process creation by intuition (5m)

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Primitive Process Creation <9 July 07>copyright zain/PSE- FKKKSA, UTM PPC - 1

“Process Creation by Intuition”

(Dr. Zain’s Primitive Process Design)

Man learn in three ways….1st, through imitation, that’s the easiest,2nd, through experience, that’s the hardest,3rd, through meditation, that’s the noblest


Why did you choose Chemical Engineering?

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Chemical Engineering Concerns You !!!

Challenge:Bringing chemical

engineering to your doorstep


Each of us have some chemical engineering (i.e., process design)

experience!!!

Dr Zain’s….Believe it, or not…

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Basic Needs: Any example?• E.g. Food? • Shelter? • Clothing?• Medication?• Transportation • Cosmetics• …….


Basic Needs (Physical)• Food •Clothing

•Shelter

Health & Medication

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Other Needs• Transportation

• Cosmetics/Cosmeceuticals


How to get them?

Buy,

Let’s try to make all the things that we could make!……

Make !

or

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Let’s start with the most basic need!

• Food!


Key Terminology-Chemical Engineering

..is the field of study thatinvolves the process ofconverting resources intovalue-added products

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What is Chemical Engineering?..is the field of study that involves the process ofconverting resources into value-added productsthrough the application of basic sciences (math,chemistry, physics and biology) and engineeringprinciples for the development, design, operation andmaintenance of processes

MathematicsChemistry

PhysicsBiology

Economics

Natural Gas

Air Energy

Minerals

Plants/Crops

Petroleum


Let’s start with the most basic need!

Example of food as a basic need: Rice….Let’s make “Biryani Rice”

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The 5M of Converting Resources to Value Added Products in

Chemical Engineering

Mini Project: Create a Process to Produce e.g. Biryani Rice, Bread,

cookies, cakes and etc

Using…..


Dr Z’s 5M’s of Chemical Engineering

• Materials – ingredients and the product (what,how much, where, cost) ?

• Method (steps...any recipe? Own recipe?...orprocess (of making..))

• Machinery/Tools/Equipment (what, how big?,how many, where, cost, any tools alreadyavailable?, any new one? limitations)

• Manpower (skill required? how many? who?, whoto do what (job-spec)?

• Money (net income?)

We need 5M to convert resources into VA products!

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Some Key Terminologies• Create Steps = Synthesise/Design a Process• Recipe/Steps = Methods, Processes/Operating

Procedure• Tools = Equipment, Unit Operations• Variables = Process Conditions• Net income = Gross Profit/Profitability Analysis• Recipe Improvement = Debottlenecking, Process

Improvement, Optimisation


Methods (Recipe)

• Steps involved – e.g. wash, heat, mix, stir, cool)• Key variables for each step

– Amount of each material…i.e composition– Temperature? Pressure? Additives? Colour? Smell?, – Duration?

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The 5M of Chemical Engineering

Student Project:Create a Process

Manufacture Bahulu Kemboja


“Bahulu Kemboja”

• Introduction– Also known as “Kuih Bakar’ – Traditional ‘kuih’– Pandan flavour– Home based business – Market demand wide; morning breakfast,

gathering, official function etc.– Prod. development; how to make the ‘kuih’ last

longer, taste good with competitive price.

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M1-Materials

Raw Materials: Pandan Leaf Sesame Seed Flour Sugar Coconut Milk EggsWater


STANDARD OPERATING PRACTICE FOR BAHULU KEMBOJA

PROCESS METHOD

BLENDING- Crushing

- Filtration

-Pandan leafs to be cut to small pcs-Transfer cut pandan leaf into blender jar- Pour 700ml water into blender jar- Blend few minutes until all pandan leaf crushed- Pour the blended pandan leaf into plastic container by pass through plastic filter

M2-Methodology

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PROCESS METHOD

MIXING- Pre-Heating

-Mixing

-Transfer pandan jus and coconut jus until steel bowl- If mixed pandan and coconut become light green, add 1-2 tea spoon of green color flavor. - Heat until its boil- Pour the heated pandan extract and coconut milk into the blender jar and transfer all the flour, sugar and eggs- Blend few minutes until its properly mix-Transfer into plastic bowl

M2-Methodology


M2-Methodology

PROCESS METHOD

MOULDING- Mould Pre-heating

- Pour 1 tea spoon of cooking oil until the steel mould.- Heat on gas oven until oil boil- Pour mixed cake ingredient into the mould using plastic jar until mould level- Distribute sesame seeds evenly on the surface

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M2-Methodology

PROCESS METHOD

HEATING (BAKING)

- Switch on oven and set oven temperature knob at desired temperature.- Transfer all the mould into the oven- Set oven timer knob at desired time for bottom heating- Switch on top heater once bottom heating complete.- Heat top surface until its turn to brownish color.- Transfer all the mould out from oven when the top heating complete.


Knife Blender Plastic filter Steel bowlMould Oven Spoon

M3- Machinery/Equipment

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M4-Manpower

MAN POWER QUANTITY PRICE COST / UNIT

Wages 1 man RM60. 00/day 3.85


M5-Money: Costing

RAW MATERIAL QUANTITY (5 units OF CAKE)

PRICE, RM COST/UNIT(5 units OF

CAKE)Flour 350g 1.30/kg 0.455

Sugar 500g 1.50/kg 0.750

Pandan extract 20-30leaf 1.00/100leafs 0.20 – 0.30

Coconut milk 700ml 1.00/L 0.70

Eggs 4nos 0.2/nos 0.80

Sesame Seeds 10-15g 3.00/kg 0.03 – 0.045

Oil 5-10ml 9.00/5kg 0.009 – 0.018

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UTILITIES QUANTITY PRICE COST / UNIT(5units OF

CAKE)Electricity 3.33KW 0.218/KWH 0.72594Fuel Gas (LPG) 50 – 100g 18.50/14kg tank 0.06 – 0.13Water 700ml 0.57/m3 0.0004

Selling price = RM2.70/nos x 5 units = RM13.50GROSS PROFIT MARGIN

= RM5.7257 (73.65%)

TOTAL COST, RM(5units OF CAKE)

7.7743

M5-Money: Costing


Semi-Batch ProcesApplication: Intermediate scale of production

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Continuous (Automatic) Process

Application: Large scale production


“A radical improvement can materialise through paradigm shift”

- dr.zain -

“A paradigm is like a map. Getting to a place quicker is not a

matter of technique. It is a matter of getting the right map”

- Covey -

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“Process Synthesis is paradigm.

Process Design, Process Control and Optimisation are merely

techniques.”

- dr.zain -

process creation by intuition (5m)

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