The document discusses several topics related to process planning and analysis: 1. It outlines the key steps in process planning including requirement gathering, team building, planning and implementation, auditing, and end of life planning. 2. It describes different types of production processes and how they are classified based on factors like continuity and standardization. 3. It provides an overview of how to perform an economic analysis of a farm including defining the situation, calculating depreciation and production data, determining farm profit and cash flows, conducting scenario analysis. 4. It discusses process and material flow concepts like operation symbols, process charts, material, equipment and two-handed charts, and charts using a time scale like multiple

1. MODULE # 1
Design and Management of AB Processing Systems
Process Planning
Steps:
1. Process Requirement: The very 1st step is to collect and
gather information to give structure with the end
objective.
2. Team Building: for each objective, a team is finalized
based on skill level and experience.
3. Planning and Implementation: Process planning team
will develop module; policies and procedure require for
production, which are after required approval internal as
well as external is implemented.
4. Audit: carried out to ensure that process thus
implemented is in line and delivering value to customers.
5. End of Life: Over a course of time there may be
enhancement of the product or product may get
discontinued in these circumstances, process thus
develop is discontinued.
Production Process
Based on the nature of product and service production
• continuous production
• intermittent production
Based on standardization of product or service
• single project assignment
• mass production project
How to perform the Economic Analysis of the farm and
chosen strategy?
1. FARMER HAS TO DEFINE THE BASIC SITUATION OF
THE FARM
2. COUNTING THE DEPRECIATION OF THE FARM
Indirect costs – the costs which can’t be clearly
assigned to the particular production activities. A typical
example of a fixed/indirect cost of the farm is the
depreciation of fixed assets
Depreciation = Purchase value of a fixed asset:
Number of years of service
or
Depreciation = Purchase value of a fixed asset *
Depreciation rate
(where depreciation rate = 1 / number of years of
operation).
3. CROP AND ANIMAL PRODUCTION DATA FOR GROSS
MARGIN
Gross margin = Production value - direct costs.
Direct costs – the costs which can be clearly assigned
to the particular production activities
4. CALCULATING FARM PROFIT
Farm profit = Revenues (incomes) - Costs
Farm profit = Revenues (incomes) - Direct costs
- indirect costs

2. Farm profit = Gross Margin - Indirect costs
Gross Margin is the sum of incomes from various
activities.
5. CALCULATION OF CASH FLOWS
Cash flow statement - consists what we compile
(balance) all deposits and withdrawals
FOUR ACTIVITIES
i. Operating activity – includes inflows and
outflows from the basic activity of a farm,
ii. Investment activity – includes inflows and
expenses related to the purchase / construction
and sale of fixed assets,
iii. Financial activity – covers all loans and loans
taken for the purpose of the farm and the
repayment of such loans with interest
iv. Private money flows – includes all payments
and withdrawals related to the personal life of
the farmer and his family
Cash balance formula:
BALANCE OF TOTAL CASH IN THE FARM = Cash held at
the beginning of the period + operating balance +
investment activity balance + balance on financial
activity + private balance.
Farm Profit vs. Cash Flows
Agricultural income (farm profit) should be treated as an
economic measure of economic efficiency, and cash flow
is an element of financial management on the farm.
6. SCENARIO ANALYSIS
The scenario analysis allows to simulate the possible
changes depending on the strategy choice of the farmer.
It gives information about the future farm gross
margins, net profit, cash flows and cash balance, after
realization of a certain strategy.

3. MODULE # 2
Process and Material Flow
Material flow is the most important factor in a production
company because products are created from materials.
Material flow is a sequence of processes ranging from the
extraction of raw material via its processing, reprocessing and
machining up to the finished product and delivery to the end
consumer.
Activity symbols:
OPERATION PROCESS
- is a graphic representation of the sequence of an
operations and inspections taking place in a process.
- Also known as outline process chart.
PROCESS CHART
- A chart may be a diagram, a picture or a graph which
gives an over view of the situation, say a process.
- A process chart records graphically or diagrammatically
in sequence the operations connected with a process.
- Symbols are used to represent the activities like
operation, inspection, transport, storage and delay.
Process Chart Symbols
1. Operation
- large circle indicates operation.
- takes place when there is a change in physical or
chemical characteristics of an object. An
assembly or disassembly is also an operation.
- When information is given or received or when
planning or calculating takes place

