EPA

Benefits of process control management systems

Reduces variation in product quality. More Consistent Production, Maximises yield. Ensures process and product safety. Reduces man power and enhances operator productivity. Reduces waste. Optimises energy efficiency.

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Define Health and Safety at Work Act 1974

It shall be the duty of every employer, to ensure, so far as reasonably practicable, the health, safety and welfare at work of all employees. Its intent is to provide an adequate, enforceable law to prove safety in the workplace and protection for visitor

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What are the 4 C's of Health and Safety Management

Control, Competence, Communication, Co-operation.

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Who is responsible for health and safety at work.

Employers, Employees, Other. EVERYONE!!

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Employer Duties within the Health and Safety at Work Act 1974

Provide a safe regularly maintained plant. Provide safe systems of work. Provide a safe workplace. Provide safe access and egress to the workplace. Provide safe use, storage, handling and transport of all equipment and materials.

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Employee Duties within the Health and Safety at Work Act 1974

To take reasonable care for the health and safety of self and others in the workplace. Not to intentionally or recklessly interfere with anything provided in the interest of health and safety. To comply with the employers health and safety rules and also

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What does a Safe System of Work require

Audits of statutory obligations. Hazard spotting inspections. Improvement plans. Safe working procedure rules. Roles and responsibilities identified in the workplace.

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Benefits of Good Food Safety Standards

Prevents food poisoning, food spoilage, food contamination, allergic reactions, loss of productivity, prest infestations, prosecution for contravention of food safety legislation, closure of businesses by enforceable authorities.

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7 Principles of HACCP

Identify hazards to be controlled. Identify CCP's at necessary points. Establish critical limits at CCP's. Establish procedures to monitor CCP's. Establish corrective action if critical limits are passed. Establish Procedures to verify correction action i

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3 Main Food Safety Hazards

Microbiological. Chemical. Physical

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TACCP and its purpose

Threat Assessment Critical Control Points. Focuses threat to product before the production process. Tampering, Intentional alteration of food and drink defence systems.

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VACCP

Vulnerability Assessment Critical Control Points. Focuses on threats to the product after the production process. Including food fraud and any potential alteration of the product whether intentional or not.5

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5 Steps to Risk Management

Identify the Hazards. Assess the risks. Control the risk. Record your finding. Review the Controls.

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Waste Disposal Regulation

Controlled Waste Regulation 2012

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Waste Hierarchy

Prevention. Re-use. Re-cycle. Energy Recovery. Disposal.

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Condition Based Maintenance (CBM)

Maintenance strategy that monitors the condition of an asset to decide the necessary maintenance.

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Advantages of CBM

Reduces the chance of disruption to normal operation. Reduces asset failure costs. Improves equipment reliability. Minimises unscheduled downtime due to catastrophic failure. Minimises time spent on maintenance. Minimises overtime costs by scheduling acti

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6 Key Steps to Problem Solving

Define the problem. Analyse for root cause. Generate solutions. Plan and implement solutions. Measure improvement. Standardise.

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Stages of a Complete Supply Chain

Raw materials. Suppliers. Production. Warehouse. Retailers. Customers. Consumers

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Main Stages of Manufacturing

Goods in. Production plant. Transport to Packing. Packing Machines. Transport to dispatch. Dispatch equipment.

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What is B2B

Business to Business. Refers to business to business transactions rather than sales to customers. Example is when we sell our product to a retailer who can sell the product for a slightly higher price to customers/consumers.

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What is Red Tractor Standard

Claims to ensure the product is traceable. safe to eat and has been produced responsibly. Covers animal welfare, food safety, traceability and environmental protection. The union flag on the logo gives the guarantee that the produce was farmed, processed

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Steps to CIP

1. Recovery of product residues. 2. Pre-clean rinse. 3. Alkaline detergent wash. 4. Rinse. 5. Acid detergent wash. 6. Final Rinse. 7. Sanitise

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Components to a CIP system

Pipes. Tanks. Spray devices. Pumps. Heating systems. Sensors. Valves. Automatic control.

