(Tiểu luận) report yakult operation management

The factory maintains production processes with the highest quality standards, just like at the Yakult factory in Japan.. The Yakult manufacturing process applies strict manufacturing st

MINISTRY OF EDUCATION AND TRAINING UNIVERSITY OF ECONOMIC & FINANCE

1 Nguyễn Thị Bích Trâm 205085067 Introduction 20% G 2 Phan Hoàng Gia 200041002 Department and funtion 20% G 3 Đinh Nhật Long 195080227 Quality Standard 20% G 4 Trần Th Ninh Giang ị 205141764 Producttion process and lean 20% G

Total: 100%

Lecture: Đỗ Sỹ Hoàng

GUARANTEE

I hereby declare that this research work is my own work and has been completed under my supervision by Dr Tony Do References have been clearly cited, complete and noted like the rules I hereby declare that this is the result of our research The data and results stated in the report are truthful and have never been published in any other way any other project I certify that any assistance in preparing the midterm report

Thank you, the information cited in the report has been cited

Student

Team 3

WORDS OF GRATITUDE

My group's name is Team 3 all members of belonging to the economic faculty of the , University of Economics and Finance.

This report was made by our group during the course of studying the subject "OPERATION MANAGEMENT" with the help of lecturer: Tony Do In the process of learning and implementing the project implemented topic He has guided and helped our group as well as the whole class a lot to be able to understand and grasp how to research and perform well this midterm report

Therefore, first of all, our group would like to express our sincere thanks to him, thank you for your guidance, knowledge, and experience to help our team complete the report well

In the process of implementing the group, we tried our best, our knowledge and experience were limited, so the midterm report could not avoid errors We look forward to receiving comments from Mr Hoàng and others so that our team can complete our midterm report

Finally, our team would like to thank Mr Hoàng!

Ho Chi Minh City, August 8, 2022.

TABLE OF CONTENT

3.1.2 The production steps of Yakult plastic bottles 19

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In the 1920s, Japan was still an economically poor country and sanitation was inadequate, thus causing many children to die from infectious diseases and malnutrition These are issues of great concern for managers and scientists At that time, Minoru Shirota, now a research student in the medical field at Kyoto Imperial University (now Kyoto University), set out to take a stance on preventive medicine, with the aim of helping people And he began to study the group of microorganisms that live symbiotically in our intestines, which he found to have a huge role in health From those studies he discovered a strain of the lactobacilli group that effectively inhibits harmful bacteria in our intestinal tract He then became the first to successfully isolate and stabilize the lactobacilli in 1930, which is known as Lactobacillus casei Shirota

Figure 1: A picture of Yakult's members in the early years of establishment

The foundation of the Yakult company is built on the research of Dr Minoru Shirota in 1930, he successfully isolated and cultured lactic acid bacteria, Lactobacillus casei Shirota strain is a beneficial strain In 1935, Yakult was first commercialized in Japan

In 1955, Yakult Honsha Company was established Research Center Established in Kyoto Yakult Honsha is a pioneer in the field of probiotics and one of the leading, Dr Minoru Shirotacompanies in Japan Since Yakult entered the market in 1935 until now, Yakult Honsha company has more than 75 years of research experience And now Yakult has spread across the globe and every day about 40 million bottles of Yakult are consumed across countries and regions Yakult Honsha is trading in 3 main product lines food and beverage, cosmetic and cosmetic line –

In 2007, Yakult Company started doing business in Vietnam and in 2008, the company's factory in Binh Duong was officially put into operation Yakult Vietnam was established on June 26, 2006, with a total investment of over 400 billion VND due to the capital contribution of Japan's Yakult Honsha company (80%) and France's Danone group (20%) Yakult Vietnam started its business in August 2007

Currently, Yakult products are available in most supermarkets and retail stores throughout Vietnam In addition, Yakult is also distributed directly to customers' homes in Ho Chi Minh City, Hanoi, Hai Phong, Dong Nai, Binh Duong, Da Nang, Nha Trang, Vinh through the Yakult delivery system Lady

