Murree

Brewery
A deeper look into
its operations

Production
Process of Murree
Brewery

Beer Production
Process
0 The barley for the manufacturing
of beer is exported from Austria,
Ukraine and some other
European countries

Beer Production
Process
Beer Production
Process
Non-Alcoholic
Beer Production
 Process Strategy
of Murree
Brewery
1 organizations’ approach to
transfer resources into goods
and services
2 to build a production process
that meets the customer
requirements and product
specifications within the required
costs and managerial
constraints.
 Murree
Breweries’
Process Strategy
-Batch Processes
3 Batch processes which are fairly
repetitive
4 Modules for the main product are
prepared in advance which are then
combined differently to produce
different versions of product

Process Analysis
& Design
5 Response
 6 production process,
management and operation
techniques allow competing
on response
7 Company’s efficient policies
and strategies
allow it to promote alcoholic
products

8 production processes are designed to

reduce as much waste as possible
9 employees’ suggestions and feedback
about manufacturing processes is taken
regularly
10 Process Control
11 use of information technology to control
a physical process
12 “Robots and Automated guided
vehicles”
13 Conveyer belts
 14 Machinery for bottling process

15 Electronically guided & controlled carts

Process Redesign
16 rethinks about the process
design on annual basis.
17 process is thoroughly analyzed
and then suggestions for the
improvement are taken
18 Redesigned their process –
doubled the quantity produced,
reduced the cost of
manufacturing to half and
doubled the capacity
19 Recycling waste material and
usage of waste for energy
purposes
Quality
Manageme
nt at
Murree
Brewery
Production
process Steps
Materials
20 Murree Brewery does its own
malting, imports high quality
Barley from European Countries
21 To prevent bacteria formation,
sodium fluoride is used with the
raw materials, which adds value
22 Providing customers with the
best experience
23 MB has also established its own
glass factory and therefore make
their own quality bottles
24 Mission to continuously find good
quality raw materials at the best
prices to promote continuous
improvement in its products

Brewing
25 It is important that the process is
followed exactly and measured
precisely to ensure quality brew
26 Finished product is run through
physical, chemical and sensory
analysis
27 Beer is protected to ensure
bacteria do not contaminate the
products
28 CO2 is used to clean the tanks
29 Sanitation is a very important
aspect of brewing and is
maintained as per HACCP
certification

Inspection
30 Process Manager and Quality Control
Manager in every hall
31 Throughout assembly line employees
are stationed to inspect all the bottle
passing through
32 Production process, cleaning, filling,
capping, labelling etc. in the Bottling
Hall are monitored closely
33 Every forty five minutes the Quality
Manager is required to report progress
and fills in a quality check report
34 The Quality Manager has the authority
to stop the whole process if any
problem is observed in quality and
immediate action to find the root cause
of the problem and fixing it is the main
priority before the process can be
restarted

Maintenance
35 Consistent maintenance involving
machinery and proper maintenance
team in place to see that there is no
halt in operations
36 Preventive Maintenance is to make sure
no fault occurs during the whole
production process
37 Corrective Maintenance is for taking
corrective action if a problem occurs
during the bottling process and spare
parts are kept at hand
38 Bottle counting digital machines
installed to keep track of the output and
the performance of the employees

Employee
Empowerment
39 Meetings held daily. Production teams
review process
40 Meetings continue with higher
management as well in the case of
further improvements
41 Employees are continually given
trainings, abroad and in-house training,
to increase productivity and knowledge

Audits
42 Third part audits
43 MB has 3 certifications:

44 ISO 9001: good quality management,

high customer satisfaction and
credibility.
45 HACCB: distribution of safe and
hygienic food (beverages)
46 ISO 14001: recycles and handles
wastage effectively

Cost of Quality
47 This methodology will be used to
measure where and what
amount of Murree Brewery's
resources are being used for
prevention activities and
maintaining product quality as
opposed to the costs resulting
from internal and external
failures.
Cost of Quality
(cont’d)
48 Prevention Costs
49 costs
incurred from activities
intended to keep failures to a
minimum.
50 In house Trainings
51 Foreign Trainings
52 Quality Planning

Cost of Quality
(cont’d)
53 Appraisal Costs
 54 costsincurred to maintain
acceptable product quality
levels.
55 Process
Controls at every
production level
56 Quality Audits
57 Material Inspections

Cost of Quality
(cont’d)
58 Internal Failure
59 costs
associated with defects found
before the product or service
reaches the customer.
60 Defectsoccurred during the
assembly process (labelling,
crackled glass, uncapped
bottles, improper filling of
bottles etc)
 61 Machine
breakdown due to
improper maintenance
62 Costs
associated with failure
analysis

Cost of Quality
(cont’d)
63 External Failure
64 costsassociated with defects found
after the customer receives the
product or service.
65 Products tested in extreme
conditions
66 Shipping
Damage due to
Inadequate Packaging
 Dynamic
Response
Capabilities
Dynamic Response
Capabilities
Performance
Objectives
67 Quality
Murree brewery has consistent
quality products. For example Big
Apple
68 Cost
 Murree brewery efficiently
minimizes the extra cost of production
by reducing the processes which
doesn’t add value.
69 Delivery time
Storage size of the product in
Murree brewery is 50,000-60,000
batch due to expiry time of soft drink.
While the delivery time mostly
depends on the market demand one
week or two maximum.
70 Flexibility
Plant of Murree Brewery is flexible
because it produces different products
with flavor.
Operations
process in Murree
Brewery
71 In Murree Brewery, operations are
continuous.
72 Production plan changes day by day
and six month data base depend on the
demand by marketing department.
73 Volume of the production unit of Murree
Brewery is 30,000 cases. ------Cases are
of three types.
74 24 bottles pack
75 1 dozen pack
76 6 bottles pack

Capacity
77 Three input source of machine for
production.
78 The capacity of the input source
machine is as follows
79 833 carton per hour

80 333 carton per hour

81 1005 carton per hour

82 So total capacity of plant is 2171 carton

per hour.

Utilization
Peak Capacity
83 Utilization = Average output rate/peak
capacity * 100

84Average output rate =

total output/24
85Average output rate =
30000/24 = 1250
 Peak capacity utilization
86

= 1250/2171*100 =
57.57% per hour

RECOMMENDATIO
NS
Recommendations
87 More Automation.

88 Install heavy machinery on conveyor

system.
Results
89 Reduces Labor cost.
90 Saves Time.
91 Minimize errors.

92 Avoid manual monitoring of

bottles at conveyor belt.
93 Can detect any discrepancy
in the system through IR
rays.

RECOMMENDATIO
NS
Recommendations
94 Install camera in filling section.

95 Improve process and redesign old

practices.
Results
96 Avoid theft and inventory
loss.
97 Saves cost and time spent on
rechecking the inventory
count and hiring security
officials.

98 Achieve new standards

fulfillment and better quality
control.

RECOMMENDATIO
NS
Recommendations
99 Human Resource should add value to
the production performance.
Results
 Devolution of authority empowers
100
workers.
Involving them encourages work
101
intimacy.
Murree brewery can enhanced its
102
production quality by improving
workplace environment.

RECOMMENDATIO
NS
Recommendations
Relocation of factory from Rawalpindi
103
to Karachi.

Relocate glass factory from Hattar, KPK

104
to Karachi.
Results
 Reduced the cost of distributing
105
important raw materials.
106 Maximize profits.
107 Diversified labors availability.

Distribution of empty glass bottles is

108
diminished.

Thank you