Final pl doc

PLANT LAYOUT ARCHITECTURAL BRIEF 2011

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PLANT

LAYOUT

LAYOUT DEVELOPMENT

FACULTY IN-CHARGE:

Ms. JONALEE D BAJPAEI

SUBMITTED BY:

AMALESH DEKA

ANOOP SINGH

RAJEEV SHARAN

SHARAT CHANDRA

ALOK LIEVENS DFT (BFT- AP 07)

NIFT BANGALORE


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Introduction about the company

Product:

• Formal Jacket

• Formal Trouser

Output:

• Trouser : 1000 pieces/day/line

• Jacket: 500 pieces/day/line

No. of Production Line:

• Trouser: 05

• Jacket: 04

Total Output:

• Trouser: 5000 pieces/day

• Jacket: 2000 pieces/day

Working per day: 08 Hours or 480 min. with a break of 30 min for Lunch.

Work Timing: 9 a.m to 5.30 p.m

Work Days: Monday to Saturday

Total Plant Area: 287077 sq. feet

Gross Built-Up Area: 180164 sq. feet

FAR: 0.63


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TABLE OF CONTENTS:

Sr. No. CONTENT PAGE NO

1. OBJECTIVES 2. AR CHART 3. ARTITECTURE BRIEF OF SHOP FLOOR

STRUCTURE

4. SAMPLING 5. PM & CAD 6. FABRIC STORE 7. TRIM STORE 8. SPREADING & CUTTING 9. SEWING 10. FINISHING 11. WAREHOUSING 12. TRAINING 13. MAINTENANCE 14. UTILITY 15. ADMINISTRATION 16. OTHER SUPPORTING DEPARTMENTS


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OBJECTIVES:

1. To know material handling.

2. To know material flow.

3. To understand the importance of location & its study.

4. To develop ACTIVITY-RELATIONSHIP Chart.

5. To develop architectural brief.

6. To develop a plant layout having optimum material flow


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AR CHART:

Activities

Sto

res

Sp

read

ing &

Cu

ttin

g

Sew

ing

Fin

ish

ing

Ware

hou

se

Mer

chan

dis

ing

Sam

pli

ng

Qu

ali

ty

CA

D r

oom

IE-

Dep

t.

Acc

ou

nts

Main

ten

an

ce

IT-D

ept.

Stores A O U U O U U U U U U E

Spreading &

cutting

A A O U U U U I U U O U

Sewing O A A U X U O U O O O U

Finishing U O A A U U O U O O O O

Warehouse U U U A U U U U U U U U

Merchandising U U X U U A U O O O X A

Sampling U U U U U A U O O O X I

Quality U U O O U U U O U U X X

CAD room U I U U U O O U U U X A

IE- Dpt. U U O O U O O U U O O U

Accounts U U O O U O O U U O X E

Maintenance U O O O U X X X X O X U

IT-Dpt. E U U O U A I X A U E U

KEYS

A: Absolutely necessary E: Especially important I: Important

O: Ordinary closeness OK U: Unimportant X: Undesirable


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DIFFERENT SECTION OF DEPARTMENTS

STORAGE

FABRIC STORE

WARE HOUSE

SEWING TRIMS STORE

PACKING TRIMS STORE

PRODUCTION CUTTING SECTION

PREPARATORY SECTION

ASSEMBLY SECTION

FINISHING SECTION

PACKING SECTION

SUPPORT SAMPLING SECTION

CAD ROOM

IE-DEPT.

OFFICE IT-DEPT.

ACCOUNTS & FINANCE

PURCHASE DEPT.

PRODUCTION ROOM

PPC OFFICE

HR DEPARTMENT HR

MEDICAL ROOM

TRAINING SECTION

CRECHE

REST ROOM

MEETING ROOM + COUNSELLING ROOM

CLOAK ROOM

STAFF TOILET

CANTEEN OPERATORS TOILET

MAINTENANCE BOILER ROOM

MAINTENANCE + MC STORAGE

COMPRESSOR ROOM

POWER HOUSE

ADMIN BLOCK MEETING ROOMS

GM OFFICE

BOARD ROOM

MD OFFICE

GUEST ROOM

MERCHANDISING SECTION

ACCOUNTS

RECEPTION

EXECUTIVE TOILETS

FRONT SECTION PARKING

SECURITY ROOM


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PROCESS CHART

FABRIC STORE PROCESS ACTIVITIES

IDENTIFICATION

a) Incoming goods

b) Fabric inspection area

c) Inspected goods Ok

d) Rejected Goods area

e) Stickers of pass and reject

f) Colour codification shade and shrinkage

g) Bin Card

FABRIC RECIEPT

a) Physical check for length, width of

received e.g. invoice

b.) Communication of excess/shortage goods

e.g. receipt

FABRIC INSPECTION

a) Adequate light

b) 4 point system for visual inspection

report (10 %)

c) Shade segregation

d) Approvals of shade and ratio

e) Trims & Fabric approvals

f) Fabric Lab Test Report

FABRIC ISSUE

a) Issue record to be maintained

b) Fabric issue must be

shade/shrinkage/width wise

c) Pass rolls must be identified with green

stickers.

DISPLAY

a) Fabric Defect Standard

b) 4 point system chart

c) Face side/nap direction/ grain line of the

fabric

d) Shade approved

e) Store layout

f) Process flowchart

OTHERS

a) Fabric issue record

b) Inward record

c) Outward record

d) Handling /House keeping


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PROCESS CHART

CUTTING PROCESS ACTIVITIES

APPROVED REFERENCE SAMPLE

a.) Plaid matching requirement

b.) Grain line, centre/feature line

requirement

c.) Nap/design direction

d.) Fusing standard / requirement

e.) Trim requirement

FABRIC

a.) Approved face side display

b.) Approved shade band

c.) Fabric receipt

d.) Fabric inspection report

e.) Fabric relaxation tag on roll

f.) Fabric width report

g.) Fabric Shrinkage report

DISPLAY

a.) Display cutting SOP

b.) Approvals (shade etc.)

c.) Fabric face side

d.) Numbering/Stickering/Bundling / tagging

e.) Process flow chart

f.) Layout

PREVENTIVE MAINTENANCE

a.) Cutting m/c maintenance

b.) Spreading m/c maintenance card

c.) Band knife m/c maintenance card

d.) Die Click maintenance card

STORAGE

a.) Cut parts must be stored in racks

b.) Fabric must be stored shade, shrinkage

c.) Mobile cut parts storage

CAD MARKERS

a.) Cutting CAD markers must be used

b.) Markers must be colour coded in case of

multiple shrinkage

c.) Markers must have all the details e.g.

Patterns , Cut, Plies, size, style etc.

d.) Pattern’s duplicate and ready patterns

must be available & issued.

