PRESENTATION | END – REVIEW �Driving Operational Excellence | Yield Optimization in Ragi Bites

25^th May’2026

Arijit Mondal�Operations

PSO

Project Agenda

• Process Challenges
• Operational Challenges
• Manufacturing Challenges
• Data & Analytical Challenges�

• Project Outcomes
• Operational Learnings
• Analytical Insights

• Leadership & Collaboration
• Analytical Development
• Industrial Exposure
• Process & Improvement Mindset

• Project Brief
• Execution Timelines

• Process Flow
• Stakeholder Identification
• Micro – Mapping
• Data Analysis
• Outline : DMAIC�

• The project aims to improve the operational yield of Ragi Bites production by identifying and reducing process losses across critical manufacturing stages.
• The focus is on minimizing losses related to spillages, transfer inefficiencies, material retention, and operational variability in Ragi Cleaning, Blend Mixing, and Extruder Fills operations.

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• The project follows the DMAIC (Define, Measure, Analyze, Improve, Control) methodology to systematically identify, analyze, and reduce process losses.
• Process mapping, shop-floor observations, operational data analysis, fishbone analysis, and line-loss evaluation are used to identify root causes and improvement opportunities.
• Improvement initiatives and sustainable control mechanisms are proposed based on practical and data-driven operational insights.

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• Reduction in process losses across Ragi Cleaning, Blend Mix, and Extruder Fills operations.
• Improvement in overall operational yield through process standardization, better material handling, and operational control.
• Enhanced process visibility, reduced spillages, improved process stability, and implementation of sustainable monitoring and control systems.

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Objective

Methodology

Expected Outcomes

PROJECT BRIEF I KEY DELIVERABLES

Process Improvement | Project Timeline

7-Week Implementation Plan and Key Milestones

Full Process Flow Mapping : Ragi Bites

Handling, Pre-Processing Blending, Extrusion, Coating, Drying, Cooling, Packing

Process Flow Mapping

Key Stakeholders Identification

Production, QA, Maintenance coordination

Stakeholder Identification

Obtained Data Across Various Stages

Extruder Output, Oven Output, Cream Production, Coating Composition

Data Collection

Yield/Loss Determination & Primary Driver

Blending, Extruder, Oven stages. Systematically identifying all possible factors contributing to loss.

Analysis & Driver Identification

Process Improvement

Corrective actions and process optimization measures to minimize controllable losses and improve overall yield.

Optimization & Corrective Actions

Engineering Control

Standardized controls, monitoring practices, and operating procedures to maintain process stability.

Implement Standard Controls

Internal

Reduction of Yield Losses in Ragi Bites Production

Process Optimization & Efficiency Improvement Initiative

86.4%

Current Yield

91%

Target Yield

Yield Improvement Target

Current: 86.4%

Target: 91%

Total Improvement:

+4.6%

In Scope

Sugar coating

Oven drying

Cooling

Oven output losses

Spillages

Breakage

Product sticking

Out of Scope

Raw material procurement

Warehouse operations

Dispatch activities

Development activities

D E F I N E

Project Scope

Extrusion

Material Transfer

6

Process Flow : Ragi Bites

6

Portfolio : Ragi Bites�Healthy breakfast cereals for adults

Composition

Choco Fills*

Vanilla Fills*

Strawberry Fills*

D E F I N E

*Data Source : �Material Distribution on the backside of the packet

Internal

D E F I N E

Key Stakeholders�������

�

RM HANDLING & PRE-PROCESSING

Storage of Processed Flour

(Ragi, Cereals, Sugar etc.)

BLENDING & PRE – EXTRUSION

Yes

COATING, DRYING & SFG - STORAGE

Yes

Despatch to Vehicle

Yes

MICRO – MAPPING | RAGI BITES | PROCESS FLOW | YIELD WASTAGES

Moisture Loss

Spillages

D E F I N E

Internal

Blending

Totals

Input (I/P): 19.840 kg

Output (O/P): 19,720 kg

Total Loss: 120 kg

Yield (Avg) :99.4%

Loss %: ~0.6%

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Observation

• Blending is highly efficient and stable
• Losses are minimal and controlled

Observation

• Total Wastage: 135 kg

Wastage Split Insights

• Drying Loss: Primary contributor

(6–10% range)

• Spillages: ~6–13 kg per batch

Performance Metrics

• Availability: 100% (constant)
• Quality: 100% (no rejection)
• Performance: ~78% – 100%
• OEE Range: ~71% – 83%

CONSOLIDATED VIEW

MARCH

• Average Wastage %: 2.009%

Extruder

Performance |

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Output | Yield

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M E A S U R E

Internal

10

Modified Target : 88%

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Additional improvements

• Spillage Reduction
• Handling Control
• Reduced rework��Optimizing these 3 can contribute to 0.3 – 0.4% increase in yield.�

