VI) Frying

The raw doughnuts fall automatically, one row at a time, into the attached open fryer. It is important to drop just a certain amount of raw doughnuts into the grease at a time. After frying they plop, ahead to get coated. VII) Topping There are two topping stations and they are bifurcated into warm topping and cold topping station. Cheese and chocolate is considered as warm toppings .in the cold station all cold toppings and scaling of the product is done. VIII) Racking

From here the donuts are send to the rack for resting .The donuts are then Made to stock. Make to stock (MTS) can provide faster service to customers from available stock and lower costs than MTO process. Customers order occurs after production process is completed and results in finished goods. The MTS process has a standard product line specified by the producer, not by customer. The products are carried in inventory to immediately fulfil customer demand.

Batch production requires that a group of items move through the production process together, a stage at a time. For example when a bakery bakes loaves of wholemeal bread, a large ball of wholemeal dough will be split into several loaves which will be spread out together on a large baking tray. The loaves on the tray will then together be cooked, wrapped and dispatched to shelves, before the bakery starts on a separate batch of, for example, crusty white bread. Note that each loaf is identical within a batch but that loaves can vary from batch to batch.

Types of Production
Mad over Donuts uses two production process, batch process and line process. Because it has predictable sales, the flow of the product is sequenced. They produced in batches. The production numbers go from 100s in batch. And based on the flow of customers. On weekend the production never stops, weekdays they are timely placed and made to stock as per the flow. Line process: It produces donuts in large quantities where conformity is maintained among them. Here no customisation is required as the donuts are usually a base. Batch process: On the topping table the donuts are them segregates into batches, of various toppings that are in demand. There is high degree of customisation here as per the customer needs.

Plant Layout
A unique aspect of the MOD outlets is its unique glass viewing kitchen at select outlets; which has been specially designed for the customer to watch the entire preparation process of the donut - from dough to donut. They have their kitchen located within the outlet itself. Its layout is designed to facilitate quick and easy transitions in the production process. All the mechanised machines are positioned back to back with the mixing, sheeting and cutting processes conducted in one area while the proofing chamber is separately located. The frying station is open, and mechanised. The topping station is the one located towards the racking area.

Flow Chart
Start

Source Raw material

Mixing of Ingredients

Flour, Yeast,Water, Salt

Making of donuts Sheeting, Cutting, Proofing, Frying.

Toppings

Hot station or cold station?

Storing and Racking

END

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