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Contents
1. NATIONAL FOODS LIMITED........................................................................................................6
1.1. VISION STATEMENT:..............................................................................................................6
1.2. MISSION STATEMENT:...........................................................................................................6
1.3. INTRODUCTION:......................................................................................................................6
2. ORGANIZATIONAL CHART...........................................................................................................7
2.1. Corporate Organizational Chart..................................................................................................7
2.2. NFL Organizational Chart...........................................................................................................8
3. NFL’S PRODUCT LINE:..................................................................................................................9
4. MANUFACTURING PROCESS.....................................................................................................10
4.2. INTERMITTENT PROCESS.........................................................................................................12
4.3. BOTTLENECKS............................................................................................................................12
4.4. PRODUCTION PROCESS FLOW CHART:.................................................................................13
5. Factors Related to Competitiveness:................................................................................................14
5.1. National Foods Pricing and Quality:...............................................................................................15
5.2. Quality assurance:...........................................................................................................................15
5.3. National food limited is a proactive company:...............................................................................16
6. FACILITY LAYOUT........................................................................................................................17
7. TECHNOLOGY................................................................................................................................19
8. Scheduling Table for Ketchup Manufacturing................................................................................21
8.1. Performance Measurement Though Gantt Charts...........................................................................22
9. Sequencing stages for manufacturing of Ketchup at national foods Pvt.ltd...................................23
9.1. Customer’scentric approach used by national Foods Pvt.Ltd..........................................................24
9.2. Performance Measurements............................................................................................................25
10. TOTAL QUALITY MANAGEMENT.................................................................................................26
10.1. DIMENSION OF QUALITY:......................................................................................................26
10.4. TOTAL QUALITY MANAGEMENT TOOLS:..........................................................................28
10.5. FISHBONE ANALYSIS.....................................................................................................................30
11.1. UPSTREAM AND DOWNSTREAM OPERATIONS.................................................................32
11.2. Bull Whip Effect:..........................................................................................................................33
11.3. NATIONAL FOOD KETCHUP’S VALUE DELIVERYNETWORK.........................................34

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13. PERSONAL / ORGANIZATIONAL GOALS:...................................................................................36
14. SWOT Analysis...................................................................................................................................38
15. Appendix A.........................................................................................................................................39

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 ACKNOWLEDGMENT:

I would like to express my sincere gratitude to all those who contributed to the completion of this
report on National Foods Limited. Their invaluable support, insights, and assistance have played
a significant role in making this endeavor a success.

First and foremost, I extend my deepest appreciation to the management and staff of National
Foods Limited for their willingness to share information, their time, and their willingness to
answer our questions. Their cooperation and transparency were instrumental in providing the
necessary data and insights for this report.

Additionally, I extend my thanks to the group members who provided support and assistance in
data collection, analysis, and discussions. Your contributions were essential in shaping the
comprehensive nature of this report.

.This report would not have been possible without the collective efforts of these individuals and
organizations. Their commitment to the project and their willingness to assist are deeply
appreciated.

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 ABSTRACT:
National Food Limited (NFL) is a prominent Pakistani food brand that has evolved from a spice
manufacturer to offering over 250 food items across 13 different categories. Founded in 1970 by
Mr. Zaheer Majeed, NFL has become a leading brand in Pakistan and has expanded its
operations globally. The company has production facilities in Faisalabad,Nooriabad, Karachi,
and Gujranwala, and its products are distributed in Pakistan, the United Arab Emirates, Canada,
and the United Kingdom.

NFL's success can be attributed to its focus on differentiation, production operations, taste,
lifestyle, flexibility, and work environment. The company emphasizes customer retention by
providing high-quality products such as masalas, sauces, mayonnaise, and desserts. NFL has also
adapted to changing consumer preferences and lifestyles by offering convenient and time-saving
food options.

The company is committed to quality assurance and holds ISO certifications. NFL's proactive
approach includes comprehensive training programs for its employees, environmental safety
measures, and initiatives to reduce its carbon footprint.

NFL has received recognition for its achievements, including awards such as the Global
Standards Certification, Gender Diversity Award, Top Brand Award in Brand Collection, Effie
Award, and Dr. Ruth Pfau CSR Award. The company also promotes gender equality through
mentorship programs and has signed on to the UN Women's Empowerment Principles.

National Food Limited adopts a pricing strategy that aims to make its products affordable.

In terms of quality, NFL excels in performance, aesthetics, special features, conformance, safety,
reliability, perception, and after-sales service.

Overall, National Food Limited's success lies in its commitment to quality, innovation, customer
satisfaction, and employee well-being. By continuously adapting to changing market dynamics
and focusing on excellence in all aspects of its operations, NFL has established itself as a leading
food brand in Pakistan and beyond.

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 1. NATIONAL FOODS LIMITED

1.1. VISION STATEMENT:

"Creating Food that Enriches the Lives of People Everywhere”

1.2. MISSION STATEMENT:

“To achieve their vision by designing and manufacturing food and related products, conforming
to international standards and guidelines for nutrition, health, wellness and quality, bringing joy
and happiness to people everywhere."

