Ensuing Food Safety & Nutrition – A Journey towards Food Safety Excellence The Akshaya Patra Foundation, Bangalore, India By: Muralidhar Pundla 2 nd Dec 2015
The Akshaya Patra Foundation The Akshaya Patra Foundation is a not-for-profit organization headquartered in Bengaluru, India. Akshaya Patra is an implementation partner for the Govt of India for their flagship MDM program. Akshaya Patra reaches out to 1,429,878 children in 24 locations across 10 states of India, providing them with freshly cooked meal on all school days. Currently, we implement the mid-day meal programe in 10,845 schools of the country, with plans to increase that number to hundreds more. http://www.akshayapatra.org/about-us
The Akshaya Patra Foundation
The Akshaya Patra Foundation State / Location Number of Children Number of Schools Type of Kitchen Andhra Pradesh 21,333 82 Vishakhapatnam 21,333 82 Centralised Kitchen Assam 53,649 592 Guwahati (ISO) 53,649 592 Centralised Kitchen Chhattisgarh 23,674 160 Bhilai (ISO) 23,674 160 Centralised Kitchen Gujarat 400,158 1,653 Ahmedabad (ISO) 121,508 666 Centralised Kitchen Vadodara (ISO) 113,593 616 Centralised Kitchen Surat(ISO) 165,057 371 Centralised Kitchen Karnataka 463,682 2,629 Bengaluru - HK Hill (ISO) 85,204 487 Centralised Kitchen Bengaluru - 99,326 568 Centralised Kitchen Vasanthapura (ISO) Ballari (ISO) 115,945 575 Centralised Kitchen Hubballi (ISO) 126,693 789 Centralised Kitchen Mangaluru 22,679 147 Centralised Kitchen Mysuru 13,835 63 Centralised Kitchen Odisha 125,242 1,461 Cuttack 4,000 28 Centralised Kitchen Puri 55,835 648 Centralised Kitchen Nayagarh 24,580 352 Decentralised Kitchens Rourkela 40,827 433 Centralised Kitchen Rajasthan 135,910 1,830 Jaipur (ISO) 92,763 1,081 Centralised Kitchen Jodhpur 6,417 148 Centralised Kitchen Nathdwara (ISO) 25,274 435 Centralised Kitchen Baran 11,456 166 Decentralised Kitchens Tamil Nadu 718 1 Chennai 718 1 Centralised Kitchen Telangana 54,849 454 Hyderabad 54,849 454 Centralised Kitchen Uttar Pradesh 150,663 1,983 Lucknow 11,401 109 Centralised Kitchen Vrindavan (ISO) 139,262 1,874 Centralized Kitchen TOTAL 1,429,878 10,845
Vision “No child in India shall be deprived of education Because of Hunger”
Mission “Reach out to 5 million children by 2020”
Board
Ensuing Food Safety & Nutrition – A Journey towards Food Safety Excellence
Ensuring Food Safety & Nutrition – The Akshaya Patra Way People Food Org Wide C I Safety Processes Programs Excellence Technology & Innovation
People
Ensuring Food Safety & Nutrition - PEOPLE
Ensuring Food Safety & Nutrition - PEOPLE 50+ Hrs Training / Year 5500+ For employees Monthly News Working Level letters employees 30+ Policies 100+ GBs Quarterly Town Halls
Ensuring Food Safety & Nutrition - PEOPLE Lean Six Sigma Quarterly Medical Rewards Kaizen Thunder 5% Savings to Insurance Awards to family including the Team Parents Trainings from Industry Experts Annual Day Functions Sunman Awards
Ensuring Food Safety & Nutrition - PEOPLE
Ensuring Food Safety & Nutrition - PEOPLE
Ensuring Food Safety & Nutrition - PEOPLE
Processes/ Systems
Ensuring Food Safety & Nutrition - PROCESSES
Ensuring Food Safety & Nutrition - PROCESSES
Ensuring Food Safety & Nutrition - PROCESSES Target – 100% Compliance,
Ensuring Food Safety & Nutrition - PROCESSES
Ensuring Food Safety & Nutrition - PROCESSES Cold Room Temperature Cooking Temperature Temperature @ Delivery Point
Ensuring Food Safety & Nutrition - PROCESSES
Ensuring Food Safety & Nutrition - PROCESSES ISO22000 • GMP • GHP • Supplier Assessment • Supplier Qualification • Product Approval • Supplier Rating •
Ensuring Food Safety & Nutrition - PROCESSES New Products Development • Process Optimization • NV Compliance • Nutritional Value Calculation • NV Audits – 3 rd Party Lab Test •
Technology, Innovation