So far, Yakult has been present in 40 countries and territories The factory maintains production processes with the highest quality standards, just like

at the Yakult factory in Japan The Yakult manufacturing process applies strict manufacturing standards, which ensures a product close to 99% (that means 99% of the raw materials are fully utilized to the final product, with very little waste)

With the Yakult philosophy of "contributing to the healthy life of people all over the world", Yakult believes that protecting the earth's environment is the most important aspect in operating production in order to harmonize with life and society

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Figure 2: Commodity Distribution System

1.Business philosophy

Professor Minoru Shirota's concept wishes that the next generations, when doing business in the Yakult product line, must be based on his three views as below, known as the Shirota theory - the source of all activities business activities of the company Yakult Longevity Facts: The gut is not only a place to receive nutrients to nourish the body, but also has an immune function So if we know how to keep the gut healthy, we will have a healthier and longer life Preventive medicine: This perspective focuses on prevention rather than cure Exercise, sports, eating right and taking daily probiotics are all ways to maintain good health Reasonable cost: Professor Minoru Shirota wishes that everyone in the world can enjoy the beneficial properties of Yakult probiotics That's why the company tries to offer a price that everyone can accept

2.Research and development

Yakult Honsha has 2 Yakult microbiological research institutes located in Japan and Belgium The Yakult Central Microbiology Institute, through its commitment to discovering and promoting a healthy lifestyle, has many years of research into the use of good bacteria as a factor in maintaining health health, conducting a series of studies on the benefits of microorganisms Currently, every day, more than 250 researchers are actively pursuing research to effectively apply beneficial bacteria in the prevention and treatment of diseases In addition, Yakult works closely with the scientific and medical communities, holding conferences, seminars and research, all to advance understanding of the role of bacteria in health

Yakult: Yakult is a fermented yogurt drink made from skim milk powder, water

sugar and contains live bacteria Lactobacillus casei Shirota In Japanese, the name Yakult comes from the word “Jahurto” which means yogurt (in the term Esperanto popularized around 1880) Each bottle of Yakult contains more than 6.5 bacteria Lactobacillus casei Shirota Unlike most standard bacteria Normal in other yogurts, L.casei Shirota bacteria is able to survive in gastric juice and bile to enter the intestine still alive, supporting the restoration of the balance of intestinal microflora When consuming Yakult daily, L.casei Shirota helps to improve digestion, regulate the immune system and prevent cancer

Figure 3: Product Description

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II MAIN CONTENT 1 DEPARTMENT AND FUNCTION

During the tour to Yakult, from manufacturing to distributing products to customers, the Yakult facility follows a precise process that includes a closed line and machinery imported straight from Japan There, the total number of employees of the company is about 93 people, 25 Japanese managers in the management department The air in the room is cleaned through many layers and most of the rooms are automated, the machines are working very well, the engineers work in the room at the factory There are 6 departments introduced: seed room; culture and mixing room; quality control room; bottle moulding room; filling room; packing room

Figure 4: Six departments are guided in the tour

The six departments' tasks and operating systems are shown below:

1.1 Seed room

To grow bacterial biomass, their staff will prepare the environment using the major components such as skim milk, glucose, sugar and water A delicious milky solution is

created by combining the skim milk powder, sugar, glucose, and filtered, sterilized water

Following the mixing of the ingredients, they will be sterilized at a temperature of 120 degrees Celsius for 20 minutes, eliminating any germs that may be present The probiotic strain Lactobacillus casei Shirota is the most significant The bacteria used to manufacture Yakult is imported from Japan and kept in the seed tank to proliferate The seed tank's goal is to cultivate Yakult-Lactic acid bacteria Within 24 hours, the fermentation process occurs at a temperature of 37 degrees The engineers will wait for the bacteria strains to colonize this location at the conclusion of 24 hours So, this department's job is to multiply the Lactobacillus casei Shirota biomass