1.3. INTRODUCTION:

The National Food Limited, owned by Mr. Zaheer Majeed and founded in 1970 with
headquarters in Karachi, is an international firm with Pakistani roots. From its humble
beginnings as a spice manufacturer, National Food Limited has become one of Pakistan's most
prominent food brands, offering more than 250 items over more than 13 different categories.
These include salt, ketchup, mayonnaise, sauces, pickles, sweets, jams, and jellies. Faisalabad,
Nooriabad, Karachi, and Gujranwala are all home to National Food Limited production facilities
in Pakistan.

National Food Limited's origins may be traced back to 19 February 1970, when it was formally
established as a private limited company under the Company's Act. Forbes's ranking of Asia's
200 best companies includes National Food Limited. In 2017, National Food Limited, a
Canadian company that wholesale distributes food service products, recyclables, and
sanitation/janitorial products, acquired an interest in a United Arab Emirates-based company

6
called National Foods DMCC, a United Kingdom-based company called National Foods
Pakistan (UK) Ltd., and a Canadian company called National Epicure Inc.

The achievements of national food limited are:

✔ A1 Cash and Carry Gets Recognized by Growth 500

✔ British Retail Consortium Global Standards Certification

✔ Gender Diversity Award

✔ Top Brand Award in Brand Collection

✔ Effie Award Winner

✔ Dr. Ruth Pfau CSR Award From MALC

2. ORGANIZATIONAL CHART

2.1. Corporate Organizational Chart

Board of Directors
Company Secrtrary

Chief Executive Officer

Corporate

Internal Audit

Audit Committe

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Human Resource
2.2. NFL Organizational Chart

Board of Directors
Chief Executive Officer
NF DMCC

Quality Research & Development

Sales

Marketing

Information Technology

Manufacturing

Supply Chain

Human Resource

Corporate Finance

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 3. NFL’S PRODUCT LINE:

1: Salt 2: Mayonnaise 3: Pickles

4: Ketchup 5: Desserts 6: Pastes

7: Chutneys 8: Sauces 9: National Recipe Mix

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 4. MANUFACTURING PROCESS

The ketchup manufacturing process involves several steps to transform fresh tomatoes and other
ingredients into the familiar condiment. Here's a simplified overview of the NFL ketchup
manufacturing process:
1. RAW MATERIAL
 Tomato
 Vinegar
 Sweeteners
 Salt
 Onion powder
 Natural flavor
 Water
2. SORTING AND WASHING:
 Tomatoes are sorted to remove any foreign materials or damaged pieces.
 They are thoroughly washed to remove dirt and impurities.
3.PEELING AND DESEEDING:
 The tomatoes are usually subjected to a hot water bath to soften the skin.
 Afterward, they go through a peeling and deseeding process, where the skins and seeds
are separated from the flesh.
4. COOKING:
 The peeled and deseeded tomato pulp is cooked in large kettles.
 During cooking, ingredients like sugar, vinegar, salt, and various spices are added to
achieve the desired flavor profile.
5. REDUCTION AND THICKENING:
 The mixture is reduced and thickened by simmering for an extended period. This process
helps remove excess moisture and concentrate the flavors.
6. HOMOGENIZATION:
 The cooked ketchup is passed through a homogenizer to break down any remaining solid
particles and ensure a smooth texture.

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7. COOLING AND PACKAGING:
 The ketchup is rapidly cooled to preserve its quality.
 It is then pumped into bottles or containers, which are sealed to maintain freshness.
8. QUALITY CONTROL:
 Quality control checks are performed to ensure the ketchup meets quality and safety
standards.
 This includes testing for consistency, flavor, color, and pH levels.
9. LABELING AND PACKAGING:
 Bottles or containers are labeled with product information and branding.
 The ketchup is packaged into boxes for distribution.

10. STORAGE AND DISTRIBUTION:

 The finished ketchup is stored in a warehouse until it is shipped to distributors, retailers,
or customers

4.1. TYPES OF PROCESS USED IN PRODUCTION PROCESS:

BATCH PROCESS
National Food Limited produces a wide range of food products, including spices, sauces, and
other products. These products involve different manufacturing methods. Some food products,
like spices and sauces (including ketchup), are produced using batch process.
Each batch goes through a series of steps, from process of mixing different ingredients, cooking,
and packaging. Once a batch is complete, the equipment is cleaned, and a new batch can begin.
Batch processing allows for flexibility in recipe variations and quality control, making it well-
suited for food production where consistency and quality are essential.

CONTINUOUS PROCESS:
National Foods Limited uses continuous process in mixing and cooking process (to mix and
cook ingredients with a continuous flow at precise temperature and time), in Packaging line (for
filling, capping, labelling, and packing products in an automated fashion).

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 4.2. INTERMITTENT PROCESS
LINE PROCESS:
Some elements of line processing are incorporated. Within the ketchup production facility, there
are assembly lines and conveyor belts that help move containers (e.g., bottles or jars) from one
stage of the process to another. These lines aid in filling, capping, labeling, and packaging. This
approach helps streamline the packaging phase and improve efficiency.

4.3. BOTTLENECKS
Tomato Supply:
Limited availability or quality issues with tomatoes can lead to delays or interruptions in
production.

Processing Capacity:
If the processing equipment or machinery is unable to handle the desired volume of tomatoes or
mix the ingredients efficiently, it can slow down the production process.