LAYING/SPREADING

a.) Paper should be used to avoid slippage of

line fabrics.

b.) Relaxation of fabric should be done

c.) Selvedge should match on one side

d.) Static should be avoided.

e.) Spreading report should be prepared

f.) Check the roll no., shade, meterage,

width against the lay plan & fabric roll

details

a.) Flow charts to know audit points

b.) Pilot run record


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QUALITY CONTROL c.) Marker/spread audit

d.) Cutting audit

e.) Bundle inspection

CUT PANEL INSPECTION

a) Adequate light

b) Display defect standard

c) Parts replacement to take place from

same rolls

d) End bits must be stored neatly with

identification

FUSING

a) fusing standard(approved report)

b) fusing must be done 4times a day

c) bond strength report

d) preventive maintenance calendar

e) fusing audit report

f) fusing shrinkage and swatch report

OTHERS a) Handling/house keeping.

PROCESS CHART TRIM STORE

PROCESS

IDENTIFICATION

ACTIVITIES

a) incoming goods

b) trim inspection area

c) inspected goods ok

d) rejected goods area

e) RTG(return to godown)

f) stickers for paas/reject

g) bin card

TRIM INSPECTION

a) adequate light

b) adequate person

c) 100% inspection of buttons

d) trims inspection 100%

e) trims counting 100%

f) qty. inspection record

g) Communication of pass fail record

OTHERS

a) storage PO wise

b) needles must be stored safely lock

c) labels must be stored safely locked

d) material issue DC

e) handling

f) house keeping

DISPLAY

a) approved trim cards

b) sampling plan

c) store layout

d) process flowchart


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PROCESS CHART QA DEPT.

Process Activities

QUALITY SYSTEM

a) pre production meeting conducted before

pilot run

b) all concern nominated people must attend

the PPM

c) PPM comments must be available

d) Pilot run

e) Batch setting must be as per technical

specification

f) Needle procedure

g) Label procedure

h) Bundle integrity

i) Self trimming

j) Self inspection

k) Handling/ housekeeping

l) Job specification/ operation std./ mocks

on all m/c & must be signed by QA,

operator & supervisor

m) Machine maintenance card

n) All metal parts must be tied(trimmers,

scissors, patterns etc)

o) Inspection area must have adequate light

p) End line inspection

q) Regular visit of QA, sup, PM, QAM

DISPLAY

a) Display cutting SOP

b) Approvals( embroidery, shade etc)

c) Fabric face side

d) Numbering/ stickering placement mocks

e) Process flow chart

f) Layout

PREVENTIVE MAINTENANECE

a) Cutting m/c maintenance chart

b) Spread m/c maintenance chart

c) Band knife m/c maintenance card

STORAGE

a) Cut parts must be stored in racks

b) Fabric must be stored shade, shrinkage,

width wise

c) Mobile cut parts storage available


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PROCESS CHART SEWING DEPT.

Process Activities

Sewing methods a) Proper work station

b) Proper work aid

Bundle control sheet follow up a) Check list

Bundle follow up a) Bundle report

Serial maintenance a) Serial maintenance sheet

QC records a) Quality reports

Planning follow up a) Loading follow up

Cut clearance a) Cutting report

Checker quality records a) Quality checker evaluation sheet

FINISHING DEPT. Trimming methods a) Trimming reports

b) Operator trimming productivity chart

Checking methods a) Proper work aid

b) Proper work station

Inline audit records/ procedures a) Inline audit sheet

Pressing methods a) Pressing defect sheet

Folding methods a) Operator wise productivity reports

Packing methods a) Presenting quality reports

PACKING DEPT. Carton dimension checking a) Checking carton dimension

Packing ratio a) Packing ratio report

Final auditing a) Checking packing quality

b) Final auditing


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ARTITECTURE BRIEF OF SHOP FLOOR STRUCTURE

The Plant has a FRAME STRUCTURE with columns and pillars

The no. of floor in the Shop Floor will be one with a Basement.

Ground Floor Area: 51427.5 Sq.Ft.

Basement Floor Area: 51427.5 sq.Ft

The Roof is a truss

Type of truss = King post truss

Sheet used: Aluminium Coated steel sheets

Trust Area has DOUBLE SKIN

Double Skin means two layers with 100mm insulation material in between to safe

guard from heat.

The truss has certain cut out parts covered with transparent sheets to get natural

light in the industry.

On the extreme right of the truss area, there is a 10 * 60 sq.mts Mezzanine with RCC

floor.

Roof is of Coarse and same truss material

This area accommodates the offices of the production unit and a store unit.

The height of this area is 3 mts and less which is appropriate for the office area.


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FOUNDATION: The 8 ‐9 feet deep foundation with load bearing pillars

The foundation is in accordance with the soil of the area. (Hard soil)

The 2 floors are built in accordance with the framed structure having columns of

pillars and beams that interconnect these columns, thus acting as a supporting

structure.

FLOORING: Because of the heavy machinery required in the industry, the floor have been

given special attention

Flooring is the important parameter in the industry.

Flooring used in the building is concrete.

The concrete flooring is used as the machinery used is of medium weight in nature,

which requires strong flooring.

Concrete offers compressive strength to the floor that is about 60% higher than usual

flooring solutions used.

Tensile Strength of flooring tiles increases by 70% in case of concrete flooring.

Floors are epoxy coated hardened floor (work on a quick drying mechanism). This

floor is very strong and bears a lot of load without facing any cracks

VENTILATION: The places requiring more ventilation are fusing, finishing and ironing

section.

These departments or sections are placed in the industry which had large windows

and ventilators to exhaust the excess heat.

Windows are 20% of the floor area.

LIGHTING: Lighting system consists of tube lights and natural lights.

Sufficient tube light should be installed for proper light

The garment industry requires a lot of lighting.

The places near to walls have huge windows providing lighting.

Huge number of tube light attachments is provided for artificial lighting.

The illumination required in the sewing department is higher due to intricate

requirements of lighting

Lighting in fabric store is at a higher distance as it did not require any processing.

The lighting in the spreading and cutting department is around 2 mts. above the table

as high lighting was required during cutting.

The lighting required in the sewing is highest as sewing required stitching at complex

places and it was around 2 ft. above the table height.

LIGHTING STANDARDS

General office 500 lux

Inspection 1,000 lux

Cutting 750 lux

Sewing 500 lux

Computer workstation 500 lux

Fabric Store & Trim Store 300 lux

Finishing 500 lux


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Source: ILO standards

SAFETY NORMS AND FACTORY ACT

Some of the important laws that must be considered while designing a new plant layout are as

follows:


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OPERATIONAL DPARTMENTS


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SAMPLING DEPARTMENT

This department serves the purpose of sample making before the actual production. The

department requires a set of machinery to manufacture these samples. Following are the basic

activities carried out in this department.