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Types of Flow

Laminar Flow, a smooth flow in which no crossover of fluid particles occurs between adjacent streamlines. Turbulent Flow, movement of liquid within a stream that occurs as discrete eddies and vortices. Turbulent flow is caused by pipe layout, velocities a

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Factors Affecting Flow

Low capacity pumps. Unmatched pumps. Large diameter. Change in pipe diameter. Blank pipe ends and T pieces. Long pipe runs. Blocked spray devices. High number of pipe bends. Blocked sieves and strainers. Flow measurement devices not passed correctly. Leak

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Energies Used for Cleaning

Kinetic Energy, provided by the pump, usually centrifugal. Chemical Energy, transformed to other forms of energy though chemical reactions, reacts with certain types of food to ease removal. Thermal Energy, 75 degree for acids and 85 degree for alkaline/c

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Chemicals Used in CIP

Detergent, removes grease and fats. Disinfectant, removes bacteriological contamination. Sanitiser, combination of detergent and disinfectant.

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Three forms of cleaning verification

Visual. Bacteriological. Rapid Swab Test.

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Food Sampling Techniques

Random Sampling. Systematic sampling. Convenience Sampling. Cluster Sampling. Stratified Sampling.

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Total Quality Management (TQM)

TQM is a continual process for detecting, reducing or eliminating errors in manufacturing, streamlining supply chain management, improving customer experience and ensuring employees are upto speed with training.

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Computerized Maintenance Management System (CMMS)

CMMS is software that centralizes maintenance info and facilitates the processes of maintenance operations. Helps to optimise the utilization and availability of physical equipment like machinery and other plant assets. It organises information about the

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Sections of a CMMS

Resource and labour management. Asset registry. Work order management. Preventative maintenance. Materials and inventory management. Reporting, analysis and auditing.

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ISO 9000

International standards on quality management and quality assurance. Developed to help companies effectively maintain quality management system.

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Eight Principles of ISO 9000

Customer Focus. Leadership. Involvement of people. Approach as a process. Systematic approach to management. Continuous improvement. Factual approach to decision making. Mutually beneficial supplier relationship.

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PDCA

Plan, do, check, act. Simple and effective approach for solving problems and managing change. Enables businesses to develop hypothesis and what needs to be changed. Test hypothesis. Gain valuable leaning and knowledge from the process.

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Pareto Graphs

Principle that helps focus on the most important matters to obtain the maximum benefits. Identify the vital few causing the biggest issues from the trivial many causing smaller problems.

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Toyota Production System

A production system based on the philosophy of achieving the complete elimination of all waste in pursuit of the most efficient method. Lean Manufacturing System. Just in Time System.

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Just in Time System

Improves productivity. Makes only what is needed, when it is needed and in the correct amount needed.

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Performance Management

An approach used to manage performance of an organisation. Applied to measure the performance of a business. Ensures goals are constantly being met in an efficient manner.

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What are Performance Indicators

Measurements that define and assess the performance and success of an organisation. They are objectives to be targeted in order to add the most value to the business.

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Key Performance Indicators (KPI's)

Spoilage/rejection rate. Re-work rate. Time spent on product re-work. Total units manufactured. Units per day/hour. Line efficiency. Production capacity. Capacity utilization. First time right ratio. Average change over time. Material Usage.

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Visual Maintenance management System

5S. Sort, Set in order, Shine, Standardise, Sustain.

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Examples of 5S

Labels. Shadow boards. Floor markings. Wall signs and banners. Tagging systems. Colour coding.

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Eight Categories of Waste

In lean manufacturing waste is described as anything that doesn't add value to a product. Transport. Inventory. Motion. Waiting. Overproduction. Over-processing. Defects. Unutilized talent.

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Asset care process

Asset Maintenance Management. Defined as a continuous process improvement strategy for improving the availability, safety, reliability and longevity of physical assets.

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What does the Asset care process involve

Identifying assets. Asset location. Asset condition. Asset design criteria. Asset care programme. Optimizing operational costs. Review.