Heating and Cooking Time:

Achieving the desired flavor and consistency of ketchup requires heating and cooking the
mixture. If this step takes too long, it can become a bottleneck in the production process.

Cooling and Packaging Time:

After pasteurization, the ketchup needs to be cooled before it can be packaged. If the cooling
process takes too long or if there is a limited capacity for packaging, it can slow down overall
production.

Quality Control:
Ensuring consistent quality throughout the manufacturing process is essential. If there are issues
with quality control, such as detecting impurities or maintaining flavor consistency, it can cause
delays and affect production efficiency.

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 4.4. PRODUCTION PROCESS FLOW CHART:

Raw material Picking ripe Is raw

tomatoes material
Store raw ready to
use?
material
NO
Yes
70-90 degrees

Heating Sorting & Washing

Pulping
3-5 mins Trimming

Staining of Add spices and

Cook pulp with one Add vinegar cook
Pulp third of sugar

Checking of Judging of end Add reaming

consistence point Cooking sugar

Checking of Removal of air

Again cook Delay consistence

Labeling and Cooling and Bottle filling

Dispatched packing store 13
 5. FACTORS RELATED TO COMPETITIVENESS:

Differentiation:
National food is being distributed in 4 countries, recently, UAE, CANADA, UK, and many
services in PAKISTAN. It is a challenging product as compared to Shan masala. These are two
of the top leading brands not only in masala but more products as well. National Foods is now a
top leading brand in Pakistan compared to other brands. It focuses on customer retention through
best-quality products like masala, mayonnaise, ketchup, chutney sauces, desserts, etc. It is now
producing multiple products which are being exported to different regions. National Foods does
not compromise on any quality or packaging measures and still sells its product at the same
market prices now. In the recent surveys of our group in university, people mostly prefer national
masalas and preserved or half-cooked national meals for their traveling purpose.

Production operation:
National Foods first introduce its masala; it is easy for people to cook food from the national
masala. In inception in 1970, NFL involved many food companies that produced 250 products
within 13 categories. NFL also holds ISO certifications and also work on its improvement to
ensure that it will give high-quality products to their customers

Taste:
As time changes now, the days eating habits of people also get change, NFL works on these
factors. They also look and take care of hygiene to save the life of several, health, people's
choice, demand, etc. NFL produce their product according to their customers want.

Lifestyle:
NFL also provide ease to their customers by providing traditional taste, which gives them a
modern lifestyle. It is best, for now, a day to cook the best food in a few minutes.

Timely NFL faces many challenges like globalization, migration, technological advancement,
and the changing customer wants and lifestyle; as time goes on, NFL work on these things for
the betterment of their customers and to retain their customers, which People Penetrate positive
word of mouth and ultimately, revenue became higher. When national food becomes expected in

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the market, they start exporting their product, and after some time, they introduce their new
products such as jams, garlic mayonnaise, garlic ketchup, etc. NFL exports its product and now
uses it worldwide.

Flexibility:
National food limited mainly focus on flexibility as they provide ease to their employees, such as
they allow their workers to bring their kids when they are under the supervision of babysitting;
NFL also looks at women's rights and provides jobs to women by these women also get
independence, provide perks and benefits to their employees, flexibility in time, they also
provide the medical facility, health insurance and many other things they provide to their
employees by which employee remains to sustain and work there freely.

5.1. National Foods Pricing and Quality:

National Foods price strategy is more reliable than its competitors. When we converse prices in
certain products, it shows a comprehensive picture of the price tactic of selected products.

• Pricing objective
• Determining demand
• Competitors price
• Pricing method

We are considering the country's fiscal conditions and the buyers' purchasing power so our
product price will be affordable for all customers. From the middle class to the elite class.

5.2. Quality assurance:

National Foods are committed to the best quality and innovation. Hence, they well-timely
introduce new products and tastes to meet their customers' demands. National foods meet the
requirement of everything needed at a reasonable rate. Their initiative to make hygienic foods
and decrease the time spent in the kitchen for women with a philosophy that the products must
be pure and adopt international standards.

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National foods are ISO 9001 certified. Food inspectors regularly visit and check the quality and
ingredients to make sure quality.

5.3. National food limited is a proactive company:

National food limited is a proactive company because most food-oriented companies believe in
something other than a reactive approach as it is directly connected to customers' health.

National Food is committed to being proactive so that its record will be standardized, efficient,
and ready for systematic examination. Maintaining proper supervision of sanitation, along with
that, they also take of immediate actions.

NFL is a proactive company in the sense that they train their employees before any mishaps and
follow strict training schedules for the staff. They train both management and non-management
staff. They also provide knowledge to their staff by this; they can efficiently and safely perform
their responsibility and duties. They make sure all their safety measure for any future foreseeable
accidents. NFL strongly rely on environmental safety as they prevent the emission of exhaust
smoke into the environment. They regularly monitor the environment in their labs to ensure
compliance with critical parameters such as air quality, vehicle emission, drinking water, and

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noise—a legitimate waste management system for hazardous and non-hazardous waste as per
legal requirements.

NFL also started a campaign called #LETSPLANTOURFUTURE for the betterment of the
environment by reducing carbon footprint and awarding people for reutilizing the resources.
Consequently, NFL productively reduces the usage of paper by 25%.