Sampling

Patterns, sample approved

Machineries required

Cutting tables

Sewing Machines

Iron tables

Inspection tables

GENERAL OVERVOEW- AREA CALCULATION

1. TROUSER SAMPLING

SL.NO M/C Make

Machine Model

No M/C DESCR

M/c

Length

M/C

Width M/C Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

1 HIGHLEAD GC-1088-M S/N LS 4 3 12 4 1.5 6

2 D/A 272 S/N LS 4 3 12 4 1.5 6

3 D/A 272 S/N LS 4 3 12 4 1.5 6

4 HIGHLEAD GC128-M S/N LS 4 3 12 4 1.5 6

5 HIGHLEAD GC-1088-M S/N LS 4 3 12 4 1.5 6

6 HIGHLEAD GC128-M S/N LS 4 3 12 4 1.5 6

7 D/A 272 S/N LS 4 3 12 4 1.5 6

8 HENGTAI GK-68

SADDLE

STITCH 4 3 12 4 1.5 6

9 PFAFF 1183

S/N LOCK

STITCH 4 3 12 4 1.5 6

10 D/A 272

S/N LOCK

STITCH 4 3 12 4 1.5 6

11 SIRUBHA 757F 5TH O/L 2.8 2 5.6 2.8 1.5 4.2

12 HIGHLEAD GC-1088-M

S/N LOCK

STITCH 4 3 12 4 1.5 6

13 HIGHLEAD GC-1088-MD

S/N LOCK

STITCH 4 3 12 4 1.5 6

14 SINGER 16694101 BARTACK 4 3 12 4 1.5 6

15 HIGHLEAD GK0058

CHAIN

STITCH 4 3 12 4 1.5 6

16 D/A 171

CHAIN

STITCH 4 3 12 4 1.5 6

M/C

AREA 185.6 O/P AREA 94.2

ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2


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2. JACKET SAMPLING

M/C Make

Machine

Model No

M/C

DISCRIPTION

M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator Area

1 JUKI DLN5410N-7 S/N LOCK STITCH 4 3 12 4 1.5 6

2 PFAFF 1183 S/N LOCK STITCH 4 3 12 4 1.5 6

3 JUKI DDL-550N-7 S/N LOCK STITCH 4 3 12 4 1.5 6

4 HIGHLEAD GC-188-MD S/N LOCK STITCH 4 3 12 4 1.5 6




8 D/A 271 S/N LOCK STITCH 4 3 12 4 1.5 6

9 D/A 272 S/N NEEDLE FEED 4 3 12 4 1.5 6

10 STROBEL BLIND HEMMING 4 3 12 4 1.5 6


12 D/A S/N NEEDLE FEED 4 3 12 4 1.5 6

13 MAIER HEMMING 4 3 12 4 1.5 6

14 D/A 381 DNLS 4 3 12 4 1.5 6

15 JUKI DLN5410N-7 S/N LOCK STITCH 4 3 12 4 1.5 6

M/C

AREA 180

O/P

AREA 90

Description

No. Of

M/C M/c Length M/C Width M/C Area O/P Space(Length)

O/P Space

(Width) O/P Area

1 pm table 2 6 5 60 6 2 24

2 Inspection Table 2 6 3 36 6 2 24

M/C AREA 96 O/P AREA 48

Sub Total Space 693.8

Allowance (150%) 1040.7

Total Required Area 1734.5



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PERSONNEL CALCULATION:

DESIGNATION NO.

SAMPLING Executive 1

Pattern Master 2

Cutting Master 1

Supervisor 2

Cutting Operator 2

Sewing Operator 22

Helper 6

Ironing Operator 4

FURNITURE:

FURNITURE DESCRIPTION QUANTITY

Computer Table 6

Executive Table 1

PM Tables 2

Inspection Table 2

Executive Chair Dimension (2 * 2) 9

Normal Chairs Dimension (1.5 * 1.5) 22

Flooring Material: Epoxy Coated Hardened Floor

Working Area:

The working area will include all the PM tables with the inspection tables. It will also have

the storage area for paper & wastes. It will also include the space for the following

equipments & machines:

Stitching M/Cs

Iron/ Steam Press

It will also include the space for the following personnel with their computer tables:

Supervisors


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Cutting Master

The total window area must be equal to the 1/6th

of the total floor area.

Administration/ Official Block:

There should be a separate wooden partition for the personnel offices, where we will have the

separate cubic’s with computer table for each of the personnel mentioned below:

Pattern Master

The partition should be done in a way that working area will be supervised from the

section/partition only. So, it should have one side transparent windows/ glasses, 4.5 feet

above from the floor. It should have a sided entry and exit.

Here, the file storage rack will also be placed.

The administration block should have a separate, medium sized, cabin for the Office of

SAMPLING Executive. It will be furnished with an Executive table and computer table. It

should also have 3 extra chairs along with an executive chair for the officer.


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PM & CAD DEPARTMENT

The purpose of the CAD department is to generate pattern for the garment and thus produce

the production marker for the same. The CAD department also requires producing costing

markers for the merchandisers. Following are the activities and assets required in the

department.

Plotter

Digitizer

Marker making

Marker Preparation

Costing marker

Bundle preparation report


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GENERAL OVER VIEW- AREA CALCULATION:


SL.NO Description

No. Of

M/C

M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

1 pm table 4 6 5 120 6 2 48

2 Plotter 2 8 3 48 7 2 28

3

computer

table 5 5 3 75 3 2 30

4

Inspection

Table 4 6 3 72 6 2 48

5 Digitizer 1 6 1.5 9 6 2 12

6

pattern

cutter 1 6 5 30 6 2 12

7

Pattern

Storage

Rack 1 6 3 18

Total

O/P

Space 178

8

Paper

Storage 2 3 3 18

9

Waste Paper

Bin 1 4 4 16

Total

M/c

Space 406

Sub Total Space 584

Allowance (150%) 876

Total Required Area 1460


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PERSONNEL:

DESIGNATION NO. CAD Executive 1

CAD Pattern Master 2

Junior Pattern Master (manual) 2

Costing Executive 1

Costing Engineer 1

Plotting & digitising Master 2

Helper 3

MACHINE:

M/C DESCRIPTION QUANTITY

Computer IBM 5

Plotter Gerber 2

Digitizer Gerber 1

Pattern Cutter Gerber 1

FURNITURE:


Computer Table 5

Executive Table 1

PM Tables 4

Inspection Table 4




Working Area:

The working area will include all the PM tables with the inspection tables. It will also have

the storage area for paper & wastes. It will also include the space for the following

equipments & machines:

Plotter

Digitizer

Pattern Cutter




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Costing Executive

Costing Engineer

Plotting & Digitising Master





The administration block should have a separate, medium sized, cabin for the Office of CAD

Executive. It will be furnished with an Executive table and computer table. It should also

have 3 extra chairs along with an executive chair for the officer.


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FABRIC STORE DEPARTMENT

This department is required for the storage of fabrics received as raw material.. Following are

the activities carried out in this department.

• Raw Material (fabric receipt)

• Quality checking

• Issue material for production

• Weighing machines

• Spring balance

Flooring Material: Concrete

PERSONNEL:

DESIGNATION DESCRIPTION NO.

RMQA Executive Operates trim & fabric stores both. 1

Store Manager For the Fabric storage. 1

MRP Engineer For the planning of material

requirements.