Reasoning �Based on the actual line-loss data, targeting 91% becomes difficult to justify realistically because:

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• The major oven loss (Fills = 6.78%) is already operating close to the standard (7.0%)
• Therefore, the oven line does not provide enough recoverable opportunity to achieve the full +4.6% improvement
• Hence, a revised target of 88% is established by focusing on realistically recoverable losses in Ragi Cleaning, Blend Mix Loss and Extruder Fills

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M E A S U R E

* Out of Project Scope

** Recovery in VFFS/PFS not included

Internal

Accumulated Loss

De-stoner

Jet Polisher

Roto Sifter

Extruder

Conveyor

Coating Drum�Spillage 1

Coating Drum�Spillage 2

Packaging Silos

Blender

Loss/Spillage | Process Flow | Ragi

A N A L Y S I S

Internal

Internal

Blend Mix Loss

Actual : 1.4%

Std. : 0.5% �∆ : 0.9%

Improper material handling (F)

Poor transfer practices (F)

Improper unloading from Blender

(D)

Inadequate SOP adherence

(F)

No dead stock quantification

Inaccurate blend yield calculation

Excess blending time (B)

Improper loading sequence (B)

Improper cleaning between batches

Dust formation during transfer

Hygroscopic material behavior

Poor ventilation

Material sticking inside the blender

Sticky ingredients

Material accumulation during transfer (D)

Leakage from transfer system (D)

Man

Measurement

Environment

A N A L Y S I S

Extruder Fills loss : 2.46%�Standard : 2%

Moisture variation in ingredients

Dead-stock in blender/hopper (D)

Improper weighing system

Fishbone Analysis

Blend Mix Loss

Improper hopper discharge flow (D)

Open transfer handling

between stages (B)

Improper collection of spillages

(D)

Internal

Product sticking inside barrel (E)

Errors in calculation (if any)

Cutter synchronization issues (J)

Fishbone Analysis

Extruder Fills Loss

Delayed response to product accumulation (E)

Internal

Improvement Focus Areas

Focus Areas:

Reducing Material Losses

Improving Process Consistency

Minimizing Handling Inefficiencies

Stabilizing Operational Performance

Standardization of Process Parameters

1

Objective: Reduce process variation across all critical stages

Standardize cleaning intensity (A), blending time (B), material transfer & discharge

practices (B)

Develop parameter-setting guidelines for operators (A) (B)

Introduce batch-wise parameter validation before startup (A) (C)

Expected Impact

Reduced variability

Lower rejection

Improved yield

Reduction of Material Spillages, Transfer & Retention Losses

2

Objective: Minimize spillages, open transfer losses accumulation, and product retention across the process flow.

Improve transfer practices between process stages (C) (D) (E)

Reduce material accumulation in hoppers (D), blenders (D) & conveyors (C) (E)

Expected Impact

Reduced spillages

Lower blend losses

Better utilization

Enhancement of Operator Awareness (H) & SOP Adherence (F)

3

Objective: Reduce operator-dependent process variability

Improve containment at transfer & discharge points (D)

Reinforce adherence to SOPs across critical stages (G) (H)

Introduce visual controls (F) and operational checkpoints (G)

Expected Impact

Improved discipline

Faster correction

Reduced effort loss

Preventive Maintenance (J) & Equipment Reliability (J)

4

Objective: Improve machine efficiency and consistency

Regular inspection and calibration of cleaning systems (I) (J)

Minimize leakages (I), transfer gaps (D) and material hold-up areas (D)

Improve preventive maintenance scheduling (I)

Expected Impact

Better performance

Reduced downtime

Lower mechanical loss

Standard Work Combination Sheet - Improvement Areas

I M P R O V E

Improve product discharge flow from blender/extruder systems (D) (E)

Improve response time (H) to visible spillages & accumulation

SUSTAINING IMPROVEMENTS

Loss Prevention & Sustainability Strategy

Objective: Ensuring improvements are sustained over time, consistently followed, and continuously monitored to prevent recurrence of losses

1.

Standard Operating Procedure (SOP)

Measures

• Display SOPs near critical stations

• Use visual one-point lessons (OPLs)

• Ensure shift-wise SOP verification

Reduces variation

Improves consistency

2.

Daily Stage-wise Loss

Monitoring

Measures

• Maintain shift-wise loss tracking sheet

• Display daily losses on visual board

• Compare actual vs standard losses

Early identification

Better accountability

3.

Transfer & Spillage Inspection

Measures

• Hourly inspection by operators

• Checklist-based monitoring

• Immediate corrective action

Controls losses

Reduces accumulation

4.