6. FACILITY LAYOUT

Arrangement of equipment, workstations, departments, and resources within a physical space to

optimize efficiency, productivity, safety, and workflow. NFL use both process and product
layout.
PROCESS LAYOUT:
In the main production facility, where the ketchup is processed and prepared, NFL employe
process layout. This layout is suitable for multiple processing steps.
Ketchup manufacturing involves various processes like sorting, washing, cooking, and bottling.
Each of these processes have its own dedicated area, machinery, and workforce to maximize
efficiency.

PRODUCT LAYOUT:
In the bottling and packaging section of the factory, a product layout is used. This layout is
suitable for high-volume production of identical products.
Ketchup bottles move along a conveyor belt through different stages of filling, capping, labeling,
and packaging. This continuous flow ensures consistency and high productivity.

HYBRID LAYOUT:
In the shipping and logistics department, National foods uses hybrid layout. This is where
ketchup bottles are packed for distribution and transported to various locations.
The company use aspects of both process and product layouts. The distribution center has
sections dedicated to different products (product layout) while also maintaining a separate area
for packaging and labeling (process layout) to customize orders or address specific customer
requirements.

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The choice of layout depends on the specific needs of each area within company. By using
different layouts in different parts of the operation, the company optimize efficiency, quality, and
cost-effectiveness, while also accommodating various production requirements.

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 6.1. CYCLE TIME CALCULATION:

PRODUCT: KETCHUP
9gram
Per Annum 60000000
Per annum/No of days 60000000/365 164384 Per Day

UNIT PRODUCE PER

164384
DAY
Labor hours 9
Units Produced Per Day / Labor
Productivity 164383/9
Hours
Productivity 18265 Unit per hour

Cycle time
Desired output 18265 Cycle time = (3600 seconds/hour) 18265/3600
Cycle time 3600
Cycle time 0.20 sec/unit

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 30 GRAMS
Per Annum 60000000
160000000/36
Per annum/No of days 5
438356 Per Day

UNIT PRODUCE PER

438356
DAY
Labor hours 9
Units Produced Per Day / Labor
Productivity 438356/9
Hours
productivity per day 48706 Unit per hour
7. TECHNOLOGY

ENTERPRISE BUSINESS PROCESS AND DIGITAL TRANSFORMATION

NFL IT is leading “Enrich with SAP” – NFL’s SAP Transformational Program, moving to the
latest S/4HANA Enterprise Suite through the “RISE with SAP” program that will enable us to
expand our SAP landscape on the cloud and allow for hyper-scaling with SAP’s cloud-based
add-on applications like Integrated Business Planning, Ariba Procurement Solution & the
Governance, Risk Management & Compliance suite to provide a convenient one-window
solution to all our enterprise needs
CYBERSECURITY
Enhanced cybersecurity measures have become the need of the hour and with the vision to go
global, information security becomes a key compliance requirement. NFL IT is on a two-year
journey to implement the CIS Cybersecurity Framework, consisting of 153 action items
categorized under 18 controls, focused on improving data protection and security
STRATEGY & GOVERNANCE
NFL’s IT Strategy was developed and aims to align our strategic business goals and IT goals &
initiatives for the next three years, focusing on Delivery Excellence, Customer Experience,
Employee Experience, Operational Excellence and Corporate Growth.

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 8. SCHEDULING TABLE FOR KETCHUP
MANUFACTURING

This table is representing a scheduling review process taking place at national foods Pvt, ltd a
leading food manufacturer. It details job operations, machine assignments and processing time in
hours. Efficient scheduling provide plays a vital role in efficient manufacturing, which makes
this table a vital asset for optimizing production.

Job Operation Number Machine number Processing time

A A1 Tomato washer machine 3 hours

A2 Mandolin Slicer 2 hours

B B1 Vacuum thermoforming machine 1 1 hour

C C1 Printing Machine -1 1 hour

JOB Operation a (Washing and Cutting machine)

 Operation A represents a washing and cutting process of tomatoes at national foods in
manufacturing of ketchup.
 It is divided into two operations i.e. A1 which is a washing process of tomatoes and A2
which is responsible of cutting tomatoes and tomato washing machine takes about 3
hours in washing and slicing machine needs about 2 hours.

JOB Operation B (Vacuum thermoforming machine)

 Labeled as B1 and assigned to Vacuum thermoforming machine -1
 Requires a process time of 1 hour.
 Job operation B involve in extracting out any kind of air that is residing in finely made
tomato paste which in later stage would responsible in growing bacteria or fungus in the
pulp, damaging taste and quality.

JOB Operation C (Printing Machine)

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  Labeled as C1 and assigned to “printing Machine -1”
 Requires a process time of 1 hour
 Job operation C is likely related to the final stages of ketchup manufacturing in which
printing machine designs and label on the ketchup packages produced by the company.