2

DATA Entry Operator For maintaining and keeping the

records.

2

Store Supervisor Each for jacket and trouser fabric

storage

2

Helper 6

Inspection Supervisor 1

Inspector 2


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MACHINE


Computer IBM 6

Fabric Inspection Machine Gerber 2

Lifting Machine 1

FURNITURE


Computer Table 6

Executive Table 1



Flooring: Epoxy Coated Hardened Floor

Working Area:

The working area will include the space for the following equipments & machines:

Fabric Inspection Machine

Lifting Machine

Storage Racks

It will also include the space for the cubic of following personnel:

Store Supervisor

Inspection Supervisor


of the total floor area. It should also have the

space for the storage of excess material.






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Store Manager

MRP Engineer

DATA Entry Operator



above from the floor. It should have 2 sided entry and exit.


RMQA Executive. It will be furnished with an Executive table and computer table. It should

also have 3 extra chairs along with an executive chair for the officer.


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TRIM STORAGE DEPARTMENT:

This department is required for the storage of trims received as raw material. This department

also keeps a record of trims received and issued to the production. Following are the activities

carried out in this department.

• Raw Material (Trim Card)

• Quality checking

• Issue material for production

GENERAL OVERVIEW- AREA CALCULATION:

TROUSER:

S.NO. ITEM

AVG.

QTY./PACKAGE

TOT. REQ. /DAY

(CAP. = 5000 TRS./DAY)

INVENTORY

REQUIREMENT

(30 DAYS) Length Width Area

1 Button 1728

pcs. (12gross)

/ box 20000 11.57407 box 347.22 1.5 1.5 781.25

2 thread(count tubes) 10000 m (10tubes) / box 1525000 152.5 box 4575.00 0.75 0.5 1715.625

3 tapes(bias/binding etc.) 137.16

m (150yds.) /

roll 5000 36.45378 rolls 1093.61 0.75 0.5 410.105

4 w.b. lining 137.16

m (150yds.) /

roll 6100 44.47361 rolls 1334.21 0.75 0.5 500.3281

5 fusing banroll 137.16

m (150yds.) /

roll 6950 50.67075 rolls 1520.12 0.75 0.5 570.0459

6 zipper tape 137.16

m (150yds.) /

roll 1200 8.748906 rolls 262.47 1.5 0.5 196.8504

7 zipper slider 1000 pcs./pkt 5000 5 pkts. 150.00 0.5 0.5 37.5

8 hook & bar 1000

sets/pkt (4

pcs./set) 5000 5 pkts. 150.00 0.5 0.5 37.5

9 Label 1500 pcs./pkt 10000 6.666667 pkts. 200.00 0.5 0.25 25

10 Tags 100 pcs./pkt 5000 50 pkts. 1500.00 0.5 0.25 187.5

11 Hanger 150 pcs./box 5000 33.33333 box 1000.00 1 0.25 250

12 Polybags 1000 pcs./bundle 5000 5 bundle 150.00 1.25 0.75 140.625

13 sticker(polybag/carton) 100 pcs./bundle 5000 50 bundle 1500.00 0.5 0.25 187.5

14 packing cartons 5 pcs./bundle 200 40 bundle 1200.00 4.25 0.25 1275

Total 6314.829


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Jacket

S.NO. ITEM

AVG.

QTY./PACKAGE

TOT. REQ. /DAY

(CAP. = 2000

JKTS./DAY)

Monthly

Consumpti

on DIMENSION AREA

1 Button 1728

pcs.

(12gross) / box 26000 15.05 box

451.3888889 1.5 1.5

1015.625

2 Thread 10000

m

(10tubes) / box 650000 65.00 box 1950 0.75 0.5 731.25

3

tapes(bridal/besom/armhole/s

atin etc.) 137.16

m

(150yds.) /

roll 12000 87.49 rolls

2624.67191

6 0.75 0.5

984.25

2

4

sh. Pads(no. weighing at

present - need broad platform

weighing m/c)

500 pairs/box 2000 4.00 box

120 2

1.2

5 300

5 Label 1500 pcs./pkt 4000 2.67 pkts. 80 0.5 0.2

5 10

6 Tags 100 pcs./pkt 2000 20.00 pkts. 600 0.5

0.2

5 75

7 hanger (no. weighing at present - need broad platform

weighing m/c)

150 pcs./box 2000 13.33 box

400 1.25

0.7

5 375

8 Polybags 1000 pcs./bundle 2000 2.00 bundles 60 1.25

0.75 56.25

9 sticker(polybag/carton) 100 pcs./bundle 2000 20.00

bund

les 600 0.5

0.2

5 75

10 packing cartons 5 pcs./bundle 320 64.00

bundles 1920 4.25

0.25 2040

TOTAL

5662.3

77

Assume that trims are kept at 3 levels in a rack

Sub Total Space(trims) 3992.402

Let’s consider of rack having 3levels of storage space

Dimension

width length height

2 8 6

Surface area of shelf

operator

allowance

16

2 2

Total area 4

Total area for a

rack

Total reqrd racks

20

249.5251

250


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Sub Total Space 5000

Allowance (150%) 5988.603


PERSONNEL:

DESIGNATION DESCRIPTION NO.

Store Manager For the Fabric storage. 1

MRP Engineer For the planning of material

requirements.

2

DATA Entry Operator For maintaining and keeping the

records.

2

Store Supervisor Each for jacket and trouser fabric

storage

1

Helper 6

Inspection Supervisor 1

Inspector 10

FURNITURE:


Computer Table 16

Executive Table 1



MACHINES:


Computer IBM 6

Weighing Machine 5


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Working Area:

The working area will include the space for the following equipments & machines:

Storage Racks

It will also include the space for the cubic of following personnel:

Store Supervisor

Inspection Supervisor

It should also have the space for the storage of excess material.

The inspection area should be separated, partitioned by wooden structures of height 4.5 feet,

which will include space of inspection tables.





Store Manager

MRP Engineer

DATA Entry Operator



above from the floor. It should have 2 sided entry and exit.


32 | P a g e

CUTTING & SPREADING DEPARTMENT:

The department serves the purpose of spreading of the fabric on long tables and cutting the

pattern pieces out of it. The critical factor in deciding the area of the department is the length

of the cutting table. The process of numbering and bundling is also carried out in this

department. The department requires the storage space for the cut fabric rolls, cut

components, bundles etc. Following are the requirements for this department.

