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SUBJECT : MANUFACTURING SYSTEM

CODE : BFF2513

LECTURER : MR MEBRAHITOM ASMELASHGEBREMARIAM 

Prepared by:

MUHAMMAD HABIBULLAH BIN BADULHISHAM FA12043FARITH HAZIQ BIN MUHAMMAD FA12021MUHAMMAD AIMAN BIN ISYAK FA12016

MUHAMMAD ALIEF BIN OTHMAN FA12018

UNIVERSITI MALAYSIA PAHANG

TABLE OF CONTENT

TITLE PAGE

Introduction about your manufacturing plant a. Objective b. Technology c. Economic advantage

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Organizational Structure 4

Plant design procedures a. Product design b. Identification of the processes needed or manufacturing process design c. Determination of the number of machines or equipment needed d. The number of worker needed e. Determination of the cycle time or Manufacturing lead time

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Manufacturing process a. Flow diagram b. Process diagram

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Material handling systems design a. Types of material handling system needed b. Number of material handling machines needed

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Layout design a. Production or manufacturing layout b. Administration layout

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Total plant cost a. Capital cost b. Production costs c. Material costs d. Unit production cost e. Unit selling price f. Profit margin

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Conclusion 17

OBJECTIVE:

There are several objective of our company. Some of them include that our company to be one of the long-term market forecast for Malaysia. Our next objective is that to be able to penetrate foreign markets and to increase the quality of production of our products. Our next objective is the availability of fibre raw material and possibilities to increase the availability in the long term and the final objective of our company is to improve management practices.

TECHNOLOGY:

Formed from wood pulp or plant fiber, paper is chiefly used for written communication. The earliest paper was papyrus, made from reeds by the ancient Egyptians. Paper was made by the Chinese in the second century, probably by a Chinese court official named Cai Lun. His paper was made from such things as tree bark and old fish netting. Recognized almost immediately as a valuable secret, it was 500 years before the Japanese acquired knowledge of the method. Papermaking was known in the Islamic world from the end of the eighth century A.D.

Knowledge of papermaking eventually moved westward, and the first European paper mill was built at Jativa, in the province of Valencia, Spain, in about 1150. By the end of the 15th century, paper mills existed in Italy, France, Germany, and England, and by the end of the 16th century, paper was being made throughout Europe.

Paper, whether produced in the modern factory or by the most careful, delicate hand methods, is made up of connected fibers. The fibers can come from a number of sources including cloth rags, cellulose fibers from plants, and, most notably, trees. The use of cloth in the process has always produced high-quality paper. Today, a large proportion of cotton and linen fibers in the mix create many excellent papers for special uses, from wedding invitation paper stock to special paper for pen and ink drawings.

The method of making paper is essentially a simple one—mix up vegetable fibers, and cooks them in hot water until the fibers are soft but not dissolved. The hot water also contains a base chemical such as lye, which softens the fibers as they are cooking. Then, pass a screen-like material through the mixture, let the water drip off and/or evaporate, and then squeeze or blot out additional water. A layer of paper is left behind. Essential to the process are the fibers, which are never totally destroyed, and, when mixed and softened, form an interlaced pattern within the paper itself. Modern papermaking methods, although significantly more complicated than the older ways, are developmental improvements rather than entirely new methods of making paper.

ECONOMIC ADVANTAGE:

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The advantage of being involve in the paper business include that the raw material of paper are cheap material which are easily available. It is also can be cut easily into desired shaped and paper is not harmful as a waste product.

The disadvantage is that paper is very flammable, it is easily damaged by water and insects. It also not strong enough to be use in heavy duty work.

ORGANIZATIONAL STRUCTURE

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FARITH HAZIQ BIN MUHAMMAD

Director

MUHAMMAD HABIBULLAH BIN BADULHISHAM

Head Of Finance

MUHAMMAD AIMAN BIN ISHAK

General Manager

MUHAMMAD ALIEF BIN OTHMAN

Head Of Engineer

PLANT DESIGN PROCEDURES

a) PRODUCT DESIGN

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b) IDENTIFICATION OF THE PROCESSES NEEDED OR MANUFACTURING PROCESS DESIGN

Making pulpSeveral processes are commonly used to convert logs to wood pulp. In the mechanical process, logs are first tumbled in drums to remove the bark. The logs are then sent to grinders, which break the wood down into pulp by pressing it between huge revolving slabs. The pulp is filtered to remove foreign objects. In the chemical process, wood chips from de-barked logs are cooked in a chemical solution. This is done in huge vats called digesters. The chips are fed into the digester, and then boiled at high pressure in a solution of sodium hydroxide and sodium sulfide. The chips dissolve into pulp in the solution. Next the pulp is sent through filters. Bleach may be added at this stage, or colorings. The pulp is sent to the paper plant.

