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SUBJECT : MANUFACTURING SYSTEM
CODE : BFF2513
LECTURER : MR MEBRAHITOM ASMELASH
GEBREMARIAM
Prepared by:
MUHAMMAD HABIBULLAH BIN BADULHISHAM FA12043
FARITH HAZIQ BIN MUHAMMAD FA12021
MUHAMMAD AIMAN BIN ISYAK FA12016
MUHAMMAD ALIEF BIN OTHMAN FA12018
UNIVERSITI MALAYSIA PAHANG

2. 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
5
6-7
8
9
Manufacturing process
a. Flow diagram
b. Process diagram
10 -11
Material handling systems design
a. Types of material handling system needed
b. Number of material handling machines needed
12
Layout design
a. Production or manufacturing layout
b. Administration layout
13-15
Total plant cost
a. Capital cost
b. Production costs
c. Material costs
d. Unit production cost
e. Unit selling price
f. Profit margin
16
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3. Conclusion
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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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4. 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

5. PLANT DESIGN PROCEDURES
a) PRODUCT DESIGN
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6. b) IDENTIFICATION OF THE PROCESSES NEEDED OR MANUFACTURING
PROCESS DESIGN
 Making pulp
Several 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.
 Beating
The 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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7. 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 paper
In 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.
 Finishing
Finally, 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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8. c) DETERMINATION OF THE NUMBER OF MACHINES OR EQUIPMENT NEEDED
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9. 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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10. 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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11. 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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12. 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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13. 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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14. LAYOUT DESIGN
a) Production Layout
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15. b) Administration Layout
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17. 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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18. 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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19. 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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20. 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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