Equipment Calibration & Maintenance

Measures

• Weekly inspection schedule

• Preventive maintenance logbook

• Calibration tagging system

Reduces variability

Minimizes leakage

5.

Operator Training & Skill Reinforcement

Measures

• Monthly refresher sessions

• Shift-based awareness meetings

• Visual examples of practices

Sustains improvements

Reduces errors

6.

Parameter Monitoring & Control

Measures

• Parameter recording sheet per batch

• Supervisor approval before startup

• Deviation escalation process

Maintains stability

Prevents variability

7.

Visual Management &

5S Controls

Measures

• Floor marking and color coding

• Color-coded bins/trays

• Audits for housekeeping

Improves discipline

Reduces spillages

8.

Recovery & Reconciliation Mechanism

Measures

• Batch-wise reconciliation sheet

• Tracking of reusable material

• Loss variance review in meetings

Improves accountability

Sustains yield

Control Phase | 8 Key Measures for Loss Prevention

C O N T R O L

1. STANDARD OPERATING PROCEDURE (SOP)

Action: Display SOPs near critical stations

↓

Dept: RM Cleaning

Blending & Extrusion

↓

Person: Cleaning Operator,

Blending Operator, Production Executive

↓

Freq: Ongoing Validation

↓

Impact: Improved process consistencies and fewer deviations

2. SHIFT-WISE LOSS MONITORING

Action: Display daily losses

Compare Yesterday’s vs Today’s

↓

Dept: Production / Processing

↓

Person: Production Executive

Shift In-charge

↓

Freq: Shift-wise

↓

Impact: Faster loss Identification

Improved accountability

3. TRANSFER & SPILLAGE INSPECTION

Action: Immediate corrective action during spillages

↓

Dept: Processing / Material Handling

↓

Person: Extruder Operator, Blending Operator, Line Operator

↓

Freq: Every 30 mins - Hourly

↓

Impact: Reduced spillages and lower accumulation, less wastage

4. EQUIPMENT CALIBRATION & MAINTENANCE

Action: Maintain PM logbook and calibration checks

↓

Dept: Maintenance / Production

↓

Person: Maintenance Technician

↓

Freq: Weekly / Fortnightly

↓

Impact: Improved reliability

Fewer machine losses, Better Yield

5. OPERATOR TRAINING & REINFORCEMENT

Action: Shift-based meetings

SOP reinforcement

↓

Dept: Production / Operations

↓

Person: Production Executive

Shift Supervisor

↓

Freq: Shift-wise

↓

Impact: Better discipline

Improved adherence

6. PARAMETER MONITORING & CONTROL

Action: Maintain parameter recording sheet per batch

↓

Dept: Processing / Production

↓

Person: Extruder Operator

Production Executive

↓

Freq: Batch-wise / Hourly

↓

Impact: Process stability

lower variability, High Consistency

7. VISUAL MANAGEMENT

& CONTROLS

Action: Mark loss-prone zones across critical areas

↓

Dept: Production / Shop-floor

↓

Person: Prod Ops, Shift Sup

↓

Freq: Ongoing Setup

↓

Impact: Better housekeeping, reduced handling losses

8. RECOVERY & RECONCILIATION

Action: Track & reconcile

reusable material

↓

Dept: Production / Warehouse / QA

↓

Person: Production Executive

QA Executive

↓

Freq: Batch-wise or Shift wise

↓

Impact: Yield accountability

Fewer recoverable losses

ENGINEERING CONTROL MEASURES | EXECUTION FLOW

End-to-end procedural alignment, monitoring, and corrective actions directly within each stage

C O N T R O L

Challenges

Process Loss Analysis | Optimization

Process Challenges

Process Tracking: Tracking material movement and losses across multiple interconnected manufacturing stages

Stage-wise Mapping: Mapping losses accurately at each process stage with detailed observation

Hidden Losses: Identifying material retention, accumulation, and minor spillages

Real-time Monitoring: Monitoring process losses in real time across different stages

Operational Challenges

Shop-floor Observation: Continuous visits to understand actual operational practices

Cross-functional Coordination: Coordinating with Production, QA, and Maintenance teams

Continuous Follow-up: Frequent follow-ups to track operational changes

Multiple Stages: Monitoring cleaning, blending, extrusion, coating operations

Manufacturing Challenges

Loss Identification: Identifying exact sources of material losses across equipment

Material Flow: Understanding movement between process stages

Spillages & Transfer: Observing spillages and transfer losses

Machine-Process Interaction: Analyzing machine settings influence on losses

Data & Analytical Challenges

Data Collection: Collecting operational data from multiple process stages

Data Validation: Validating accuracy and consistency of collected data

Data Analysis: Analyzing process losses and identifying trends

Consolidation: Consolidating line-loss data across operations

Key Outcomes, Learnings & Insights

Ragi Bites Manufacturing Yield Loss Reduction Study

Personal Learnings | Development

(A) Leadership & Collaboration

Team dynamics & communication skills

Ownership & Accountability: Developed a stronger sense of responsibility towards project execution, follow-ups, and outcome delivery.