BeatingThe pulp is next put through a pounding and squeezing process called, appropriately enough, beating. Inside a large tub, the pulp is subjected to the effect of machine beaters. At this point, various filler materials can be added such as chalks, clays, or chemicals such as titanium oxide. These additives will influence the opacity and other qualities of the final product. Sizings are also added at this point. Sizing affects the way the paper

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will react with various inks. Without any sizing at all, a paper will be too absorbent for most uses except as a desk blotter. A sizing such as starch makes the paper resistant to water-based ink (inks actually sit on top of a sheet of paper, rather than sinking in). A variety of sizing’s, generally rosins and gums, is available depending on the eventual use of the paper. Paper that will receive a printed design, such as gift wrapping, requires a particular formula of sizing that will make the paper accept the printing properly.

Pulp to paperIn order to finally turn the pulp into paper, the pulp is fed or pumped into giant, automated machines. One common type is called the Fourdrinier machine, which was invented in England in 1807. Pulp is fed into the Fourdrinier machine on a moving belt of fine mesh screening. The pulp is squeezed through a series of rollers, while suction devices below the belt drain off water. If the paper is to receive a water-mark, a device called a dandy moves across the sheet of pulp and presses a design into it.The paper then moves onto the press section of the machine, where it is pressed between rollers of wool felt. The paper then passes over a series of steam-heated cylinders to remove the remaining water. A large machine may have from 40 to 70 drying cylinders.

FinishingFinally, the dried paper is wound onto large reels, where it will be further processed depending on its ultimate use. Paper is smoothed and compacted further by passing through metal rollers called calendars. A particular finish, whether soft and dull or hard and shiny, can be imparted by the calendars.The paper may be further finished by passing through a vat of sizing material. It may also receive a coating, which is either brushed on or rolled on. Coating adds chemicals or pigments to the paper's surface, supplementing the sizings and fillers from earlier in the process. Fine clay is often used as a coating. The paper may next be supercalendered, that is, run through extremely smooth calendar rollers, for a final time. Then the paper is cut to the desired size.

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c) DETERMINATION OF THE NUMBER OF MACHINES OR EQUIPMENT NEEDED

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d) THE NUMBER OF WORKER NEEDED

Qf= pq

(5x200000) =1000000ton/year

Total no of part produced

Mpf=pqmp=(5)(200000)(1)

1000000tonnes/years

Mof=(pqmq)mo=(1×109)(4)

4×109 operation/year

No of worker needed=Mof(0.5/60)

(33.33×106)/8760= 3805.17

3806 worker

In our company, the manpower needed is not much because our company have modern

technology and most of the job can be done by machine. Therefore, the estimated manpower in

the factory is to be less than 3806 persons. Less in manpower also will bring benefit to company

due to less money need to pay for workers salary.

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e) DETERMINATION OF THE CYCLE TIME OR MANUFACTURING LEAD TIME

MLT = (setup time + batch size(operation time) + non-operational time) n

= ( 1hr + 2739726.027(8×10-6) + 1hr)(1) = 23.91 hours

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MANUFACTURING PROCESS

a) Flow Diagram

The first section of the machine is called the ‘ Wet End’ .  This is where the diluted stock first comes into contact with the paper machine.  It is poured onto the machine by the flow box, which is a collecting box for the dilute paper stock.  A narrow aperture running across the width of the box allows the stock to flow onto the wire with the fibers distributed evenly over the whole width of the paper machine.

Press section consists of a number of heavy rollers.   The paper is conveyed through these rollers on thick felts of synthetic fiber.   More moisture is squeezed out of the paper like a mangle, and drawn away by suction. At this stage of the process the paper is still very moist.