Spreading Tables

Cutting tables

Numbering tables

Bundling tables

Checking tables

GENERAL OVERVIEW- AREA CALCULATION & MACHINES

1. JACKET

M/C

MAKE

MACHINE

MODEL

NO M/C DESCR

NO OF

MACHINES

M/C

LENGTH

M/C

WIDTH AREA

OPERATOR

LENGTH

OPERATOR

WIDTH

O/P

AREA

EASTMAN Eagle™

low-ply CNC

conveyor 2 50 8 800 50 2 200

EASTMAN

Power

Cradle

System Feeding System 4 1.5 8 48 1.5 2 12

Spreading Table 4 25 8 800 25 2 200

Pinning Table 4 25 8 800 25 2 200

EASTMAN Band Knife 2 8 4 64 8 2 32

FUSING MACHINE 2 8 5 80 8 2 32

Inspection Table 2 12 8 192 12 2 48

Ticketing Table 2 12 8 192 12 4 96

RECUTTING

TABLE 1 25 8 200 25 8 200

Cut Parts Storage

Rack 5 8 1.5 60 8 2 80

Fabric Storage Rack 3 8 4 96 8 2 48

Lining Storage Rack 2 8 4 64 8 2 32

Trolley 15 3 2 90

EASTMAN Blue Jay™

Spread and End

Cutting System 4 1.5 8

TOTAL M/C SPACE 3486 TOTAL O/P SPACE 1180


33 | P a g e

2. TROUSER

M/C Make

Machine

Model No

M/C

DISCRIPTION

No of

Machines

M/C

LENGTH

M/C

WIDTH AREA

operator

length

operator

width o/p area

EASTMAN Eagle™

low-ply CNC

conveyor 1 50 8 400 50 2 100

EASTMAN

Power Cradle

System Feeding System 2 1.5 8 24 1.5 2 6

Spreading Table 4 25 8 800 25 2 200

Pinning Table 4 25 8 800 25 2 200

EASTMAN Band Knife 2 8 4 64 8 2 32

FUSING

MACHINE 2 8 5 80 8 2 32

Inspection Table 2 12 8 192 12 2 48

Ticketing Table 2 12 8 192 12 4 96

RECUTTING

TABLE 1 25 8 200 25 8 200

Cut Parts Storage

Rack 5 8 1.5 60 8 2 80

Fabric Storage

Rack 2 8 4 64 8 2 32

Lining Storage

Rack 1 8 4 32 8 2 16

Trolley 15 3 2 90

EASTMAN Blue Jay™

Spread and End

Cutting System 4 1.5 8

TOTAL M/C SPACE 2998 TOTAL O/P SPACE 1042




* ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2

PERSONNEL:

DESIGNATION NO.

CUUTING Executive 1

CUTTING Supervisor 2

SPRAEDING Operator 40

TICKETING & BUNDLING Operator 40

INSPECTION Operator 12

CUTTING Operator 16

HELPER 10

DATA ENTRY Operator 2


34 | P a g e

FURNITURE:


Computer Table 5

Executive Table 1



Cut Parts Storage Rack Dimension (8 * 1.5) 10

Fabric Storage Rack Dimension (8 * 4) 5

Lining Storage Rack Dimension (8 * 4) 3

MACHINES:


Computer IBM 5

Straight Knife EASTMAN 16

Tagging Punch Machine EASTMAN 40


Working Area:

The working area will include all the spreading & cutting tables. It will also have the storage

area for paper & wastes. It will also include the space for the following equipments &

machines with space for storage racks

The total window area should be equal to the 1/6th





Cutting Master

Data Entry Operators





35 | P a g e


CUTTING Executive. It will be furnished with an Executive table and computer table. It



36 | P a g e

SEWING DEPARTMENT:

The department serves the purpose of sewing the garment and thus carrying out the

production. Following are the various activities that go in the sewing room.

Approval of operation breakdown

Special machines and attachments approval

Sewing department

Line balancing

No. of machines required

Deciding or approval of manufacturing system

Sewing

Inspection

GENERAL OVERVIEW- AREA CALCULATION & MACHINE DETAILS

1. TROUSER

PREPARATORY LINE

S.

NO.

OPERATION

DESCRIPTION

MACHINE

TYPE

M/C MAKE &

SERIAL

M/c

Length

M/C

Width

M/C

Area

Operator

Space(Len

gth)

Operat

or

Space

(Width)

