(Source: Primary Manufacturing Department MGM Complex)
4.6.4 Cut Tobacco Store (CTS)
Stem and lamina comes into Cut Tobacco Store where following steps are involved
- First step involved in CTS is blending which is done in FP-Silos (finish product). Tobacco from FP-Silos is then put into boxes that have their code color.
- Stacker then puts blended tobacco into boxes. Each box has about 185kg of tobacco. Two types of stackers are used.
- Boxes are then picked and then put into feeder through which tobacco is sucked by pneumatic system into SMD (Secondary Manufacturing Department). Feeder has different kind of sensors that give tobacco to next section only when needed.
4.7 Secondary Manufacturing Department
4.7.1 Mission Statement
“ We are willing to change, dedicated to become the lowest cost, highest quality, highest manufacturing of Pakistan
The Secondary Manufacturing Department is the final process department, which gives final shape to the product. It gets tobacco from PMD and wrapping material from MMD and processed them to make cigarettes and then packed them in different variants. SMD is the department in which the actual manufacturing of the cigarette takes place. Two types of materials are used in the manufacturing process.
§ Tobacco
§ Wrapping Material
Tobacco is issued to the SMD through CTS. Tobacco is sucked through suction pipes to the SMD. The tobacco for each blend of cigarette is different and stored in CTS, which are color-coded. Each color represents different blends of tobacco. The different brands of cigarettes manufactured in SMD are Melburn Gold KSF, Melburn KSF, Weldon KSF, Bonus KSF, Melody KSF.
The wrapping material are issued to SMD from External Suppliers include.
§ Acetate Tow
§ Till box
§ Gum or Adhesive
§ Plug Rap
§ Packing Material
§ Shell Slides
§ Flats
§ Inner Collar Board
§ Aluminum Foil
§ Adhesive
§ Poly prop
§ Tear off ribbon
§ Parcel Paper
§ CBC Carbonate board center
§ End Labels
§ Hang lets
§ Tipping Paper
In order to achieve the functional objective and make the working more efficient, SMD has been divided into different formation of teams. Each team has a team leader who acts like a bridge between workers and management. There are certain targets for each team on the achievement of which they are appreciated and motivated in the shape of bourses and other incentives. But incase of not achieving its target, is a matter. If regret and shame for the whole team. Thus increasing the efficiency and productivity of the teams.
There are many teams in the SMD department in which one team works for the manufacturing of the filter rod while the other six teams manufacturing the cigarettes. The filter rod department prepares the filter rod. The material department supplies the raw materials, which are mainly acetate Tow, plug warp, till box, hot melt and adhesives. When cigarettes are made they are sent to packers, which packs them in the packets and send them for further processes. After the cigarettes are packed in packets they are than send to the percales that packs them in shape of outers. The outers thence prepared are packed into CBCs. They are then taped and air tightened and sent to the shipping godown. Wastages are an integral part of the manufacturing process. It is rather impossible to even risk of a perfect manufacturing process free of wastages. But what is possible is to make sure that the amount of wastages shall be reduced to the minimum possible quantity.
In the manufacturing process the wastages can occur in two forms.
§ Wastages of tobacco
§ Wastages of wrapping material
In tobacco is wasted in the form of dust or the blended mixture of stem and lamina. The dust is disposed off or sold and where as the stem and lamina is again put into the PMD process. The wastages of the wrapping material are the most common and frequent form of wastage occurring in the SMD. Since these wastages cannot be put into process again therefore, it is necessary to identify them in time and reduce the volume of these wastages.
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