DESIGNING OF PLANT SUPPORT SERVICES

Presented by:

Mr. Sonwane S.A(Roll No: 307)

Under the Guidence ofMr. Nikam V.K

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AMRUTVAHINI COLLEGE OF PHARMACY, SANGAMNER

CONTENT Introduction

Plant Support Services

A. Services related to Manufacturing

B. Services related to Employees

Reference

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INTRODUCTION

Definition :- Activity or function required for successful completion of a process , program or project in the plant is called as plant support services.

Pharmaceutical manufacturing facility required 2 principle areas ;

1) Production Area

2) Support Area

Requirement for the construction of plant :-

1) Requirements related to GMP

2) Requirements related to Factories Act and Rules

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PLANT SUPPORT SERVICES

Plant Support Services includes ;

A. Services related to Manufacturing

B. Services related to Employees

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A. Services related to Manufacturing

1) Security Office

2) Fuel Storage

3) Scrap Yard

4) Toilet Facility

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B. Services related to Employees

1) Vehicle Parking

2) Canteen and Cooking

3) Garden and Horticulture

4) Administrative Block and Training Centre

5) Sports and Entertainment Block

6) Resident Managers Bungalow

7) Residences for Essential Service Staff

8) Medical Services

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PHARMACEUTICAL PLANT LAYOUT7

Production blockAdmin

Parkingplace

Canteen

Utilitiesblock

Security

Main road

Fact

ory

Roa

d

Warehouse

Scrap yard

Fuel storage

SECURITY OFFICE

In every factory 1000 or more workers are ordinarily employed. Also number of Safety Officers may be specified in factory. The duties, qualification and conditions of service of Safety

Officers shall be prescribed by the State Government. Pharmaceutical industry is one of the most diverse fields,

encompassing research, manufacturing, distribution and marketing with a board range of potential security vulnerabilities.

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Facilities protection requires highest level of security services related to access control, ingress and egress monitoring, after-hours protection and alarm monitoring.

Security services required;

1) Access control

2) Fire prevention and life safety programs

3) Demonstration mitigation

4) Facilities protection

5) Crisis management

6) Emergency or unusual event response

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Security offices also required Security Guards working in private organizations have to keep a tab on people which entering and leaving the building .

Security guards maintain a book which contains name or in and out time of the person .

Security guards are responsible for safety of people working in building .

Security guards also check each and every person before entering the building .

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DESIGNING OF SECURITY OFFICE

Entry to Factory

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Locker

Document Room

Alarm Section Sitting

Table

Waiting Room

Security Cloth Room

Toilet Facility

Exit from

Factory

Entry

Exit

DESIGN OF FUEL STORAGE FACILITY

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C o m m o n P a s s a g e

Receiving Fire ExtinguisherIntermediate Liquid Fuel

Storage

Final Liquid Fuel

Storage

Final Gas FuelStorage

Intermediate Gas Fuel

StorageFire Extinguisher

FUEL STORAGE FACILITY Fuel is required in pharmaceutical industries for generating power

during interruption of regular power supply . Generally Coal, Diesel can be used for this purpose and storage of

these material is necessary. Canteen required gas for cooking purpose, LPG cylinders are

utilized for the activity. Care has to be taken while storing these substances. Storage has to be near the generator room. Constant check has to be kept on the quantity of the material

stored.

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As these substances are highly inflammable, protection from fire

becomes a basic requirement.

Fire safety equipments are to be in vicinity of such facility and

people are to be trained in handling of the same.

All such fuel are to be stored in a secured area, to avoid

tampering or misuse of these substances.

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SCRAP YARDS FACILITY During working in the industry, large amount of waste material or

scrap is generated. This includes the empty cartons in with raw material or packaging

material is plastic sheets, discarded powders, discarded or rejected products, printed packaging materials, machinery/equipments or parts of machinery/equipments.

The most common method employed for destruction of these material is incineration.

Monitoring of particulate matter entering the environment is critical.

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All materials moved to the scrap yard are to be documented systematically, record of destruction is also to be maintained.

Precaution during incineration process are necessary with respect to the material to be destroyed, fumes generated, toxic gases evolved.

If material is to be discarded then complete procedure for metal processing is to be used.

Security measures are also important as any material in scrap yard should not get stolen.

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DESIGN OF SCRAP YARDS FACILITY

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Receiving Area Inspection Room

Disposable scrap

Nondisposable scrap

Scrap treatment

Scrap treatment

TOILET FACILITY

Objective :- To provide separate toilet facility for male as well as female .