Operator Area

PREPARATORY

Loading Table 5 4 20 5 2 10

1 W/B Extension SNLS

Durkopp Adler 0272-

990103-272-140342

4 3 12 4 1.5 6

2 4 3 12 4 1.5 6

3 Back Pocket

Facing

Auto Facing

Attach

Durkopp Adler 0271-

992001-271-992001 6.5 4.5 29.25 6.5 1.5 9.75

4

Front Pocket

Facing

Auto Facing

Attach

Durkopp Adler 0271-

992001-271-992001

6.5 4.5 29.25 6.5 1.5 9.75

5 6.5 4.5 29.25 6.5 1.5 9.75

6 6.5 4.5 29.25 6.5 1.5 9.75

7

Front Pocket O/L 3T O/L

Hilead GM288-302 2.8 2 5.6 2.8 1.5 4.2

8 Hilead GM288-4 2.8 2 5.6 2.8 1.5 4.2

9 Hilead GM288-302 2.8 2 5.6 2.8 1.5 4.2

10

Front Pocket

Turning Manual

5 4 20 5 1.5 7.5

11 5 4 20 5 1.5 7.5

12 5 4 20 5 1.5 7.5

13 5 4 20 5 1.5 7.5


37 | P a g e

14

Front Pocket TS SNLS Durkopp Adler 0271-

990103-271-140342

4 3 12 4 1.5 6

15 4 3 12 4 1.5 6

16 4 3 12 4 1.5 6

17 4 3 12 4 1.5 6

18 Fly Serging 5T O/L Hilead GM288-5 2.8 2 5.6 2.8 1.5 4.2

19 Fly stitch to Front Auto Fly Felling Brother S-7200A-403 4.5 3.25 14.625 4.5 1.5 6.75

20 Stitch Side Pocket

to Front

SNLS w

Differential Feed

Durkopp Adler 0275-

990103-275-140342

4 3 12 4 1.5 6

21 4 3 12 4 1.5 6

22 Side Pocket

Ironing Steam Press

Macpi 558-00-2058-

00 4.25 3.5 14.875 4.25 1.5 6.375

23 Side Pocket Edge

Stitch SNLS

Durkopp Adler 0271-

990103-271-140342

4 3 12 4 1.5 6

24 4 3 12 4 1.5 6

25 Side Pocket

Tacking SNLS

Durkopp Adler 0271-

990103-271-140342

4 3 12 4 1.5 6

26 4 3 12 4 1.5 6

27 Back Panel

Serging Auto 5T O/L Pegasus EXT5204-02 2.8 2 5.6 2.8 1.5 4.2

28 Dart Fusing Buck Press Macpi 558-00-2058-

00 5 5 25 5 1.5 7.5

29 Dart Marking Manual+Template

3.5 3 10.5 3.5 1.5 5.25

30 Auto Dart Making Auto SNLS Pfaff 3586 6 5 30 6 1.5 9

31 Dart Press Steam Press Macpi 558-00-2058-

00 4.25 3.5 14.875 4.25 1.5 6.375

32 Auto-welt Auto Welt m/c

6 5 30 6 1.5 9

33 6 5 30 6 1.5 9

34 Back Pocket

Corner Stitch SNLS

Durkopp Adler 0272-

990103-272-140342

4 3 12 4 1.5 6

35 4 3 12 4 1.5 6

36 Welt Back Press Steam Press Macpi 558-00-2058-

00 4.25 3.5 14.875 4.25 1.5 6.375

37 Welt Front Press Steam Press Macpi 558-00-2058-

00 4.25 3.5 14.875 4.25 1.5 6.375

38 Back Pocket Loop

Marking Manual+Template 3.5 3 10.5 3.5 1.5 5.25

39 Back Pocket Loop

Attach SNLS

Durkopp Adler 0272-

990103-272-140342

4 3 12 4 1.5 6

40 4 3 12 4 1.5 6

41 Welt Closing SNLS

Pfaff 1183-8/31-

900/24-909/04-

910/06

4 3 12 4 1.5 6

42

Back Pocket

Pouch Closing SNLS

Durkopp Adler 0271-

990103-271-140342

4 3 12 4 1.5 6

43 4 3 12 4 1.5 6

44 4 3 12 4 1.5 6

45 Welt Pocket

Bartack Bartack

Durkopp Adler 510

Premium 4 3 12 4 1.5 6

46 Back Loop

Bartack Bartack Juki LK-1900HS 4 3 12 4 1.5 6

47 Back Loop Press Steam Press Macpi 558-00-2058-

00 4.25 3.5 14.875 4.25 1.5 6.375

48 Back Loop Stitch SNLS Brother S-7200A-403 4 3 12 4 1.5 6

49 J Fly Zip Attach SNCS w Roller

Feed

Durkopp Adler 0173-

99200 1 AP-173-

142210 AP

4 3 12 4 1.5 6

50 Cut and Gape Zip YKK Zip Cutting

m/c YKK-2CPSB-78000 4 3 12 4 1.5 6

51 Straight Fly Zip

Attach SNLS

Durkopp Adler 0271-

990103-271-140342 4 3 12 4 1.5 6

52 Inseam O/L 5T O/L

Siruba 737 FS-

504M2-04

2.8 2 5.6 2.8 1.5 4.2

53 2.8 2 5.6 2.8 1.5 4.2

54 Sideseam O/L

5T O/L Siruba 737 FS-

504M2-04 2.8 2 5.6 2.8 1.5 4.2

55 Auto 5T O/L 2.8 2 5.6 2.8 1.5 4.2


38 | P a g e

56 Seam Press

Corosel Press 5 5 25 5 1.5 7.5

57 Corosel Press

5 5 25 5 1.5 7.5

58 Front Panel

serging 3T O/L Peagasus 552-134B 2.8 2 5.6 2.8 1.5 4.2

M/C

AREA 860

O/P

AREA 375.625

TROLLEY 1.5 (L) 1.5

(W)

47(no. of

Trolley)

TROLL

EY

AREA

105.75

FUSING M/C 6(L) 5(W)

1(No. of

fusing

m/c)

AREA

(Fusing

M/C)

30


ASSEMBLY LINE

Loading Table 5 4 20 5 2 10

1 W/B Iron Steam Press

Macpi 558-

00-2058-00

4.25 3.5 14.875 4.25 1.5 6.375

2 4.25 3.5 14.875 4.25 1.5 6.375

3 W/B Attachment

Marking

Manual +

Template 3.5 3 10.5 3.5 1.5 5.25

4

Seat Seam Joining

TNCS Hilead GK-

0058-3 4 3 12 4 1.5 6

5 TNCS

Durkopp

Adler 0171-

131110-171-

131110

4 3 12 4 1.5 6

6 Beltloop

Attachment SNLS

Durkopp

Adler 0272-

990009-272-

640642

4 3 12 4 1.5 6

7 4 3 12 4 1.5 6

8

W/B Attachment SNLS w

Differential Feed

Durkopp

Adler 0275-

990013-275-

140342

4 3 12 4 1.5 6

9 4 3 12 4 1.5 6

10 4 3 12 4 1.5 6

11 Left Extention

Lock SNLS

Durkopp

Adler 0272-

990103-271-

140342

4 3 12 4 1.5 6

12 Extention Turn &

Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375

13 Right Extention

Lock SNLS

Durkopp

Adler 0272-

990012-272-

740642

4 3 12 4 1.5 6

14 Rt Extention

Hook Attach

Hook Attaching

m/c

Thomas

Walker T-

4000

3.5 2 7 3.5 1.5 5.25

15 W/B Center Back

Marking

Manual + Wax

marker 3.5 3 10.5 3.5 1.5 5.25

16 Lt Extention Bar

Attach Manual 3.5 3 10.5 3.5 1.5 5.25

17

Front Rise Stitch SNLS

Durkopp

Adler 0272-

990103-272-

140342

4 3 12 4 1.5 6

18 4 3 12 4 1.5 6

19 J Stitch Auto J Stitch

Durkopp

Adler 0271-

992001

6 5 30 6 1.5 9

20 Slider & Brad

Attach

Slider & Brad

Attaching m/c

YKK

FBMST09(S)-

78000

1.5 1.5 2.25 1.5 1.5 2.25

21 W/B Label Attach SNLS

Durkopp

Adler 0271-

990103

4 3 12 4 1.5 6

22 4 3 12 4 1.5 6

23 Wash Care & Size

Label Attach SNLS

Durkopp

Adler 0271-

990103

4 3 12 4 1.5 6


39 | P a g e

24 J Stitch Bar Tack Bartacking m/c

Durkopp

Adler 510

Premium

4 3 12 4 1.5 6

25 Bar tack Front

Pocket Bartacking m/c

Brother KE-

4300C-01 4 3 12 4 1.5 6

26 Seat Seam Press Steam Press Macpi 558-

00-2058-00 4.25 3.5 14.875 4.25 1.5 6.375

27 W/B Button Hole Keyhole Making

m/c

Durkopp

Adler 580

Premium

4 3 12 4 1.5 6

28 Back Pocket

Button Attach

Button Attaching

m/c

Durkopp

Adler 530

Premium

4 3 12 4 1.5 6

29 Inline Inspection

Manual

5 3 15 5 1.5 7.5

30 Manual 5 3 15 5 1.5 7.5

31 Label Fold &

Tack SNLS Pfaff 1183 4 3 12 4 1.5 6

32

W/B Ditch Stitch SNCS Juki MVI-484

4 3 12 4 1.5 6

33 4 3 12 4 1.5 6

34 4 3 12 4 1.5 6

35 W/B Button

Attach

Button Attaching

m/c

Durkopp

Adler 530

Premium

4 3 12 4 1.5 6

36 Ditch Finish SNLS

Durkopp

Adler 0272-

990103

4 3 12 4 1.5 6

37 Belt Loop Down Bartacking m/c

Durkopp

Adler 510

Premium,

Brother KE-

430C-01

4 3 12 4 1.5 6

38 Belt Loop Up

Bartacking m/c Brother LK3-

B430E 4 3 12 4 1.5 6

39 Bartacking m/c Juki Lk-1900 4 3 12 4 1.5 6

40 Bottom Hem O/L 5T O/L Siruba 737

FS-504M2-04 2.8 2 5.6 2.8 1.5 4.2

41 Buttom Blind

Hem

Strobel Blind hem

m/c

Strobel 103-

180 4 3 12 4 1.5 6

42 Button Wrapping Loiva Button

wrapping m/c 4 3 12 4 1.5 6

43

Trimming Trimmer 6 4 24

3 1.5 4.5

44 3 1.5 4.5

45 3 1.5 4.5

46 3 1.5 4.5

47 4 1.5 6

48 4 1.5 6

49 Endline

Inspection (Inside

Out)