In conclusion this table is really important for national foods Pvt, ltd aiding in the management
and optimization of ketchup production. It outlines critical operations, their associated machines,
and processing times ensuring efficient manufacturing to meet customer needs. Effective
scheduling is necessary for maintaining quality and operational efficiencies in ketchup
manufacturing industries.
8.1. PERFORMANCE MEASUREMENT THOUGH GANTT CHARTS
Planned vs actual performance
(For minimum of order of 3500 kg)
Operations Time
(Hours)
Am PM
9 10 11 12 1 2 3 4 5 6
Pulping [ ]
Adding ingredients and [ ]
cooking
Finishing [ ]
Removing air [ ]
Filling [ ]
Cooling [ ]
Packaging [ ]

[] shows planned time slots

Shows actual events

The provided timeline illustrates planned vs actual performance that usually appears at national
foods Pvt. Ltd., with a minimum order of 3500 kg, across various operations throughout the day.
It is subsequently evident that the operations pulping, adding ingredients and cooking and
finishing are right on schedule whereas the other key operations including removing air, filling,
cooling and packaging encountered variances in their actual execution compared to the initial
plan. Filling, cooling and packaging faces tardiness due to the delay caused by the removing air
or creating vacuum department and this is usually caused due to their laziness and converting
their 1-hour lunch break into 1 and half or killing more time, so these were the findings of the
usual tardiness found in national foods of filling, cooling and packaging departments as they
were late in their planned activities of about half to 1 hour. The chart emphasizes the importance
of efficient scheduling and real time monitoring to ensure timely order fulfilment in a dynamic
manufacturing setting.

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 9. SEQUENCING STAGES FOR MANUFACTURING OF
KETCHUP AT NATIONAL FOODS PVT.LTD

RAW MATERIAL:

Raw material at national foods can be store at 5°C for about 1 year with the help of food
preservatives that are imported from Singapore which takes about 45 days and mostly other raw
material is imported fromChina which takes about 60 days and garam masala fromIndia via
Dubai, takes about 30 days and locally we require Raw Material Procured [salt, chili, bottles &
caps, plastic containers and labelsthese all materials National Food Limited locally procure
bottles from Baluchistanand sugar is purchased locally.

PULPING PROCESS:

At national foods the tomatoes are chopped and precooked, then pumped into Pulping Machines,
or Cyclones, which separate seeds, skins, and stems from the pulp. This pulp is filtered through
Screens and processed further into ketchup, and some are stored in a form of paste to use later in
the year.

ADDING INGREDIENTS AND COOKING:

The pulp is pumped into Cooking Tanks or Kettles and heated to boiling and kept at a
Temperature above 80°C. Measured amounts of sweeteners, vinegar, salt, spices, and flavorings
are added to the tomato pulp.

FINISHING:
Once cooking is completed the mixture passes through a finishing machine.

REMOVING AIR:

The ketchup is De-aerated to Prevent Discoloration and Growth of Bacteria. Excess air to
prevent contamination ketchup is kept above 88°C and passed on from filling machines to
containers. May cause unattractive air pockets and impede the closure process.

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FILLING MACHINE:
To prevent contaminationketchup is kept above 88°C and passed on from filling machines to
containers.

COOLING:

The containers are cooled to prevent Flavor Loss through Stack Burning, which occurs when
ketchup stays at high temperatures after cooking is complete. Containers of ketchup are cooled in
cold air or cold water.

LABELING AND PACKAGING PRINTING:

In this process the ketchup is packed into 5kg plastic bottle and then about 1,1/2,1/4kg packages
and then each of them is separately labeled and then in the last printing is done by thermal inkjet
printers and flexor printers.

DELIVERY:

This is the final and last step of the manufacturing process and then delivering the final product
to the customers and making sure the product is delivered on time.
These 9 sequencing steps plays vital role at National Foods Pvt.ltd in production process of
ketchup with each steps enhancing the chances of optimized delivery and production.

PRIORITIZATION BENCHMARK SET BY NATIONAL FOODS PVT.LTD

National foods offer level production strategy which entirely depends upon customer centric
approach and aligning their production levels with customer approaches and also their job
scheduling is not entirely but somewhat based on customer’s eccentricity.

9.1. CUSTOMER’S CENTRIC APPROACH USED BY NATIONAL FOODS PVT.LTD

CUSTOMER NEEDS:
We continuously seek to understand and identify customer needs.

VALUE FOR CUSTOMER:

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We focus on providing convenience and value to our customers.

CUSTOMER RELATIONSHIP:
We are clear and transparent in our communication so that our customers can understand what
type of message we are delivering so that we can prolong and elongate our meaningful
relationship.

SPECIALIZED SOLUTIONS:
We consider all customer touchpoints to offer the best possible solution and want that every
customer to think them individual values for us.

PRIORITY RULE FOLLOWED BY NATIONAL FOODS PVT.LTD

National Food Pvt.Ltd follows“Earliest due date” for fair and prompt customer order
fulfilment, irrespective of order size and history. These principals help us to implicate
efficiencies and customer satisfaction goals. In this way national foods can evaporate any type of
conflicts between them and customers.

