A brief summary of designing of plant support services.

1. DESIGNING OF PLANT SUPPORT
SERVICES
Presented by:
Mr. Sonwane S.A
(Roll No: 307)
Under the Guidence of
Mr. Nikam V.K
1
AMRUTVAHINI COLLEGE OF PHARMACY, SANGAMNER

2. CONTENT
 Introduction
 Plant Support Services
A. Services related to Manufacturing
B. Services related to Employees
 Reference
2

3. 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
3

4. PLANT SUPPORT SERVICES
 Plant Support Services includes ;
A. Services related to Manufacturing
B. Services related to Employees
4

5. A. Services related to Manufacturing
1) Security Office
2) Fuel Storage
3) Scrap Yard
4) Toilet Facility
5

6. 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
6

7. PHARMACEUTICAL PLANT LAYOUT
7
Production block
Admin
Parking
place
Canteen
Utilities
block
Security
Main road
FactoryRoad
Warehouse
Scrap yard
Fuel
storage

8. 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.
8

9.  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
9

10.  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 .
10

11. 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

12. DESIGN OF FUEL STORAGE
FACILITY
12
C o m m o n P a s s a g e
Receiving Fire Extinguisher
Intermediate
Liquid Fuel
Storage
Final Liquid
Fuel
Storage
Final Gas Fuel
Storage
Intermediate Gas
Fuel
Storage
Fire Extinguisher

13. 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.
13

14.  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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15. 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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16. 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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17. DESIGN OF SCRAP YARDS
FACILITY
17
Receiving Area Inspection Room
Disposable
scrap
Nondisposabl
e scrap
Scrap
treatment
Scrap
treatment

18. 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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19.  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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20. DESIGN OF TOILET FACILITY20
Change Room
Staff (Women)
Change Room
Staff (Men)
Change Room
Worker (Women)
Change Room
Worker (Men)
Toilet
(Women)
Toilet
(Men)

21. 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.
21

22.  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
22

23.  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
23

24.  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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25. DESIGN OF VEHICLE PARKING
Personnel Vehicle
25
Vehicle Parking
Commercial Vehicle
VIP Staff
Other Staff
Workers
Cars
4 Whealer Parking 2 Whealer Parking
Heavy Vehicle
Cars
Cars

26. 26
TYPE I (a) TYPE I (b) TYPE I (c)
TYPE II TYPE III

27. 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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28. CANTEEN AND COOKING
A. 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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29. 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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30. DESIGN OF CANTEEN FACILITY30
Cooking
place
Grain
storage
Wash
area
Cooked
food
storage
Service
counter
area
Hand
wash
34 M
13 M

31. 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.
31

32. 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

33. 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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34. 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 -
34

35. 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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36.  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 show
6) Flip charts and mounting stand
7) Disposables
8) Speaker phone / TV set with DVD
9) Training manager office
10) Washroom facility
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37. DESIGN OF TRAINING HALL37
Library
Training
Manager
office
rReception
Wash
room
White board
Table
Speaker
30 chairs
12.50 M
11 M
Lobby

38. 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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39.  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.
39

40. 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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41.  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 .
41

42. DESIGN OF SPORTS AND
ENTERTAINMENT BLOCK
42
Coridor
Table Tennis
Carom
12 M
14 M
10 M
Study Room

43. 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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44. 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
44

45. DESIGN OF RESIDENCE MANAGER’S
BUNGALOW45
Car
Parking
Residence Manager’s
Bungalow
12.5 M
12.5M
15 M
20 M

46. 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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47.  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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48. REFERENCE
1) Manohar A. Potdar, Pharmaceutical Facilities, Pharma Med
Press, Pg No: 241-258.
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49. 49
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