Ensuring Food Safety & Nutrition - TECHNOLOGY & INNOVATION Rice cooking- 2.5Tons /Hr Rice Washer- 100Kg /Hr Customer Built – Tetra Pack
Ensuring Food Safety & Nutrition - TECHNOLOGY & INNOVATION RO Plant Bio Gas with Food Waste
Ensuring Food Safety & Nutrition - TECHNOLOGY & INNOVATION Knowledge Management -Share Point
Ensuring Food Safety & Nutrition - TECHNOLOGY & INNOVATION 18KVA Solar System @ TAPF, Bangalore Roti Making Machine @ Jaipur
Ensuring Food Safety & Nutrition - TECHNOLOGY & INNOVATION Insulated Transport Vehicles Insulated Vessels for Food Tranportation
Continual Improvement Program
“Akshaya Pragathi Program” An Organization wide CI Program of Akshaya Patra While we all agree that Status Quo is not the desired state and hence we need to improve performance of various processes continuously so that we can reach to the next mile stone and this is a continuous process and every cycle of improvement leads to next level of achievement. So we adopted a holistic approach and designed a Continual Improvement Program called “ Akshaya Pragathi Program” an Organization Wide Continual Improvement Initiative of Akshaya Patra to ensure all levels of employees can participate in this program. As a part of the program we have adopted and implemented Kaizen, CI Projects using PDCA and Lean Six Sigma methodologies to ensure and make every employee practically gets involved in this.
“Akshaya Pragathi” Program- A CI Program of Akshaya Patra � Kaizen 1. Small Improvements, Very Low investment 2. Plenty in number 3. Lean principles are the key 4. Every one can do 5. Training required � CI Projects- PDCA Methodology 1. Medium level improvements 2. PDCA methodology, 7QC tools used 3. Group activity. Generally lead by Supervisors & above 4. Training required � Six Sigma – DMAIC Methodology 1. Break through / High Impact Projects 2. DMAIC methodology 3. Good Training required 4. Group activity. Generally lead by Asst .Mngr level and above
What Method for What ? Opportunities of Improvement ?! Sweet Fruit Innovation, Lean Six Sigma Bulk of Fruit Process Entitlement Lean, Six Sigma - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Low Hanging Fruit Kaizen - PDCA, Seven Basic Tools - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Ground Fruit Logic , Commonsense, Kaizen •We don't know what we don't know •We can't act on what we don't know •We won't know until we search •We won't search for what we don't question •We don't question what we don't measure •Hence, We just don't know
Kaizen
Sl #: TAPF – KT-HK Hill Kaizen – Example KAIZEN THUNDER Location : HK Hill Dept: Production BEFORE KAIZEN ( CURRENT STATE ) AFTER KAIZEN ( NEW CURRENT STATE ) DESCRITPTION KAIZEN DESCRIPTION: The perforated welded bottom was cut open and a new removable The older design of cauldrons had welded perforated bottom there by perforated sheet was fixed. leading to inaccessibility of the lower surface for cleaning . The bottom of the perforation will have remnants of the food lying for long period and ADVANTAGES/VALLUE ADD: Hygienic process, Accessibility of the continuous steam entry will render the surface hardened with calcium lower surface for better cleaning and increased safety of the cooked deposits and is unsafe. product. IMPROVEMENTCATEGORY ( QUALITY/COST/CYCLE TIME/SAFETY/MORALE ) : Quality, Hygieneincreased, Ease of cleaning is better QUANTIFICATION: - Nil- APPROVALS: VERIFICATION DESCRIPTION: ( Check after 1Month ) Sustained KAIZEN IDEA BY :NANP Date December 2012 Done by :Prashanth Kumar MB Date Feb 2013 IMPLEMENTED BY : Prabhakar, Puresh Date December Approved by : Prashanth Kumar MB Date Feb 2013 2012 APPROVED BY : Vinay N Kumar Date January 2013
PDCA – A Continual Improvement Methodology
Six Sigma
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