Process Creation by Intuition (5M)

“Process Creation by
Intuition”
(Dr. Zain’s Primitive Process Design)
Man learn in three ways….

1st, through imitation, that’s the easiest,
2nd, through experience, that’s the hardest,
3rd, through meditation, that’s the noblest
copyright zain/PSE- FKKKSA, UTM Primitive Process Creation <9 July 07> PPC - 1
Why did you choose

Chemical Engineering?
1
Chemical Engineering
Concerns You !!!
Challenge:
Bringing chemical
engineering to your
doorstep
Dr Zain’s….Believe it, or not…
Each of us have some

chemical engineering
(i.e., process design)
experience!!!
2
Basic Needs:
Any example?
• E.g. Food?
• Shelter?
• Clothing?
• Medication?
• Transportation
• Cosmetics
• …….
Basic Needs (Physical)

• Food •Clothing
•Shelter
Health &
Medication
3
Other Needs
• Transportation
• Cosmetics/Cosmeceuticals
How to get them?
Buy, or
Make !
Let’s try to make all the things

that we could make!……
4
Let’s start with the
most basic need!
• Food!
Key Terminology-
..is the field of study that

involves the process of
converting resources into
value-added products
5
What is Chemical Engineering?
..is the field of study that involves the process of
converting resources into value-added products
through the application of basic sciences (math,
chemistry, physics and biology) and engineering
principles for the development, design, operation and
maintenance of processes
Chemistry
Mathematics
Plants/Crops
Natural Gas
Petroleum
Economics
Minerals
Air Energy Physics
Biology
Let’s start with the

most basic need!
Example of food as a basic need:

Rice….Let’s make “Biryani Rice”
6
The 5M of Converting Resources
to Value Added Products in
Mini Project: Create a Process to

Produce e.g. Biryani Rice, Bread,
cookies, cakes and etc
Using…..
Dr Z’s 5M’s of Chemical

Engineering
We need 5M to convert resources into VA products!
• Materials – ingredients and the product (what,
how much, where, cost) ?
• Method (steps...any recipe? Own recipe?...or
process (of making..))
• Machinery/Tools/Equipment (what, how big?,
how many, where, cost, any tools already
available?, any new one? limitations)
• Manpower (skill required? how many? who?, who
to do what (job-spec)?
• Money (net income?)
7
Some Key Terminologies
• Create Steps = Synthesise/Design a Process
• Recipe/Steps = Methods, Processes/Operating
Procedure
• Tools = Equipment, Unit Operations
• Variables = Process Conditions
• Net income = Gross Profit/Profitability Analysis
• Recipe Improvement = Debottlenecking, Process
Improvement, Optimisation
Methods (Recipe)
• Steps involved – e.g. wash, heat, mix, stir, cool)