4. 2. Inspection
- square indicates inspection.
- It is checking an object for its quality, quantity or
identifications.
3. Transport
- arrow indicates transport.
- refers to the movement of an object or operator
or equipment from one place to another. When
the movement takes place during an operation,
it is not called transport.
4. Delay or temporary storage
- large capital letter D indicates delay.
- also called as temporary storage.
- occurs when an object or operator is waiting for
the next activity.
5. Permanent Storage
- Storage takes place when an object is stored and
protected against unauthorized removal.
6. Combine activities
- Indicates a controlled storage in which material
is received into or issued from a store form of
authorization; or an item is retained for reference
purposes.
OUTLINE PROCESS CHART is a process chart giving an over-
all picture by recording in sequence only the main operations
and inspections.
FLOW PROCESS CHART is a graphical representation of the
sequence of all the activities (operation, inspection, transport,
delay and storage) taking place in a process. It is the detail
version of outline process chart recording all the event.
OBJECTIVES OF FLOW PROCESS CHART
▪ Set out sequence of flow of events occurring in the
process.
▪ To study the event in a systematic way
o To improve the layout.
o To improve material handling.
o To reduce delays.
o To eliminate, combine or rearrange the events in
a systematic way.
▪ To compare between two or more alternative methods.
▪ To select operations for detailed study.
Type of flow process charts:
1. Man/Worker type flow process chart.
- This flow process chart records what the worker does.
2. Material type flow process chart.
- This flow process chart records how the material is
handled or treated.
3. Equipment type flow process chart
- This flow process chart records how the equipment or
machine is used.

5. Two-Handed Process Chart (or) Right Hand, Left Hand
Chart
➢ Operation: Represents the activities grasp, position, use,
release etc. of a tool, component or material.
➢ Transport: Represents the movement of the hand or
limb to or from the work or a tool or material.
➢ Delay: Refers to the time when the hand or limb is idle.
➢ Storage (Hold): The term 'hold' is used here instead of
storage. This refers to the time when the work is held
by hand.
➢ The activity 'inspection' by hand is considered as an
operation. Hence, the symbol for inspection is not used
in this chart.
➢ Two-handed process chart can be used for assembly,
machining and clerical jobs.
Charts using a Time Scale
- Multiple activity chart
- Simo chart
- PMTS chart
Multiple Activity Chart Or Man-machine Chart
• Is a chart in which the activities of more than one worker
or machine are recorded.
• Activities are recorded on a common time scale to show
the inter-relationship.
• It is used when a worker operates a number of machines
at a time. It is also used when a number of workers
jointly do a job.
• The chart shows the idle time of the worker or machine
during the process.
Multiple Activity Chart Or Man-machine Chart
• Work load is evenly distributed among the workers or
machines by this the idle time of worker or machine is
reduced. Multiple activity chart is very useful in planning
team work in production or maintenance.
• Types of Multiple Activity Chart:
- Man-Machine Chart
- Man-Multimachine Chart
- Multi-Man Chart
- Multi-Man machine Chart
Simo chart
• Simultaneous Motion Cycle Chart (SIMO Chart).
• A simo chart is a chart, often based on film analysis,
used to record simultaneously on a common time scale
the therbligs or groups of therbligs performed by
different parts of the body of one or more workers.
• It is the micromotion form of the man type flow process
chart. Because simo charts are used primarily for
operations of short duration, often performed with
extreme rapidity, it is generally necessary to compile
them from films made of the operation which can be
stopped at any point or projected in slow motion.
Predetermined Motion Time Systems (PMTS)
• is a work measurement technique whereby times
established for basic human motions are used to build
up the time for a job at a defined level of performance.