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PH Levels

7 = Neutral PH. <7 = Acidic PH. >7 = Alkaline PH.

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Foreign body detection methods

Metal detection. X-ray detection. Separation systems. Magnets. Optical sorting.

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Non-food contact materials

Wood. Iron. Soft materials. Corrosive materials. Brittle Materials.

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Food Contact materials

FDA approved materials. Austenitic stainless steel 304 and 316. Plastics, High density Polyethylene (HDPE), Low density polyethylene (LDPE), Polyethylene terephthalate (PET), Polypropylene (PP).

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What is preventative maintenance

Regular, routine maintenance of equipment and assets in order to keep them running and prevent any costly unplanned downtime from unexpected equipment failure.

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Advantages of Preventative maintenance

Improved safety. Greater equipment lifespan. Improved productivity. Reduced costs. Reduced energy consumption.

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Disadvantages of preventative maintenance

Budget constraints. Additional resources required. Time consuming. Organisational difficulties.

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What is Time Based Maintenance

Maintenance of an asset according to a strict timetable with following general attributes - Fixed intervals between maintenance activities, routine maintenance on a regular basis and contracted services by contractors through a service agreement.

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Time Based Maintenance Advantages

It provides for consistency and predictability in the administration of the maintenance program. TBM is quantity but not necessary quality as it does not seek to find optimal intervals for tasks.

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Time Based Maintenance Disadvantages

TBM may result in over maintenance of some assets. It does not recognise the changing condition of the assets over time and may not be the optimum risk management strategy.

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6 Steps to Fault Finding

Collect the evidence. Analyse the evidence. Locate the fault. Determination and removal of the cause. Rectification of the fault. Check the system.

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Aids to Fault Finding

Manufacturing Specification. Manufacturing Manuals. Schematics. Diagrams. Standard Maintenance Practices (SMP's). Asset work order history (CMMS). Machine operator relationships. Other technical personnel.

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Positive Displacement Pumps

Rotary lobe pump. Progressive cavity pump. Rotary gear pump. Piston diaphragm pump. Diaphragm pump. Screw pump. Gear pump. Vane pump. Peristaltic hose.

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Non-Positive Displacement Pumps

Centrifugal pump. Multi-stage pump. Axial flow pump.

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Benefits of lubrication

Reduces friction and wear. Protects equipment. Enhances temperature control. Improves lifespan, efficiency and reliability of machinery. Reduces the downtime and costs associated with maintenance and repair.

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Purpose of V-belts

Suitable for high power transmission over short lengths. Usually made from fabric and rubber. Angle of v belt is usually 30-40 degree. To increase power output, several v-belts can be used side by side to equally divide the load.

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What is a shim used for.

Shims are typically used in order to support, adjust for better fit or provide a level surface. Shims may also be used as spacers to fill gaps between parts that are subjected to wear.

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Purpose of a Lathe

A machine tool used primarily for shaping metal or wood. It works by rotation the workpiece around a stationary cutting tool. Main use is to remove unwanted parts of the material to create a correctly sized component.

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How to calculate Spindle Speed

1000 x Surface Speed(M)/ π x diameter (mm) = Spindle Speed (RPM)

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What is an Interference fit

Much tighter than a clearance fit. Also referred to as a press fit or friction fit. Requires a degree of force to be applied to couple and uncouple the two components. Example - pressing a bushing, bearing, dowel pin or other item into their mating compon

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What is a Transition fit

Falls between an interference fit and clearance fit. Used when accurate alignment is critical and mating parts must join with greater precision. Can be referred to as a slip fit or push fit. Should be a greater degree of clearance than an interference fit

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What is a clearance fit

Allows for loose mating, where free movement is important and an amount if play is desired. Used to allow elements to slip in and out without obstruction. Used when alignment can be loosely guided but doesn't need tight precision. Examples- Bolt/shaft hol

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What is a technical drawing

Represents the exact shape, dimensions and composition of an object with a view to its fabrication. Technical drawings should give accurate dimensions and tolerances for the component. Most common is orthographic projection. Shows a front, side and top vi

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Purpose of fluid power systems

Used to easily provide linear motion using hydraulic or pneumatic cylinders. Can transmit equivalent power within a much smaller space than mechanical or electrical drives. Offers simple and effective control of direction, speed, force and torque using co

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Components of a Hydraulic System

Hydraulic Oil. Reservoir. Filtering devices. Pump/drive. Connectors. Valves. Actuators.