• Key variables for each step
– Amount of each material…i.e composition
– Temperature? Pressure? Additives? Colour? Smell?,
– Duration?
8
The 5M of Chemical
Engineering
Student Project:
Create a Process
Manufacture Bahulu
Kemboja
“Bahulu Kemboja”
• Introduction
– Also known as “Kuih Bakar’
– Traditional ‘kuih’
– Pandan flavour
– Home based business
– Market demand wide; morning breakfast,
gathering, official function etc.
– Prod. development; how to make the ‘kuih’ last
longer, taste good with competitive price.
9
M1-Materials
Raw Materials:
 Pandan Leaf
 Sesame Seed
 Flour
 Sugar
 Coconut Milk
 Eggs
 Water
M2-Methodology
STANDARD OPERATING PRACTICE FOR
BAHULU KEMBOJA
PROCESS METHOD
BLENDING
- Crushing -Pandan leafs to be cut to small pcs
-Transfer cut pandan leaf into blender jar
- Pour 700ml water into blender jar
- Blend few minutes until all pandan leaf crushed
- Filtration - Pour the blended pandan leaf into plastic container by pass
through plastic filter
10
M2-Methodology
PROCESS METHOD
MIXING
- Pre-Heating -Transfer pandan jus and coconut jus until steel bowl
- If mixed pandan and coconut become light green, add 1-2
tea spoon of green color flavor.
-Mixing - Heat until its boil
- Pour the heated pandan extract and coconut milk into the
blender jar and transfer all the flour, sugar and eggs
- Blend few minutes until its properly mix
-Transfer into plastic bowl
M2-Methodology
PROCESS METHOD
MOULDING
- Mould Pre- - Pour 1 tea spoon of cooking oil until the steel mould.
heating - Heat on gas oven until oil boil
- Pour mixed cake ingredient into the mould using plastic jar
until mould level
- Distribute sesame seeds evenly on the surface
11
M2-Methodology
PROCESS METHOD
HEATING - Switch on oven and set oven temperature knob at desired
(BAKING) temperature.
- Transfer all the mould into the oven
- Set oven timer knob at desired time for bottom heating
- Switch on top heater once bottom heating complete.
- Heat top surface until its turn to brownish color.
- Transfer all the mould out from oven when the top heating
complete.
M3- Machinery/Equipment
 Knife
 Blender
 Plastic filter
 Steel bowl
 Mould
 Oven
 Spoon
12
M4-Manpower
MAN POWER QUANTITY PRICE COST / UNIT
Wages 1 man RM60. 00/day 3.85
M5-Money: Costing
RAW MATERIAL QUANTITY (5 PRICE, RM COST/UNIT

units OF CAKE) (5 units OF
CAKE)
Flour 350g 1.30/kg 0.455
Sugar 500g 1.50/kg 0.750
Pandan extract 20-30leaf 1.00/100leafs 0.20 – 0.30
Coconut milk 700ml 1.00/L 0.70

Eggs 4nos 0.2/nos 0.80
Sesame Seeds 10-15g 3.00/kg 0.03 – 0.045
Oil 5-10ml 9.00/5kg 0.009 – 0.018
13
M5-Money: Costing
UTILITIES QUANTITY PRICE COST / UNIT
(5units OF
CAKE)
Electricity 3.33KW 0.218/KWH 0.72594
Fuel Gas (LPG) 50 – 100g 18.50/14kg tank 0.06 – 0.13
Water 700ml 0.57/m3 0.0004
TOTAL COST, RM 7.7743

(5units OF CAKE)
Selling price = RM2.70/nos x 5 units = RM13.50

GROSS PROFIT MARGIN
= RM5.7257 (73.65%)
Semi-Batch Proces
Application: Intermediate scale of production
14
Continuous (Automatic)
Process
Application: Large scale production
“A radical improvement can materialise

through paradigm shift”
- dr.zain -
“A paradigm is like a map.

Getting to a place quicker is not a
matter of technique. It is a matter of
getting the right map”
- Covey -
15
“Process Synthesis is paradigm.
Process Design, Process Control

and Optimisation are merely
techniques.”
- dr.zain -
16

Process Creation by Intuition (5M)

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“Process Creation by

Man learn in three ways….

Why did you choose

Dr Zain’s….Believe it, or not…

Each of us have some

Basic Needs (Physical)

How to get them?

Let’s try to make all the things

..is the field of study that

Let’s start with the

Example of food as a basic need:

Mini Project: Create a Process to

Dr Z’s 5M’s of Chemical

• Steps involved – e.g. wash, heat, mix, stir, cool)

MAN POWER QUANTITY PRICE COST / UNIT

Wages 1 man RM60. 00/day 3.85

RAW MATERIAL QUANTITY (5 PRICE, RM COST/UNIT

Coconut milk 700ml 1.00/L 0.70

TOTAL COST, RM 7.7743

Selling price = RM2.70/nos x 5 units = RM13.50

“A radical improvement can materialise

“A paradigm is like a map.

Process Design, Process Control

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