Introduction to Food Industrial Management (STKM4612) Lecture Notes PDF

INTRODUCTION TO FOOD INDUSTRIAL MANAGEMENT (STKM4612) BASIC PRINCIPLES ACTIVITIES INVOLVED IN FOOD PRODUCTION IN FOOD INDUSTRIES DR NURFATIMAH MOHD THANI OBJECTIVE Understand activities in food production in industry.  Activities/ producing activities, create or change PRODUCTION...

INTRODUCTION TO FOOD INDUSTRIAL MANAGEMENT (STKM4612) BASIC PRINCIPLES ACTIVITIES INVOLVED IN FOOD PRODUCTION IN FOOD INDUSTRIES DR NURFATIMAH MOHD THANI OBJECTIVE Understand activities in food production in industry.  Activities/ producing activities, create or change PRODUCTION materials from raw to finished goods and give a service can meet consumer wishes. PRODUCTION MANAGEMENT THE PROCESS involves planning, organization, leadership and control over that activity related to the input transformation process (source: raw material, labor, machinery) to output (goods or services) that are more valuable which can satisfy the will and consumer needs. PRODUCTION METHODS Mass Batch Continuous MASS PRODUCTION Continuous specifically for identical products. High production rate, specified equipment, and high demand rate against goods. Example: Washing machine, radio, electric bulb, pen, newspaper, electrical components, snacks BATCH PRODUCTION A few items processed in groups/lot. Lots can be issued only once alone, or repeatedly on a certain scale. To satisfy the desire of the persistent users for an item, small volume production is carried out to meet the fickle demand. Savings are required because variations on production and demand. For general use, however it was designed for higher rates production. Examples: Furniture, textbooks CONTINUOUS PRODUCTION Operates 24 hours continuous non -stop. Only one type of product that is produced but in extremely high volume. If the product has very high standardization, then production flow is difficult to change. Example: Process produce chemical materials, photographic, printing, paper and oil refining plant.  Differences between Mass, Batch, and Continuous Production Mass Batch Continuous Production Non-stop production Focus Mass production according to customers’ process specification Different products Various products One product Type of product (according to which is uniform (commodity) reservation) Demand Stable Not stable Very stable Inventory storage Yes No Always available Factory layout According to product According to process According to product FLOW DIAGRAM  PROCESS FLOW DIAGRAM (PFD) To document a process for better understanding, quality control and training of employees. To standardize a process for optimal efficiency and repeatability. To study a process for efficiency and improvement. It helps to show unnecessary steps, bottlenecks and other inefficiencies. To model a better process or create a brand-new process. To communicate and collaborate with diagrams that speak to various roles in the organization or outside of it. Block diagram, process flow diagram (PFD), Piping and Instrument Diagram (P&ID) Microsoft Visio, Superpro Let's watch this video! PRODUCTION PLANNING Plan and arrange the design/ internal layout of the factory. Design selection considers factors such as plant area, volume workers, type of machine @ use and environment. Design Planning Minimize material handling costs Use space effectively Use labor effectively Facilitate communication between employees, supervisors and customers Objective Facilitate the flow of movement of materials/goods The size of the space Number of employees Type of machine/equipment Production process used Considered Subsequent operations factors Position of the factory site / environment Plant Design Principles: Site & Location Physical site -size Neighborhood Logistic -Easy access Potential of natural disaster Labor Utilities and sources -electricity, water, waste area  Process flow design Type of product, process & environmental condition requirements Size (operation, equipment, ventilation, etc) Zoning system (“clean area” & “unclean area”) to avoid cross-contamination Avoid “zigzagging” & backtracking flow Minimize use of walls Flow System -Material flow -Drainage system -Human flow -Ventilation system -Waste flow -Lighting system -Pest control system  Exterior & Interior building design Objectives: ↓ pests & microorganism ↓contamination ↑ cleanliness ↑ safety of food Pest Walls control Loading bay, Fencing platforms, etc. Working Exterior surfaces Interior Floors Exterior Roof walls Windows PRODUCTION PLANNING Be careful in choosing the site to operate so as not to suffer future losses (examples: lack of water supply, supply electric). Strategic location to minimize the company's operating costs (example: transportation costs, labor costs, raw material costs, distribution costs). Site Location Planning Expand existing organizational facilities. Provide facilities in new locations and at the same time maintain facilities at existing locations. Move to a new location Objective Labor Supply of raw materials Transportation facilities Distance with market/ consumer Infrastructure facilities Considered Financial institutions Medical and security services factors There is room for site enlargement PRODUCTION PLANNING Preparation of appropriate schedules for use during the process production Production of required goods/ services. scheduling Gantt Chart Method PERT/CPM chart INVENTORIES WHAT IS INVENTORY? A stock of raw materials/semi –goods ready/ready goods whether used to streamline production operations @ Goods/ materials that stored by meet customer demand the organization for used in the future INVENTORY CONTROL Managing control system receipt, storage, To handle stock quantities on optimal level material handling and calculation raw, work according to certain criteria namely cost, in process and inventory finished goods to profitability and quality of service ensure flow work is well maintained.  Reduce delay time in production process Identify the Objective number order of of Increase materials/goods at optimum price for inventory production volume cost saving control As a safety measures to protect from uncertainty of demand at some point/avoid excess offer  Avoid deficiency inventories Protection from Smooth inflation and production deficiencies supply process Importance Bulk purchase Cost saving discount QUALITY CONTROL QUALITY CONTROL Definition: The review process is designed for produce affordable goods or services to meet certain quality standards Quality is judged from tangible or implicit characteristics on a product or service able to meet the needs of customers  Cost Market share and Quality Product company’s reputation Affects liability International implications Purchase raw Distribution material to consumers TOTAL QUALITY MANAGEMENT A customer -oriented quality management process, runs continuously and involves all aspects within organization Aims to bring about a comprehensive change towards giving birth to an excellent organizational culture The process of cultural transformation, through which cultural characteristics are available some will be modified, changed or strengthened with new features the better one TQM Objectives Satisfaction to customers with Good quality and produce that perfect in output meet the unforeseen requirements and customers customers' taste Emphasis on continuous improvement against the process system production so that activities run smoothly.  INTERNATIONAL STANDARD ORGANIZATION (ISO) INTERNATIONAL STANDARD ORGANIZATION (ISO) A written standard Explain the basic elements necessary is in the quality system to ensure the product/services provided by the organization can meet the needs of customers. The standard implementation of this system will ensure that the product/ service produced can meet that specification set. Quality assurance standards with basic principles that is, “prevention rather than correction after a mistake " ISO PRINCIPLES As a standard for quality systems Emphasize that and rather than a ISO is a standard standard for a comprehensive product or (universal) service. Emphasize Based on prevention and documentation instead of remedial  ISO 9000 SERIES Guidelines that introduce other standards in ISO 9000. Provides definitions of ISO9000 quality -related terms and concepts. A standard for quality in the design, production or production of a product ISO9001 services, installation or follow -up services. A standard for quality in the production of a product or service and ISO9002 installation that typically takes place at the factory of the product or service. A standard for quality in its final inspection and testing often done in the ISO9003 laboratory. Guidelines for implementing quality management and system elements quality ISO9004 rather than a research process like the series above