9.2. PERFORMANCE MEASUREMENT

National Foods Pvt. Ltd. (Earliest due date)

(For Minimum order of 3500 KGs)
Jobs Time Limit Due Time Completion Tardiness
(Hours) (hours) Time
Pulping Process 1 1.5 1 0
Adding
ingredients and 1 1.5 1 0
cooking
Finishing 0.5 0.5 0.5 0
Removing Air 0.5 0.5 1.5 1
Filling 1 1 1.5 0.5
Cooling 0.75 0.75 1 0.25
Labeling and
packaging 1 1 1.5 0.5
Printing
Delivery 1 1 1.5 0.5
Total 9.5 2.75

Average completion time: 1.187

Average number of jobs: 6.333

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Average tardiness: 0.343
Max tardiness:1
Total no. Of tardy jobs: 5

The above data provides us great insight about the operations at national foods Pvt.ltd under first
come earliest due date, with a minimum order of 3500kg. The observations include the pulping
process with a time frame of 1.5 Hours due time and operation was completed in 1 hour without
any kind of tardiness and the same goes for adding ingredients and cooking and finishing
processes were also recorded without any kind of tardiness but removing air department which
uses vacuum thermoforming machines was having a tardiness of 1 hour and after that ever
process was delayed due to tardiness in removing air department. These were the usual findings
among operations at national foods Pvt.ltd. These finding shows efficiency towards optimizing
production and time deliveries to its customers.

10. TOTAL QUALITY MANAGEMENT

TQM is management approach for an organization, centered on quality, based on the

participation of all its members and aiming at long-term success through customer satisfaction
and benefits to all members of the organization and to the society.

10.1. DIMENSION OF QUALITY:

PERFORMANCE:
National foods limited provides an easy way to cook food in the minimum period and provides a
pleasing aroma in their masala. For this reason, most people prefer their masala.

AESTHETIC:
NFL deliver sustainable food packaging; the color they use attracts customers. To bring more
innovation and attractiveness to their packaging NFL redesigned their packaging with diverse,
vibrant colors; each category is defined with different colors, such as mustard color showing the
curry range, shocking pink color showing the fried range, and deep maroon color use for the
BBQ range. In their packaging, the NFL shows tradition and the proud nation of Pakistan.

SPECIAL FEATURES:

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NFL works on door-to-door free samples of biryani to capture customers' preferences. They also
introduce their discounted deals in which they add different masalas in one box named a family
pack. Sometimes they give their customers free wooden spoons and free mixed pickles and chat
masala samples.

CONFORMANCE:
They have been delivering the same taste for 50 + years as per the expectation of customers and
are renowned for their exceptional aroma-enriching Pakistani cuisine and their masala

SAFETY:
NFL produce halal and safety products; they also provide expiry date to inform their customers
about the usage time duration of the product.

RELIABILITY:
NFL work on retaining the old customers. They have a very long-term satisfaction of their
customers and developed the customer's trust in their product.

PERCEPTION:
NFL fulfill customer perception by providing their masala in an economical price range and
delivering the same taste and quality according to customer’s perception.

SERVICE AFTER SALE:

NFL allows their customers to give feedback directly on their Hotlink and complain about any
issues they have had with their products; they provide Hotlink on their website to be closer to the
customers.

10.2. STAGES OF QUALITY ASSURANCE:

National Food Limited (NFL) has an impressive grasp on the importance of quality from all
angles, as the company actively promotes and keeps published on keeping an excellent standard
of sound production, warehousing, storage, and hygiene practices by International Standards.
BEFORE THE PRODUCTION:
When it comes to "before the production," which indicates the raw material of the specific
organization, national food-limited raw materials are known; likewise, here we have

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"DANDICUT” as a sample, which is home-grown to Sindh only and is ranked highly among the
species grown in Asia.
DURING THE PRODUCTION:
National food limited has established the National Center of Excellence (NCOC), where they
perform production for goods with dedicated sensory analysis chambers, a pilot plant zone for
pilot scale machinery, and an executive kitchen to create and test the food they make. Along with
that Gujranwala site has advanced machinery for the production and packaging of some of their
primary categories as well as there is a Faisalabad site which ensure sustainability will be the key
focus in this new factory design to reduce the energy footprints in the usage of water, electricity,
gas & diesel.

AFTER THE PRODUCTION:

In this process, there is a verification after the production conformance. For this purpose, the
national food limited center comprises a research area, mini library, record room, and labs to
develop prototypes, which helps them re-verify after the production.
10.4. TOTAL QUALITY MANAGEMENT TOOLS:
Total quality management tools help to identify the qualitative and quantitative data of the
organization
NATIONAL FOODS LIMITED TQM TOOLS:
FLOWCHARTS:
National food limited practices flowcharts which are a visual representation of the design process
through which national foods limited ensures the quality of the specified products.

CHECKSHEETS:
A simple tool for problem identification provides a way for the user can record and organize data
in a way through which problems can be solved National food limited check sheets help to
identify the problems and their immediate solution, use best preventive practices at all levels, and
ensure reliable risk management.
5 WHYS:
The "5 Whys" is a problem-solving technique used to identify the root cause of an issue by
asking "why" repeatedly, each time drilling down deeper to uncover the underlying factors. Let's
apply the 5 Whys technique to a problem in ketchup production:

Problem: The ketchup production line is frequently experiencing bottlenecks and delays.

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1st Why: Why are there bottlenecks and delays in the production line?
Answer: Because the filling and packaging station frequently stops.

2nd Why: Why does the filling and packaging station frequently stop?
Answer: Because there are issues with the automated filling machines.

3rd Why: Why are there issues with the automated filling machines?
Answer: Because they often get clogged.