The area should be well lighted and ventilated . Sweepers shall be employed to clean latrines, urinals and washing

places . Facilities for washing shall be provided and maintained for the use

of the male and female workers separately. Facilities for changing, storing clothes and for washing and toilet

purposes shall be easily accessible and adequate for the number of users.

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These area shall not be directly connected with production or storage areas.

There shall be a written instruction for cleaning and disinfection of these area.

A routine sanitation program shall be drawn up , observed and properly recorded.

It indicate that :-

1) Specific areas to be cleaned and cleaning intervals.

2) Cleaning procedure to be followed including equipment and materials to be used for cleaning.

3) Personnel assigned to and responsible for the cleaning operation.

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DESIGN OF TOILET FACILITY20

Change RoomStaff (Women)

Change RoomStaff (Men)

Change RoomWorker (Women)

Change RoomWorker (Men)

Toilet (Women)

Toilet (Men)

VEHICLE PARKING Parking design is result of various policies and programs which

result in more efficient use of parking resources. Parking is an essential component of the transportation system. Parking area is generally located at the periphery of the premises. Separate area provided for parking vehicles of the employee’s and

the visitors. Separate are allocated for parking of 2 wheelers and 4 wheelers. Allottment of parking area depends on industry’s size, scope and

operations.

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Parking Management Principles :-

1) Consumer Choice

2) User Information

3) Sharing

4) Efficient Utilization

5) Flexibility

6) Prioritization

7) Peak Management

8) Quality Vs Quantity

9) Comprehensive Analysis

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Parking Management Benefits :-

1) Facility Cost Saving

2) Improved Quality of Service

3) More Flexible Facility Location and Design

4) Reduces Land Consumption

5) Supports Mobility Management

6) Supports Smart Growth

7) Improved Walkability

8) More Livable Communities

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Criteria for Design of Parking :-

1) Parking Facility for Personnel Vehicle

2) Parking Facility for Commercial Vehicle

Parameters in Design of Vehicle Parking :-

1) No of Personnel

2) Public Transport Services

3) Distance of Factory from City

4) Private Transports Facilities

5) Feasible Land for Design of Vehicle Parking

6) Environment Condition

7) Vehicle Dimension in Parking Design

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DESIGN OF VEHICLE PARKING

Personnel Vehicle

25

Vehicle Parking

Commercial Vehicle

VIP Staff

Other StaffWorkers

Cars

4 Whealer Parking 2 Whealer Parking

Heavy Vehicle

Cars

Cars

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TYPE I (a) TYPE I (b) TYPE I (c)

TYPE II TYPE III

GARDEN AND HORTICULTURE

Horticulture is the industry and science of plant cultivation

including the process of preparing soil for the planting of seeds,

tubers or cutting.

In industry, gardens are maintained surrounding the facility.

Trees are planted at proximity of the facility.

Clarified water from effluent treatment can be used for watering

the gardens.

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CANTEEN AND COOKINGA. Canteen :- These area shall not lead directly to the manufacturing and storage

areas . Canteen usually located at the periphery of the industry . It is included in the ancillary area of the company . Area of canteen will depend on the number of workers employed . The canteen furniture will be in accordance to GMP . Food may be provided by company which will lead to maintaining

a hygienic cooking facility in canteen . Employees can have their food in the canteen . Proper safety equipments are to be kept in place.

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B. Cooking :-

Cooking area has to be maintained under total hygienic condition . People involved in preparation, serving, cleaning of area are to be

well trained in each activity like personal hygiene practices, washing of utensils, cleaning of food materials.

Personnel working in canteen have to undergo periodic medical examination.

These personnel are vaccinated for Typhoid periodically. Sanitation is the general problem associated with canteen facility. Presence of food creates a potential rodent and insect problem.

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DESIGN OF CANTEEN FACILITY30

Cooking place

Grain storage

Wash area

Cooked food

storage

Service counter

area

Hand wash

34 M

13 M

ADMINISTRATIVE BLOCK AND TRAINING CENTRE

A. Administrative Block :-

Administrative block involves cabin of HOD .

Conference rooms having a capacity of 4 people and 8 people .

Meeting room having capacity of 20 people. There should be small library. There should be room for tea making and crockery storage.

Relative location of the administrative area is of importance.