In drying section, the paper passes through a large number of steam-heated drying cylinders. The sheet enters the dryer with a moisture content of 60–75% depending upon the product and the effectiveness of the presses. The paper leaving the dryer has a moisture content of 2–10%, but typically has a final moisture content of between 5–7%. Paper mill steam consumption with cylinder drying is about 4GJ/tone of the product. The ratio of energy use between the dryer and press sections is typically 15:1.

Steam of 6 to 12 bar is brought into the cylinders where it condenses. Water in the sheet is removed by evaporation. The temperature at the cylinder surface varies from 100oC to 165oC. There can be up to 50 or 60 cylinders on a fast running paper machine.  Synthetic dryer fabrics carry the web of paper round the cylinders until the paper is completely dry.  Part way down the bank of drying cylinders is the size press. It is here that a solution of water and starch can be added to the sheet in order to improve the surface for printing purposes. The paper then continues through the drying section.

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The calendar consists of a stack of polished iron rollers mounted one above the other.  The calendar ‘ irons’   the paper.  The surface of the paper is smoothed and polished. The paper now comes off the machine ready for reeling up into large reels, each of which may contain up to 20 tonnes of paper.  These large reels are either cut into sheets or slit into smaller reels according to the customer’ s requirements.

b) Process Diagram

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MATERIAL HANDLING SYSTEM NEEDED

a) Types of material handling system needed

b) Number of material handling machine needed

Conveyors – 300 units

Cranes – 100 units

Industrial Trucks – 150 units

AGV – 150 units

Robots – 100 units

AS/RS – 150 units

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LAYOUT DESIGN

a) Production Layout

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b) Administration Layout

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TOTAL PLANT COST

a) Capital cost: -Machine Paper = RM 160,360.00 /machine

-Power Plant = RM 128,284.00 /machine

-Boiler = RM160, 360.00 /machine

-Clarifier = RM120, 432.00 /machine

Total: RM 569 436.00

b) Material Cost: -RM 2,000,000 /yr

Production Labour Cost:

Direct labour cost : (Number of paper produce per day) ( Number of working hour required per day) ( Price of Labour per hour)

: (1000000/250)(24)(10) = RM 960 000

Direct labour rate ,DLC : RM 10/hr

Factory overhead cost , FOHC : RM 250 000

Applicable factory overhead rate ,FOHCm : RM 250 000/960 000 = 0.2604

Corporate overhead cost ,COHC : RM 150 000

Applicable factory overhead rate ,COHCm : RM 150 000/ 960 000= 0.15625

Capital investment in machine : RM 100 000

Service life of machine : 6 years

Rate of return : 20%

Salvage value : 0

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Calculation of machine labour:

Recovery rate:

= Capital cost x [ 0.2(1+0.2) 6 ]

[((1+0.2)6) -1]

= 569 436.00 x 0.26060

= RM 148395.0216

Labour machine rate = 148395.0216/ ( 365 days x 24hr /day) = 16.94

PRODUCTION LABOUR COST PER HOUR :

: ( Direct labour rate/ hr)(3806workers) (1+ FOHCm) +(Direct machine rate/hr)(7 machine)(1+COHCm)

: (10)(3806) [1+0.2604] + (16.94)(7) (1+0.15625]

: RM 38,198.36 /hr

TOTAL MATERIAL COST PER HOUR :[(Total material cost per year)/ (Total weight per year)] x (no. of weight per hour )

: {(RM 2000000/ 1000000)} × 114155.25

: RM 228,310.5 / hr

TOTAL PRODUCTION COST/ HR : RM 38198.36 /hr + RM 228,310.5 / hr

TOTAL PRODUCTION COST / HR = RM 266,508.86/ hr

UNIT PRODUCTION COST = (total production cost / hr)/ (total unit kg/ hour)

= (266,508.86) / (114.155.25)

= RM 2.33

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PROFIT PER KG = RM 1.66

UNIT SELLING PRICE = RM 3.99

PROFIT MARGIN PER KG = [(1.66)/(3.99)] X100%

= 41.6%

CONCLUSION

The pulp and paper industry is a very large industry nowadays. Although the industry is

criticized by environmental groups like Natural Resources Defense Council for unsustainable

deforestation and clearcuting of old-growth forest, it is still one of the most important industry

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because paper is used and needed in our everyday life. So in order to overcome the problem of

lacking of sources , we need to come out with new solutions such as using more recycled

material and many more .

Reference #http://www.ecology.com/2011/09/10/paper-chase/

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