4th Why: Why do the filling machines get clogged frequently?

Answer: Because the viscosity of the ketchup varies, causing it to get stuck in the machinery.

5th Why: Why does the viscosity of the ketchup vary?

Answer: Because the temperature in the ingredient mixing and cooking stage is not consistently
controlled.

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 Supply Chain Labor Process

High labor costs due to Inefficient production

Unreliable suppliers with manual handling and
inconsistent pricing. methods.
outdated processes.
Transportation costs and delays Inefficient staffing levels Lack of optimization in
in receiving ingredients. leading to overtime expenses. production processes.

HBONE ANALYSIS
Limited diversification in suppliers Skills gap requiring Excessive waste during
and bulk purchasing challenges. expensive specialized labor. manufacturing.

High production
costs in ketchup
Fluctuating prices of manufacturing
Frequent breakdowns key ingredients (e.g.,
requiring costly repairs. tomatoes, vinegar).
Inefficient packaging materials and
processes leading to excess waste
Inconsistent quality of
generation.
Aging machinery that raw materials.
consumes more energy.
Over-reliance on expensive or
hard-to-source ingredients.

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Packaging Waste Machine Materials
 11. SUPPLY CHAIN MANAGEMENT
National Foods Limited places a strong emphasis on effective supply chain management to
ensure the smooth flow of goods from suppliers to customers. Here's an overview of their
approach:
PROCUREMENT:
National Foods Limited selects reliable suppliers who provide high-quality raw materials and
ingredients. They establish long-term partnerships to maintain consistent supply and negotiate
favorable terms. Rigorous quality checks and audits are conducted to ensure the procurement of
safe and reliable inputs.
PRODUCTION PLANNING:
The company uses advanced forecasting techniques to predict demand and plan production
accordingly. This helps optimize resources, minimize inventory costs, and ensure timely delivery
to customers.
MANUFACTURING:
National Foods Limited operates modern manufacturing facilities equipped with state-of-the-art
technology. They closely monitor the production process to maintain consistent quality and
efficiency. Regular maintenance and calibration of equipment are performed to minimize
downtime and maximize productivity.
INVENTORY MANAGEMENT:
To prevent stockouts or excess inventory, National Foods Limited maintains a balanced
inventory level. They use inventory management systems to track stock levels, monitor
expiration dates, and manage replenishment to meet customer demands in a timely manner.
DISTRIBUTION:
The Company maintains an extensive distribution network to deliver products to various
locations efficiently. They collaborate with reputable logistics partners to ensure prompt and
reliable delivery while minimizing transportation costs.
QUALITY CONTROL:
National Foods Limited prioritizes quality control throughout the supply chain. Stringent quality
standards are implemented at every stage, from raw material selection to final product
inspection. Regular quality audits are conducted to maintain compliance with international
quality certifications.
SUSTAINABILITY:

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As part of their supply chain management, National Foods Limited promotes sustainability
practices. They engage with suppliers who follow ethical and environmentally

consciouspractices, reducing their carbon footprint and supporting local communities.

11.1. UPSTREAM AND DOWNSTREAM OPERATIONS
UPSTREAM OPERATIONS:
Upstream operations in National Foods Limited refer to the activities involved in the early stages
of the supply chain, which include sourcing, procurement, and production planning. Here's a
closer look at these operations:
SOURCING AND PROCUREMENT:
National Foods Limited collaborates with suppliers to source raw materials, ingredients, and
packaging materials. They ensure the quality and reliability of these inputs by conducting
thorough inspections and audits. Negotiating contracts and ensuring timely delivery are also part
of their sourcing and procurement activities.
PRODUCTION PLANNING:
Based on market demand and sales forecasts, National Foods Limited plans production
schedules, determines the required quantities of raw materials, and schedules manufacturing
processes accordingly. This helps optimize resource utilization while ensuring timely and
efficient production.

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DOWNSTREAM OPERATIONS:
Downstream operations in National Foods Limited involve the activities that take place after the
production process, including packaging, distribution, marketing, and customer service. Let's
delve into each of these operations:

PACKAGING:
National Foods Limited focuses on attractive and functional packaging for their products. They
ensure that the packaging materials are of high quality, visually appealing, and provide adequate
protection to maintain product freshness and safety.
DISTRIBUTION:
Once the products are packaged, National Foods Limited utilizes an efficient distribution
network to deliver goods to retailers, wholesalers, or directly to customers. They work with
logistics partners to ensure timely and secure transportation, minimizing product handling and
maintaining product integrity throughout the delivery process.
MARKETING:
National Foods Limited invests in marketing and promotional activities to create brand
awareness and drive sales. They develop marketing campaigns, engage in product advertising,
and leverage various channels such as traditional media, digital platforms, and social media to
reach a wider audience.
CUSTOMER SERVICE:
National Foods Limited places great importance on customer satisfaction. They have dedicated
customer service teams that handle inquiries, provide assistance, and address any concerns or
issues raised by customers. They aim to provide a seamless and positive experience for their
customers.

11.2. BULL WHIP EFFECT:

Usually demand increase in Ramadan or seasonal wise. Otherwise, NFL has a normal process in
sense of orders. While asking about bull whip effect NFL said, in case any fluctuations occur
then the stocks are adjusted according to the demand and then manufactured to finished goods.
NFL does not face any difficulty while producing more than normal because NFL manufactures
ketchups with underutilization capacity.