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DESIGN OF ADMINISTRATIVE BLOCK32

7

6

14

12

11

10 9 8

17

5

4

3

13

1

2

15 16

24.6 M

16 M

DESCRIPTION OF ADMINISTRATIVE BLOCK

Sr. No. Room Name Dimension (m)

Description

1 Conference Room 4 x 4 4 Peoples

2 Office – 2 3 x 3 Production Head

3 Office –3 3 x 3 Q. A. Head

4 Office - 4 3 x 3 P.A. of loacation Head

5 Office – 5 4 x 4 Location Head

6 Wash Room-M 7.6 x 4 -

7 Conference Room 12 x 4.5 20 Peoples

8 Office - 8 3 x 3 Engg. Head

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Sr. No. Room Name Dimension(m) Description

9 Office - 9 3 x 3 Q. C. Head

10 Office - 10 3 x 3 Personnel Head

11 Tea Making &

Crockery Storage

3 x 2.5 -

12 Wash Room - F 5 x 4 -

13 Conference Room 6 x 4 8 Peoples

14 Library 8.54 x 4.5 -

15 Office - 15 3 x 3 Finance &

Factory

Administration

16 Office - 16 3 x 3 Prod. Planning &

Control Head

17 Clark Office - 17 6 x 6 -

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B. Training Centre :- It is the area where training sessions for employees can be

arranged. Its location is in the administrative block. It should contain Projector, T. V, White board. Sitting arrangement of 25 people or it is also depend on capacity

of plant. Training varies according to the activity of personnel which

carries out in the industry.

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Design Aspects :-1) Sitting arrangement for a maximum of 30 persons

(30sq.m) .2) Trainees table and chair (4 x 2 m)3) White board (2 x 1.5 m)4) Projection screen (2 x 1.5 m)5) LCD projector for slide show6) Flip charts and mounting stand7) Disposables 8) Speaker phone / TV set with DVD 9) Training manager office10) Washroom facility

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DESIGN OF TRAINING HALL37

Library

Training Manager

office

rReception

Wash room

White board

Table

Speaker

30 chairs

12.50 M

11 MLobby

RESIDENCE FOR ESSENTIAL SERVICE STAFF

Essential Services means services that are necessary to enable the

employer to prevent;

1) Danger to life, health or safety.

2) The destruction or serious deterioration of machinery, equipment

or premises.

3) Serious environmental damage.

4) Disruption of the administration of the courts or of legislative

drafting.

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Essential Services Employee means an employees who is required to work during a work stoppage.

The residences for these employees have to be in vicinity of the industry.

As they will be required for the said job at any point of time, either there will be people working in shifts or in vicinity.

So that problems can be resolved immediately without any loss of time and money in the company.

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SPORTS AND ENTERTAINMENT BLOCK

Company can have recreation activity facility in their premises . Employees can use these facilities after their working hours . Large scale plants depends on company policy of indoor sports

facility . Facilities can be for sports, gym, etc . A common area can be utilized for the purpose like gatherings or

meets of the industry . Generally table tennis and carom board are placed in these area .

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There is a separate room for study to this wash room is attach .

There should be facility for drinking water .

Common toilet should be attached to study room .

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DESIGN OF SPORTS AND ENTERTAINMENT BLOCK

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Cor

idor

Table Tennis Car

om

12 M

14 M

10 M

Study Room

DESCRIPTION OF SPORTS & ENTERTAINMENT BLOCK

Sr. No. Room Name Description Dimension

(m)

1 Table Tennis Room Arrangement for 2

table tennis board 4.44 x 6.8

2 Carom Board Room Arrangement for 2

carom board 4.44 x 3.2

3 Study Room Seating arrangement

for 20 people 5.52 x 5

4 Wash Room - 5.46 x 2.70

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RESIDENT MANAGERS BUNGALOW Objective :- To provide residence facility for essential staff within

premises. These area shall not lead directly to the manufacturing and storage

areas. Bungalows are to be located at the periphery of the industry.

These can be utilized by the managers who have either come from corporate or other site of company on official duty.

Bungalows ; Resident Managers Bungalow (about 150 m2) Staff Quarters (about 75 m2/flats) – 4 block Workers (about 50 m2/flats) – 6-8 flats

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DESIGN OF RESIDENCE MANAGER’S BUNGALOW45

Car Parking

Residence Manager’s Bungalow

12.5 M

12.5 M

15 M

20 M

MEDICAL SERVICES

State Government may appoint qualified medical practitioners to be certifying

surgeons .

Duties of Surgeons:-

1) The examination and certification of young persons .

2) The examination of persons engaged in factories in such dangerous

occupations or processes .

3) Supervising the factories .

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Prior to employment, all personnel, shall undergo medical examination including eye examination.

Also shall be free from Tuberculosis, Skin and other communicable or contagious diseases.

They should be medically examined periodically at least once a year.

All records shall be maintained. The licensee shall provide the services of qualified physician for

assessing the health status of personnel involved in different activities.

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REFERENCE

1) Manohar A. Potdar, Pharmaceutical Facilities, Pharma Med Press, Pg No: 241-258.

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THANK YOU