1. Introduction and plant lay-out Flashcards
What is unit operation?
unit/equipment used to process the food physically (occur the physical change) both using mechanical energy or involving heat energy (heating/cooling)
What is unit proses?
Unit/equipment used to process/convert the food chemically, biochemically, or microbiology (occur the chemical change of food) (reactor/cioreactor) –> engineering fundamental of food industry
What is unit process?
Combination of 2 unit operation or more to process the food physically.
What’s an example of unit operation in tomato paste?
sorter
Mention and explain types of process in food industry!
- Process batch: processing a number of materials into products by following one or more se[ (set?) of production, according to the planned order and time (loading, process, and unloading takes its own time or not at the same time)
- Continuous process: processing a number of ingredients from the start of process through each production step to a final product that runs every time (non stop production cycle)
What are factors that need to be considered in designing a plant?
1) raw matter
2) products made in the food plant
3) process technology and engineering
4) auxiliary equipments
—–>
a) process and equipment selection
b) sanitary design
c) support facilities
d) welfare facilities
e) security
—–>
1) integration (materials, workers, machineries, activities/movements)
2) minimum distance
3) flow (materials and workers)
4) rooms volume
5) safety and comforts
6) flexibility
What is an overall lay-out?
the way equipment is located with respect to other pieces, is dictated by efficient flow of materials and people
What does plant layout arrange?
- personnel
- operating equipment
- storage space
- materials handling equipment
- all other supporting machineries and services
Muther grid?
summarized info inside a grid displaying various combiantions of department, work group, or machine pairs. each combination is represented by an intersection on the grid, and is assigned a letter indicating importance of closeness of two.
Qualify the relationship between departments below according to the muther gri:
1. Relationship between R&D and electronic testing
2. Electronic testing and food analysis
3. Food analysis and ultrasonic testing
5. Ultrasonic testing and sensory testing
6. Sensory and impact testing
- E
- I
- I
- I
- I
- E
Letter symbol on muther chart:
A: absolutely necessary
E: very important
I= Important
O: ordinary importance
U: unimportant
X: undesirable
There are several types of lay-out:
- Process lay-out
- Fixed position lay-out
- Product lay-out
- Cellular/group lay-out
What is a process lay-out?
- Found in firms that produce customized, low-volume products that may require different processing requirements and sequences of operations
- Called as functional layouts and the flow in a process layout can be very complex
- Example: machine shop
- Services that utilize process layouts include hospitals, banks, auto repair, libraries, and universities
What is a fixed position lay-out?
- Appropriate for a product that is too large/heavy to move
- Example: a hospital operating room where doctors, nurses, and medical equipment are brought to the patient)
- Other fixed-position layout examples include construction (e.g. buildings, dams, and electric or nuclear power plants), shipbuilding, aircraft, aerospace.
Required resources must be portable so that they can be taken to the job for “on the spot” performance
What is a product lay-out?
- Product layouts are found in repetitive assembly and process or continuous flow industries
- It produces high-volume, highly standardized, repetitive process
- The resources are arranged sequentially, based on the routing of the products
- In theory, this sequential layout allows the entire process to be laid out in a straight line, which at times may be totally dedicated to the production of only one product or product version
- Needs balancing for other lines are not idle while waiting for the current line
- Each of the counter consists of several different equipment. However, at the end of the day they would be processed in a large counter together
What is a cellular lay-out?
- Type of layout where machines are grouped according to the process requirements for a set of similar items (part families) that require similar processing -> these groups are called cells
- An equipment layout configured to support cellular manufacturing
- Processes are grouped into cells using a technique known as group technology
- Group technology involves identifying parts with similar design characteristics (size, shape, and function) and similar process characteristics (type of processing required, available machinery that performs this type of process, and processing sequence)
- Workers in cellular layouts are cross-trained so that they can operate all the equipment within the cell and take responsibility for its output
Advantages and disadvantages of fixed p.l
Adv:
1. Very high mix and product flexibility
2. Product/customer not moved or disturbed
3. High variety of tasks for staff
Disadv:
1. Very high unit cost
2. Scheduling space and activities can be difficult
Adv and disadv of process p.l
- High mix and product flexibility
- Relatively robust if in the case of disruption
- Easy supervision of equipment of plant
disadv:
1. low utilization of resources
2. Can have a very high WIP
3. Complex flow
Adv and disadv of cell p.l
adv:
1. good compromise between cost and flexibility
2. Fast throughput
3. Group work can result in good motivation????? bro so sorry gw bahkan gangerti ini apaan
disadv:
1. Can be costly to rearrange existing layout
2. Can need more plant and equipment
Adv and disadv of product p.l
Adv:
1. Low unit costs for high volume
2. Gives opportunities for specialization of equipment
Disadv:
1. Can have low mix and flexibility
2. Not very robust to disruption
3. Work can be very repetitive
Basic types of flow patterns that are employed in designing the layout?
I, L, U, S, O
Flow patterns in p.l
a) i flow: separate receiving and shipping area
b) L flow: when straight line flow chart is to be accommodated
c) V shape: for storage
d) u flow: very popular as a combination of receiving and dispatch
e) s flow: when production line is long and zigzagging on the production flow is required
f) o flow: when it is desired to terminate the flow near where it is originated
Steps of planning lay-out design
- Analysis:
Input data and activities (flow of materials & activity relationship, relationship diagram –> space requirements and space available) - Search
space relationship diagram, modifying considerations and practical limitations, develop layout alternatives - Selection
evaluation
Do read examples of incorrectly and correctly plant layout/facilities designed
Dont’s
1. Raw material, partly processed product and finished product in the same cold store
2. Adjacent inspection of prepared food and washing of raw material
3. Confused and excessive materials handling