Manual 5 3 15 5 1.5 7.5

50 5 3 15 5 1.5 7.5

51 Endline

Inspection

(Straight)

Manual 5 3 15 5 1.5 7.5

52 5 3 15 5 1.5 7.5

M/C

AREA 617.85

O/P AREA 320.95

RACK (8*5) 40 (NO.RACKS) 8 RACK AREA 320


Allowance (150%) 3465.2625


No. Of Trouser Line 5

Total Area for Trouser Sewing Dept. 28877.1875

RACK AREA 320

TOTAL AREA 29197.1875

*ALL MEASUREMENTS ARE

IN TERMS OF FEET/FEET2


40 | P a g e

2. JACKET

COLLAR SECTION

*(ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2 )

S.

NO. OPERATION DESCRIPTION

M/c

Length

M/C

Width M/C Area

Operator

Space(Length)

Operator Space

(Width) Operator Area

COLLAR

1 COLLAR MARKING 5 4

20 5 3

15

2

ZIG-ZAG STITCH TO ATTACH

UPPER COLLAR WITH UNDER

COLLAR

4.5 3.75

16.875

4.5 2.5

11.25

3

PRERULLING STITCH CREASE

LINE OF UNDERCOLLAR 4 3

12 4 1.5

6

4 FUSE COLLAR 4.25 3.5

14.875 4.25 1.5

6.375

5 COLLAR CORNER LOCK 4 3

12 4 1.5

6

6 TURN, POINT & PRESS COLLAR 4.25 3.5

14.875 4.25 1.5

6.375

SLEEVE SECTION

7 SLEEVE CAP FORMATION 4 3

12 4 1.5

6

8

TWO PIECE SLEEVE ATTACH

(SHELL FABRIC) 4 3

12 4 1.5

6

9

INTERLINING SLEEVE

ATTACH 4 3

12 4 1.5

6

10

SHELL SLEEVE SEAM FLAT

PRESS 4.25 3.5

14.875 4.25 1.5

6.375

11 PRESS ELBOW, TURN SLEEVE 4.25 3.5

14.875 4.25 1.5

6.375

12

BUTTON MARKING &

ATTCHING 4.25 3

12.75 4.25 1.5

6.375

13 SLEEVE HEAD FULLNESS 4 3

12 4 1.5

6

FRONT SECTION

14 FRONT MARKING 5 4

20 5 3

15

15 DART MARKING 5 4

20 5 3

15

16 AUTODART 6 5

30 6 3

18

17 FUSE DART 4.25 3.5

14.875 4.25 1.5

6.375

18 CENTRE BACK ATTACH 4 3

12 4 1.5

6

19 SIDE PANEL ATTACH 4 3

12 4 1.5

6

20 SIDE PANEL PRESSING 6 5.25

31.5 6 4

24

21

ARMHOLE TAPE ATT. TO

FRONT & BACK PANEL 4 3

12 4 1.5

6

22

FRONT POCKET FACING

ATTACH 5.5 4.25

23.375 5.5 3.25

17.875

23 FLAP READY 4.5 3.25

14.625 4.5 2.5

11.25

24 FLAP PRESS 4.25 3.5

14.875 4.25 1.5

6.375

25 STAYSTITCH @ FLAP 4 3

12 4 1.5

6

26

BREAST POCKET FOLD AND

PRESS 4.25 3.5

14.875 4.25 1.5

6.375

27

BREAST POCKET FACING

ATTACH TO POCKET BAG 4 3

12 4 1.5

6


41 | P a g e

28

MARK & BREAST WELT

PACKET ATTACH 4 3

12 4 1.5

6

29

BREAST PACKET NOTCH ,

TURN AND PRESS 4.25 3.5

14.875 4.25 1.5

6.375

30 BREAST PKT TOPSTITCH 4.5 3.75

16.875 4.5 1.5

6.75

31

BREAST PKT BAG ATTACH &

CLOSE 4 3

12 4 1.5

6

32

TURN & PRESS PIPED POCKET

& BREAST 4.25 3.5

14.875 4.25 1.5

6.375

33 FRONT PKT WELTING 5.5 4.25

23.375 5.5 3.25

17.875

34 FRONT PKT PRESS 4.25 3.5

14.875 4.25 1.5

6.375

35 FRONT PKT BAG ATTACH 4 3

12 4 1.5

6

36 FRONT PKT BAG CLOSE 4 3

12 4 1.5

6

37 CANVAS READY 4.5 3.75

16.875 4.5 1.75

7.875

38 FELT ATTACH TO CANVAS 5 4.5

22.5 5 2.5

12.5

39

BRIDLE TAPE ATTACH TO

CANVAS 4 3

12 4 1.5

6

40 FUSE CANVAS 4.25 3.5

14.875 4.25 1.5

6.375

41 ATTACH CANVAS 5 4.5

22.5 5 1.75

8.75

42 FRONT BLOCK PRESS 6 5.25

31.5 6 4

24

43 ARMHOLE CANVAS CUT 4 3

12 4 1.5

6

44 SIDE SEAM ATTACH 4 3

12 4 1.5

6

45 SIDE SEAM PRESS 4.25 3.5

14.875 4.25 1.5

6.375

46 SHOULDER PAD ATTACH 5 4.5

22.5 5 1.75

8.75

47 SHOULDER ATTACH 4 3

12 4 1.5

6

48 SHOULDER PRESS 4.5 3.5

15.75 4.5 2

9

49 BOTTOM PRESSING 4.5 3.5

15.75 4.5 1.75

7.875

50 INLINE INSPECTION 5 4

20 5 3

15

BACK & LININING SECTION

51 SEW CENTRE BACK 4 3

12 4 1.5

6

52 SIDE PANEL ATTACH TO BACK 4 3

12 4 1.5

6

53 FACING PIPING 4 3

12 4 1.5

6

54

PRESSING THE FACING

PIPING(EACH SIDE) 4.5 3.5

15.75 4.5 2

9

55 SADDLE STITCH 4.25 3

12.75 4.25 1.5

6.375

56 ATTACH LABEL 4 3

12 4 1.5

6

57

TURN & PRESSINSIDE

POCKETS & FACING 4.5 3.5

15.75 4.5 2

9

58 ATTACHING THE CARE LABEL 4 3

12 4 1.5

6

59 TACKING THE POCKETS 4 3

12 4 1.5

6

60 FINISH RIGHT POCKET LINING 4 3

12 4 1.5

6

61

FINISH LEFT POCKET LINING

(2) 4 3

12 4 1.5

6

62 FINISH LEFT POCKET LINING 4 3

12 4 1.5

6

63 BARTACK 4.5 3.35

15.075 4.5 1.75

7.875

65 SEW SIDE SEAM 4 3

12 4 1.5

6

66 SHOULDER SEW LINING 4 3

12 4 1.5

6

67 COLLAR ATTACH 4 3

12 4 1.5

6

68 PRESS LINING 4.5 3.5

15.75 4.5 2

9


42 | P a g e

69

SIDE PANEL, SIDE &

SHOULDER & SEW LINING TO

UPPER COLLAR

4 3

12

4 1.5

6

70 TAPE ATTACHMENT 4.5 3.5

15.75 4.5 1.75

7.875

ASSEMBLY SECTION

71 LAPEL NOTCH MAKING 4 3

12 4 1.5

6

72 COLLAR & NECK ZIG-ZAG 4.5 3.75

16.875 4.5 1.75

7.875

73 RUNSTITCH FRONT EDGE 4 3

12 4 1.5

6

74 MANUAL CUTTING 5 4