6. • PMTS also called predetermined time system (PTS), is a
database of basic motion elements and their associated
normal time values, together with a set of procedures
for applying the data to analyze manual tasks and
establish standard times for the tasks.
• The PMTS database is most readily conceptualized as a
set of tables listing time values that correspond to the
basic motion elements, the lowest level in our hierarchy
of manual work activity.
• They include motions such as reach, grasp, move, and
release.
MATERIAL AND ENERGY BALANCES
ENERGY BALANCES
- are statements on the conservation of energy.
- used in the examination of the various stages of a
process, over the whole process and even extending
over the total food production system from the farm to
the consumer’s plate.
BASIC PRINCIPLES
- The mass and energy going into the box must balance
with the mass and energy coming out.
The law of conservation of mass leads to what is called a mass
or a material balance.
Mass In = Mass Out + Mass Stored
Raw Materials = Products + Wastes + Stored Materials.
mR =  mP + mW + mS
(where  (sigma) denotes the sum of all terms).
mR = mR1 + mR2 + mR3 = Total Raw Materials.
mP = mP1 + mP2 + mP3 = Total Products.
mw = mW1 + mW2 + mW3 = Total Waste Products.
ms = mS1 + mS2 + mS3 = Total Stored Products
If there are no chemical changes occurring in the plant, the
law of conservation of mass will apply also to each component,
so that for component A:
mA in entering materials = mA in the exit materials + mA stored
in plant.
Raw Materials = Products + Waste Products + Stored Products
+ Losses
where Losses are the unidentified materials.
Energy In = Energy Out + Energy Stored
ER =  EP + EW + EL + ES
where:
ER = ER1 + ER2 + ER3 + ……. = Total Energy Entering
EP = EP1 + EP2 + EP3 + ……. = Total Energy Leaving with
Products
EW = EW1 +EW2 + EW3 + …… = Total Energy Leaving with
Waste Materials

7. EL = EL1 + EL2 + EL3 + …….. = Total Energy Lost to
Surroundings
ES = ES1 + ES2 + ES3 + …….. = Total Energy Stored
The energy consumed in food production includes:
direct energy which is fuel and electricity used on the farm,
and in transport and in factories, and in storage, selling, etc.;
and
indirect energy which is used to actually build the machines,
to make the packaging, to produce the electricity and the oil
and so on.
REFRIGERATION LOAD ESTIMATES
Refrigeration Load Estimate - Its purpose is to make an
estimate of how much amount of heat must be removed from
a storage space to maintain a certain storage condition.
REFRIGERATION LOAD - is the summation of the heat which
usually comes from different sources. For a commercial
refrigeration, the total cooling load is divided into four separate
loads:
a) the wall gain load
b) the air change load
c) the product load
d) the miscellaneous load
WALL GAIN LOAD
- sometimes called the wall leakage load
- it is the heat which passes through the walls of the
refrigerated space by conduction.
The wall heat load can be computed as follows:
Qw = AFw
where A = outside surface wall area, sq. feet
Qw = wall heat load, BTU/24 Hrs
Fw = wall heat gain factor, BTU/24 Hrs/ Sq. Ft.
of outside area
= the values of Fw are found on Table 2
and are function of insulation thickness
and outside-inside temperature difference

8. AIR CHANGE LOAD
- is the heat that is brought into the refrigerated space by
warm outside air entering the space through open doors
and cracks around windows and doors.
The air change load can be computed as follows:
QAC = V(AC)FHR
Where QAC = air change heat load, BTU/24 Hr
V = inside room or space volume, ft3
AC = average air changes per 24 hrs. Values
are found on Table 3 which is for
rooms above 32F and Table 4 for rooms
below 32F.
FHR = heat removal factor, BTU/ft3 . Values
are found on Table 5 and are function of
outside air condition and storage
temperature.
PRODUCT LOAD
- is the heat which must be removed from the refrigerated
product in order to reduce its temperature to the desired
level.
- The product load is a part of the total cooling load only
while the product temperature is being reduced to the
storage temperature. Once the product is cooled to the
storage temperature, it is no longer a source of heat and
thus, the product load stops to be a part of the load on
the equipment.
When a product is cooled and store below its freezing
temperature the product load is calculated in three parts:
a) heat given off by the product in cooling from the
entering product temperature to its freezing
temperature – QP1
b) heat given off by the product during solidification or
fusion – QP2
c) heat given off by the product in cooling from its freezing
temperature to the final storage temperature – QP3
The product load (QP1) can be computed as follows:
QP1 = WC1(TEP – TFP)
where QP1 = product load due to heat given off by the
product in cooling from
entering temperature to freezing
temperature, BTU/24 Hr
W = weight of products in pounds, to be chilled
to the storage temperature in 24-Hr
period
C1 = specific heat of product above freezing,
BTU/lb°F
TEP = entering temperature of the product, °F
TFP = average freezing temperature of the
product, °F
` = values are found on Table 6