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Components of a pneumatic system

Air compressor. Regulators. Filters. Control devices. Air tank. Actuators. Transmission system.

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Asset Car Process

To ensure equipment is reliable and available to provide a consistently good product and service at the time a customer requires it.

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5 Principles of Asset Care Process

Increase the overall equipment effectiveness. Improve existing planned maintenance systems. Make routine asset care part of the job. Increase skills. Early equipment management.

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Heat transfer theory

Heat dissipates when there is a temperature difference. heat is always transferred from a hot medium to a cold medium. There must always be a temperature difference for heat transfer to occur. The heat loss from the hot medium is equal to the heat gained

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Types of Heat exchanger

Plate. Fire tube. Water Tube. U-tube (Hairpin)

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Gasketed Plate Heat exchanger

Corrugated plates provide easy heat transfer. Plates use elastomeric gaskets as seals to to seal the channels between plates and direct mediums into alternating channels. Plate pack sits between the frame plate and pressure plate. The plates are compresse

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Refrigeration cycle

Coolant is stored in the receiver. From here it travels through a restrictor/throttling device. The coolant now at low pressure and low temp travels through the evaporator. This turns the coolant to vapour. The coolant vapour then travels to an accumulato

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Components of a steam boiler

Furnace. Reversal chamber. Smoke tubes. Front reversal chamber. Flue gas chamber. Water Vessel. Water in. Overflow water out. Steam out. Condensation return. Safety pressure relief valves.

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Hazards of cutting and welding activities.

Fire caused by heat, molten metal, contact with flame. Explosion if equipment contains residue of flammable materials. Fir/explosion caused by gas leaks, backfires and flashbacks. Fumes created during flame cutting. Fire/burns resulting from misuse of oxy

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Weld Inspection and test methods.

Destructive - Bend testing, Macro etching, fracture testing. Non-destructive - Visual inspection, magnetic particle inspection, dye penetrant, ultrasonic testing, radiography gamma and x-ray, pressure testing.

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What is TIG welding

Tungsten Inhert Gas welding is applied in all industrial sectors but especially suitable for applications requiring high quality joints. The user manually ads the filler material to the weld pool in TIG welding. The weld pool is created from a tungsten el

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What is MIG welding.

Metal Inhert/Active Gas welding (MIG/MAG) is widely used in most industrial sectors and accounts for more than 50% of arc weld metal. The filler metal is automatically fed through the welding equipment.

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What is MMA Welding

Manual Metal Arc welding is the most versatile weld process and is suitable for welding ferrous and non ferrous materials over a wide range of thicknesses and in all positions. In MMA the Electrode is also the filler material. It is knows as a consumable

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What Does the 1st digit of an IP rating represent

The level of intrusion protection from solid particles.

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What does the 2nd digit of an IP rating represent

The level of moisture protection from liquids.

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Ways to stay safe when working with high voltage

Ensure suitable PPE is used. Have a self inspection checklist to work from. Always prove voltage test indicators are working before and after. Never work alone. Never assume a circuit is safe just because it is powered down.

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What are the different supply voltages.

24v(DC)- Used for Low voltage control, usually PLC systems. 110v(AC) - Used with a transformer, usually for power tools. 230/240v(AC)- Single phase power, usually for sockets and lights. 400/415v(AC) - Three phase power, usually for industrial equipment a

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Importance of Energy Management

The process of monitoring, controlling and conserving energy in a business or organisation. Energy management is the key to saving energy. The importance stems from the global need to save energy.

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Impacts of Energy Management

Reduces cost of energy. Reduces carbon emissions and environmental damage. Reduces risk of price increases and supply voltages.

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