Communication & Coordination: Improved communication and coordination skills through continuous interaction with cross-functional teams.

Cross-functional Collaboration: Learned to work closely with Production, QA, and Maintenance teams to understand operational challenges.

Continuous Learning: Gained the ability to continuously adapt and learn from real-time operational observations.

(B) Analytical Development

Data-driven decision making & analysis

Data-driven Decision Making: Learned to make decisions and identify improvement opportunities based on operational data.

Analytical Thinking: Developed a structured approach towards identifying root causes and evaluating process inefficiencies.

Attention to Detail: Improved ability to identify small operational deviations, hidden losses, and process abnormalities.

Observation Skills: Strengthened observational skills through continuous monitoring of process flow and material movement.

(C) Industrial Exposure

Manufacturing operations & shop-floor experience

Shop-floor Exposure: Gained practical exposure to real-time manufacturing operations and production processes.

Operational Understanding: Developed a deeper understanding of how different operational stages interact and influence performance.

Manufacturing Exposure: Learned about extrusion, blending, coating, drying, and material handling operations.

Real-time Troubleshooting: Understood the importance of immediate corrective actions and practical problem-solving.

(D) Process & Improvement Mindset

Continuous improvement & optimization

Process-oriented Thinking: Developed the ability to analyze manufacturing operations from a process and systems perspective.

Practical Problem Solving: Learned to approach operational issues with practical and implementable solutions.

Process Improvement Mindset: Built a continuous improvement mindset focused on reducing losses and improving efficiency.

Understanding of Shop-floor Operations: Gained detailed understanding of material flow and machine interaction.

Key learning areas identified through practical experience and continuous improvement

PROJECTIONS

NOTE��While following the entire process flow and also discussing with the Workers, Floor Managers, Supervisors and Production Executives on the shop floor, we reached the conclusion that there aren’t any major defects or flaws in any of the machines or processes. Hence, it’s advised not to interrupt with any of the intermediate processes for the sake of improving Yield%. Whatever minor improvements required, we have tried to put them in the Improve Phase and proper engineering Control Measures to sustain those improvements in the Control Phase. Hence, the revised target of Yield was set at 88% from the current 86.4% But it should also be noted a good % of loss is observed in the Packaging Silos(Out of Project Scope). Hence, it’s advised to take a good note of that and take immediate action to deal with it. It’s very much possible that the Yield % can see a significant improvement post that.

ANNEXURE

Supporting Data & Technical Details

1. Ingredient Formulation: Ragi Bites

Standard ingredient breakdown used for 500 kg production batches.

2. Cream Filling Composition

Technical formula across flavor variants per 400 kg batch.

Note: Data derived from material distribution labels on product packaging.

3. Process Flow Overview

Production stages analyzed for process yield optimization.

Key Stages Evaluated (In Scope):

Excluded from Study (Out of Scope):

Raw Material Procurement

Warehouse Operations

Packaging Silo Activities

Cleaning

Blend Mixing

Extrusion

Coating/Drying

5. DMAIC Framework Summary

Six Sigma methodology applied throughout project duration.

Define: Identified project aim to reduce yield losses in Ragi Bites production.

Measure: Collected line-loss data across all manufacturing stages.

Analyze: Used Fishbone analysis and line-loss evaluation to find root causes.

Improve: Standardized process parameters and handling procedures.

Control: Implemented 8 sustainable monitoring and tracking mechanisms.

D

M

A

I

C

4. Cross-Functional Responsibilities

Ownership matrix established to sustain yield improvements.

Production

Ownership

Responsible for end-to-end process execution.

QA

Standards

Ensures product standards & robust quality gatekeeping.

Maintenance

Equipment

Maintains machine efficiency & critical calibration.

Yield %

Scrap %

Throughput

Rework %

Defect Rates

Compliance

Uptime %

Breakdown Freq.

6. Important Note on Yield Targets

Strategic takeaways and next steps for the engineering team.

Reality Check

Floor discussions and data analysis revealed no major machine defects; intermediate process mechanics remain untouched.

Strategy Shift

Optimization focus shifted toward behavioral, procedural, and handling-based engineering controls to secure gains.

Recommendation

Review losses in the **Packaging Silos**, which lie outside current project scope but present significant future yield opportunities.

T H A N K

Y O U