9. The product load (QP2) can be computed as follows:
QP2 = WH
Where: QP2 = product load due to heat given off during
Solidification, BTU/24 Hr
= sometimes called the latent heat of fusion
load
W = as previously defined
H = latent heat of fusion, BTU/lb
= values are found on Table 6
The product load (QP3) can be computed as follows:
QP3 = WC3(TFP-TSP)
Where: QP3 = product load due to heat given off in
cooling from freezing temperature to
storage temperature, BTU/24 Hr
W = as previously defined
C3 = specific heat of product below freezing,
BTU/lb°F
TFP = as previously defined
TSP = final storage temperature of the product,
°F
= values on Table 1-A could be used
The TOTAL PRODUCT LOAD (QP) is therefore
QP = QP1 + QP2 + QP3
Where: QP = total product load, BTU/24 Hrs
Note: If the product is stored above its average freezing
temperature then QP2 =0; QP3 =0 and the product load (QP) is
simply computed as
QP = WC1(TEP – TSP)
ADDITIONAL PRODUCT LOAD DUE TO RESPIRATION
HEAT
QP4 = m(HR)
Where: m = tons of fruits or vegetables to be chilled in
24 Hrs
HR = heat of respiration, BTU/24 Hrs/ton
= values are for fruits and vegetables and
found on Table 6
EQUIVALENT PRODUCT LOAD
QPE = QP(24/T)
Where: QPE = equivalent product load based on a 24-Hr
period, BTU/24 Hr
T = desired chilling or cooling time, HR
24 = used to determine the equivalent product load
For a 24-Hr period
QP = as previously defined

10. MISCELLANEOUS LOAD
- sometimes referred as the supplementary load. It takes
into account all miscellaneous heat sources. Among
them are the people occupying the refrigerated space,
lights and electrical equipment operating inside the
space.
The miscellaneous load could be divided into three parts:
a) heat from people or occupancy load – Qml
Qm1 = n (HE) x 24
Where: Qm1 = BTU/24 Hr
n = No. of people inside the space
HE = heat equivalent/person, BTU/Hr/person
= values are found on Table 7
24 = used to be consistent with load units of
BTU/24 Hr
b) heat from lights - Qm2
Qm2 = 3.42 (J) x 24
Where: Qm2 = BTU/24 Hr
3.42 = heat given off per watt of light, BTU/watt
J = total number of wattage, watts
c) Electrical equipment heat load – Qm3
Qm3 = 3393 (HP) x 24
Where: Qm3 = BTU/24 Hr
HP = Equipment Horsepower
3393 = Average heat given off per horsepower,BTU/HP/Hr
Thus, the total miscellaneous load, Qm is,
Qm = Qm1 + Qm2 + Qm3
COOLING OR REFRIGERATION LOAD
The refrigeration load is the sum of all the load previously
discussed. In equation form,
RL = Qw + QAC + QP + Qm
where RL = refrigeration load, BTU/24 Hr
Qw = wall heat load, BTU/24 Hr
QAC= air change load, BTU/24 Hr
QP = product load, BTU/24 Hr
Qm = miscellaneous load, BTU/24 Hr
FACTOR OF SAFETY
It is a common practice in refrigeration load calculation to add
5% to 10% to the load as a safety factor. The percentage of
the safety factor to be used depends much on the accuracy of
information used in calculating the load. As a general rule 10%
will be used.

11. REFRIGERATION LOAD WITH 10% FACTOR OF SAFETY,
(RL)SF
With 10% safety factor the refrigeration load now becomes,
(RL)SF = RL + 10% (RL) = 1.1 RL
Where: (RL)SF = refrigeration load with 10% safety
factor, BTU/Hr
REQUIRED EQUIPMENT CAPACITY, BTU/HR
The refrigerating equipment capacities are usually given in
BTU/HR while the refrigeration load is calculated for a 24-Hr
period, that is in BTU/24 Hrs. To determine the required
equipment capacity in BTU/Hr, divide the refrigeration load
(RLSF) for the 24-Hr period by the design running time of the
equipment. Thus,
(RL)SF,BTU/24 Hr
Required Equipment Capacity, BTU/HR = Design Running Time
Where: Design Running Time = 16 Hrs/Day for storage
above 32F
= 18 Hrs/Day for storage
below 32F