1.2 Culture and mixing room

The role of this department is quite crucial in completing the product Powdered milk and glucose are used first, and then the milk and sugar are dissolved After sterilization, the milk will be poured into fermentation tanks, the L.Casei strain will be added to the tub, and yakult fermentation will take place at 37 degrees Celsius for many days

Once the fermentation process is complete, Yakult milk will exhibit fertilization and layer separation; to avoid this, the milk will be homogenized to prevent curdling Finally, combine the milk solution with a white granulated sugar solution previously prepared in storage tanks The amount of sugar in the product is lowered during fermentation, and the acid generated diminishes sweetness while increasing sourness The goal of this department is to neutralize the product's characteristic sour and sweet flavors after fermentation while also providing microorganisms with nutrition from the sugar Since then, making a steady and homogeneous milky fluid will advance the Yakult milk’s perception and distinct taste.

1.3 Quality control room

In this room, engineers will perform two tasks:

Page | 7 First, they will check the quality of milk after fermentation, from raw materials to finished products, and until the product expires, such as measuring milk sweetness, checking product parameters, and ensuring consistent and uniform quality in each bottle

Next, engineers will then inspect the factory's hygiene to guarantee a clean, safe working environment

The product quality inspection will guarantee that Yakult's requirements are met As a result, they will repair or remove damaged items to ensure the product's high quality and prestige Products are created from the ground up using carefully chosen and sophisticated Japanese world-class ingredient technology The plant follows the same production method as the Yakult facility in Japan, with the same high quality standards, notably in terms of quality control We can see how Yakult satisfies the requirements, and there will be no variances in the quality of Yakult throughout the world

1.4 Bottle Moulding Room

In the bottle moulding room, six bottle-making machines are in operation in the production area; one bottle-making machine can make approximately 11000 bottles of Yakult in an hour Polystyrene resins imported from the Japanese manufacturer Yakult Honsha and kept in tanks are used to make bottles

The plastic beads will be sucked into the hopper, melted at a temperature of 235-250 degrees Celsius, a modest amount of plastic pressed into the mold, and the shaft forced into creating plastic embryos The newly created plastic billet will be hot and soft, and the revolving frame will rotate 180 degrees to force the billet into the mold shaped like a Yakult bottle Clean air will be blown into the billet, causing it to swell and form a Yakult bottle The bottles will fall down the conveyor belt and flow through a pipeline system into the milking area Each 65ml plastic bottle provides approximately 48-52 calories, as well as a variety of other nutrients such as protein, fat, carbohydrates, and up to 6.5 billion L.casei beneficial bacteria Shirota aids in the immune system's health and the prevention of various ailments

1.5 Filling Room

Below the bottle forming tank is a bottle stacking equipment, where the bottles will be neatly stacked before moving to the printing room to be printed with the production date, expiry date, and other information After that, the bottle will be taken to the milking tank

Yakult VietNam factory has 2 milking lines are in used One milk filling tank has 36 filling heads and can fill more than 45000 bottles of milk in an hour; two lines can fill more than 90000 bottles The milk bottles will be sealed with aluminum ingots imported straight from the Japanese company Yakult once the milk has been poured The milk bottles will move on a conveyor belt with cameras and sensors after being sealed, and two engineers will sit next to the conveyor belt to inspect the product Products that have met quality standards on both the inside and outside will be packaged