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 11.3. NATIONAL FOOD KETCHUP’S VALUE DELIVERYNETWORK

Customers

Retailer

Multan

Lahore Distributors Karachi

Islamabad

Multan
Ware houses
Lahore
Karachi

Islamabad
Storing after production
Customer

Manufacturing

Storage room for paste within factory

Storage room for paste within factory

SUPPLIER [CHINA]
Tomato Paste SUPPLIER [LOCAL] SUPPLIER [LOCAL] SUPPLIER [LOCAL]
Chili Labels
Salt

SUPPLIER [LOCAL] SUPPLIER [LOCAL]

Bottles cap Bottles
SUPPLIER [preservative chemical] SUPPLIER [LOCAL]
Garlic, imli, sugar

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 12. NATIONAL FOOD LIMITED INVENTORY
MANAGEMENT SYSTEM:

PERIODIC INVENTORY SYSTEM:

The national food limited production team analyses the timely previous track record of
inventory. National food limited works on a periodic inventory system where this organization
physically counts inventory with the first in, first out method to keep material fresh and timely
and prevent any unbearable cost to customer health and safety.

HOLDING OR CARRYING COST:

NFL has an in-house warehouse
A warehouse is a commercial facility designed for storing inventories. National Foods maintain
in-house warehouses to minimize the risk of damage to finished goods. This is particularly
important for food items, as they must be stored at appropriate temperatures to ensure hygiene
and protect public health.
 NFL warehouse inventory includes:
 Raw material inventory
 Packaging inventory
 Finished goods inventory

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 13. PERSONAL / ORGANIZATIONAL GOALS:

CONTINUOUS IMPROVEMENT
Consumers need to adapt their dietary choices in this era of constant lifestyle transformations
driven by rapid technological advancements. In response to this challenge, National Foods has
emerged as a brand that creates innovative food products catering to the needs of modern
lifestyles, emphasizing convenience and quick preparation while upholding traditional values. By
offering an impressive range of food products, National Foods successfully fulfills its
commitment to providing consistent value to consumers. Moreover, the brand fosters stronger
family bonds by facilitating shared experiences during family traditions, festive celebrations,
seasonal holidays, and even ordinary moments of everyday life.
LEADERSHIP
CEO Abrar Hasan shares his transformative vision for National Foods Limited in the captivating
Leadership Series. Guided by the belief that "Transparency builds trust and trust builds teams,"
Mr. Hasan exemplifies a leadership style that fosters openness and collaboration. The CEO
Leadership Series would provide an insight into the years of experience Abrar Hasan has had as
an industry trailblazer while navigating the complexities of the culinary world, positioning
National Foods as one of the leading food manufacturers with cutting-edge systems and
processes to enrich people's lives everywhere.
MANUFACTURING PLANNING AND CONTROL GOAL OF JIT
National Foods Limited in Pakistan uses several Just in Time (JIT) control goals to improve
manufacturing planning and control. These control goals include:
 Level loading
National Foods Limited uses level loading to ensure that production is evenly distributed over
time. This helps to avoid overproduction and underproduction, which can lead to waste and
inefficiency.
 Pull system
National Foods Limited uses a pull system to ensure that production is driven by customer
demand. This helps to avoid overproduction and reduce inventory costs.
Visual system: National Foods Limited uses a visual system to ensure that production is
transparent and easily understood. This helps to improve communication and reduce errors.

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  Close vendor relationship
National Foods Limited maintains a close relationship with its vendors to ensure that raw
materials are delivered on time and in quantity. This helps to avoid delays and disruptions in the
supply chain.
 Reduce transaction processing
National Foods Limited reduces transaction processing to minimize the time and effort required
to manage inventory and production. This helps to improve efficiency and reduce costs.
 Preventing measures and housekeeping
National Foods Limited uses preventive measures and housekeeping to ensure that equipment
and facilities are well-maintained and in good working order. This helps to reduce downtime and
improve productivity.
Using these control goals of JIT, National Foods Limited improves manufacturing planning and
control, reduces waste, and increases efficiency.

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 14. SWOT ANALYSIS

STRENGTH:
 Broad product line
 broad market coverage
 Brand name reputation
 Enhanced research and development
 Good finance management

WEAKNESS:
 Currently NFL is operating with full capabilities and the company;s sales manager does
not think that there is any internal weakness in the organization.

OPPORTUNITIES:
 Expanding into foreign market
 Expansion of core business

THREATS:
 New entrants
 New cheaper substitutes in the market
 Fixed quota system on company's import

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15. APPENDIX A

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 16. OUR CERTIFICATIONS

SISO 9001: 2015 Quality Management System

ISO 22000: 2018 Food Safety Management System at SITE & Gujranwala Plant

BRC Global Standard for Food Safety at Port Qasim Plant

ISO 45001: 2018 Occupational Health and Safety

PS 3733: 2019 Pakistan Standard for Halal Food Management System

MS 1500: 2019 Malaysian Standard for Halal Food Management System at SITE,
PQ &Nooriabad Plant

SMETA SEDEX Audit

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