1.6 Packing room

The milk at the Yakult factory will be packaged twice To begin, packing will combine 5-10 milk bottles into a single batch An OPP roll is used as the starting material for bottling Yakult into a block The milk bottles will then be relocated to the second packing facility, where 5-10 packs of Yakult will be put into one carton using polyethylene plastic imported from Yakult in Japan The milk cartons will be moved to where the Yakult crates with 10000 - 12000 - 15000 bottles of Yakult are being loaded For preservation, the balet will be relocated to cold storage at a temperature of 0-10 degrees Celsius, where it must be kept for at least 2 days from the day of manufacturing in order to execute the final quality check If quality is attained, the Yakult bottles will be transported to consumers on refrigerated trucks Refrigerated trucks bring Yakult to huge grocery chains' facilities for distribution to individual stores The company's sales consultants deliver Yakult directly to independent supermarkets, dairy shops, schools, hotels, aged care centers, hospitals, and other stores To conclude, the production process is carried out in six function rooms in a row, all of which can be seen through the glass Yakult's system is arranged in a very scientific fashion, resulting in great manufacturing efficiency and a low amount of faulty goods According to Japanese technology, the production process is entirely mechanized and

Page | 9 closed Yakult gains efficiency, productivity, and cost savings throughout the whole lea manufacturing process

2 QUALITY STANDARDS

Amid growing concerns regarding food safety and quality assurance among consumers, companies in Japan and overseas are under intense pressure to provide reliable and safe food products Yakult recognizes that this trend demands greater levels of safety and quality assurance for the products it handles, which are subject to Japan's Food Sanitation Act, Pharmaceuticals and Medical Devices Act, and other laws and regulations in Japan and overseas As a Group, Yakult also strives to strengthen their quality assurance system, with the supply of safe products as their highest priority

Yakult gives us the sensation that they do not just sell products for profit, but more than that they want to bring healthy products to consumers And this is also true for Yakult's mission: “Contribute to the health and happiness of every person around the world through the pursuit of excellence in life sciences and the study of microorganisms” This greatly affects the quality management of Yakult To bring such healthy sweetened probiotic fermented milk products, Yakult's quality control procedure is very strict and thorough

To effectively manage the food safety for their products, Yakult has to build a worldwide quality standard list It implies that all the Yakult produce the identical prime quality products, which is termed Quality Assurance With this Quality Assurance, we are able to understand how Yakult’s quality meets the standards, and there will be no differences between Yakults around the world

Quality Assurance of Yakult is shown by a range of international certificates that it has:

2.1 ISO 14001: 2004

ISO 14001:2004 requires businesses to manage factors affecting the environment during operation Through the achievement of ISO 14001:2004, enterprises can prove themselves that they have been, are, and continue to carry out activities consistent with the goal of a better living environment

ISO 14001:2004 does not discriminate between the size and type of business, so any business has the opportunity to achieve this standard

With the following principles:

o Principle 1: Leadership commitment o Principle 2: Participation of all members o Principle 3: Process management o Principle 4: Management by system

o Principle 5: Ensuring the law and balancing socio-economic needs o Principle 6: Ensure an adequate system of documentation and records

Benefits of Reaching ISO 14001:2004 Standard:

Yakult Vietnam factory has been certified to ISO 14001:2004.The international standard for environmental management systems is ISO 14001 (EMS) was created to build a management system to assist enterprises in reducing their negative environmental consequences This International Standard establishes a framework for businesses to show their commitment to environmental challenges This demonstrates the company's dedication to environmental protection, societal responsibility, pollution prevention, and reducing the influence on the environment during the manufacturing process

Yakult is made using a closed technological process that ensures the product is roughly 99 percent identical to the original raw material, resulting in very little waste being released into the environment Furthermore, all of the raw materials utilized in this manufacturing process are non-toxic, do not release smoke, and do not produce noise Furthermore, the wastewater generated during production is treated with microbiological technology before being handled by the VSIP (Vietnam Singapore

Page | 11 Industrial Park) waste treatment system before being discharged into the environment

Yakult is committed not only to its customers in terms of product quality assurance, but also to environmental protection, coordinating and executing production activities in general to ensure a safe and healthy working environment.Employee-friendly and environmentally friendly

This is the first result obtained, and the company will continue to maintain and enhance the Management System in order to increase product quality and meet societal and community criteria for food safety and hygiene

Figure 5: ISO 14001