20 5 3

15

75

IRON OPEN FRONT EDGE

SEAM 4.5 3.5

15.75 4.5 2

9

76 BOTTOM & VENT STITCH 4 3

12 4 1.5

6

77 LAPEL PIPING PRESSING 6 5

30 6 3.5

21

78 LAPEL PRESSING 4.5 3.5

15.75 4.5 2

9

79 SLEEVE ATTACH 5 4.5

22.5 5 2

10

80 SLEEVE CAP PRESSING 4.5 3.5

15.75 4.5 2

9

81

BUTTON AND FLOWER

MARKING 5 4

20 5 3

15

82

BUTTON AND FLOWER

MAKING 4.5 3.75

16.875 4.5 1.75

7.875

83 SHOULDER PAD ATTACH 4 3

12 4 1.5

6

84 ARMHOLE BASTING 5 4.5

22.5 5 2

10

85 SLEEVE LINING CLOSE 4 3

12 4 1.5

6

86 TRIMMING 5 4

20 5 3

15

87 END LINE INSPECTION 5 4

20 5 3

15

M/C

AREA 799.95

O/P AREA 437.375

RACK (8*5) NO.RACKS 6 RACK AREA 240


Allowance (150%) 1866.4875

Total Reqired Area 3110.8125

No. Of JACKET LINE 4

Total Area for Jacket Sewing

Dept. 12443.25

RACK AREA 280

TOTAL AREA 12723.25



43 | P a g e

PERSONNEL:

DESIGNATION NO.

SEWING Executive 1

Supervisor (TROUSER) 10

Operator (TROUSER) 560

Helper (TROUSER) 60

Supervisor (JACKET) 4

Operator (JACKET) 344

Helper (JACKET) 40

DATA Entry Operator 2

IE Engineers 2

FURNITURE:


Computer Table 20

Executive Table 1



Storage Rack Dimension (8 * 5) 15

Operator’s Chair Dimension (1.5 * 1.5) 910

MACHINE:


Computer IBM 3


Working Area:


44 | P a g e

The working area will include all the stitching machines, end-line inspection table & other

required equipments. It will also have the storage area wastes. It will also include the space

for the following:

Supervisors’ table

Storage Racks






IE Engineers







SEWING Executive. It will be furnished with an Executive table and computer table. It


MATERIAL HANDLING:

Overhead conveyor is used to transport the stitched garment to the Finishing Section.

Switch-Track is used for pieces movement (TROUSER- assembly section)

E-TONE is used at JACKET sections.

Trolleys are used at preparatory section (TROUSER).


45 | P a g e

FINISHING DEPARTMENT

The finishing department is meant for ironing, folding and packing of the garment the

department will require tables for checking as well as tables for folding and packaging.

Following are the activities.

Ironing

Tags attached

Checking

Folding and Packaging

GENERAL OVERVIEW- AREA & MACHINES REQUIRED

1. TROUSER

FINISHING

Machines Model

No. of

machines M/c Length

M/C

Width M/C Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

Thread Sucker Ramsons

1 4.5 3 13.5 4.5 2 9

Double

legger/ carousel press Macpi

1 5.5 3 16.5 5.5 2 11

Topper Macpi 4 5 3 60 5 2 40

Spotting M/C Macpi 2 5 4 40 5 2 20

Checking tables Ramsons

4 5 3 60 5 2 40

TOTAL M/C AREA 190

TOTAL O/P

AREA 120

Sub Total Space 310


Total Reqired Area 775

No. Of TRS Finishing Line 5

Total Area for Trouser

Finishing Dept. 3875

PACKING

M/C

DISCRIPTION

No. of

M/c M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

Packing Table 5 6 3 90 6 2 60

Storage Box 5 3 2 30


46 | P a g e

Sub Total Space 180



2. JACKET

FINISHING

Name of Operation Machine

No. of

machines

M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

Spot Removing Manual 8 5 4 160 5 2 80

Front & Back Press Macpi 8 5.5 4 176 5.5 2 88

Shoulder Pressing Macpi 8 4 3 96 4 2 64

Sleeve Inseam Press Macpi 8 4 3 96 4 2 64

Sleeve Pressing Indupress 8 5 4 160 5 2 80

Button Marking Manual 4 4 3 48 4 2 32

Button Attach Front Pfaff 4 4 3 48 4 2 32

Inside Button Attach Juki 4 4 3 48 4 2 32

Button Wrapping Loiva 4 3 2 24 3 2 24

Collar Master Indupress 4 5 4 80 5 2 40

Lining Touchup Macpi 4 5 4 80 5 2 40

Final Touchup Manual 4 5 4 80 5 2 40

Elbow Seam Press Macpi 4 5 4 80 5 2 40

Lapel Pressing Macpi 4 5 4 80 5 2 40

Checking Manual 4 5 4 80 5 2 40

Sleeve Label Attach Juki 4 4 3 48 4 2 32

Total M/c Area 1384

Total O/P

Area 768

PACKING

SL.NO

M/C

DISCRIPTION

No. of

M/c M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

1 Packing Table 8 6 4 192 6 2 96

2 Storage Area 4 5 4 80






47 | P a g e

PERSONNEL REQUIREMENT:

OPERATION TIME / GARMENT (sec) TROUSER Thread Sucker 15

Double legger/ carousel press 15

Topper 60

Spotting M/C 30

Checking tables 60

Packing 15

TOTAL 195

JACKET

Spot Removing 60

Front & Back Press 60

Shoulder Pressing 60

Sleeve Inseam Press 30

Sleeve Pressing 30

Button Marking 30

Button Attach Front 30

Inside Button Attach 30

Button Wrapping 30

Collar Master 30

Lining Touchup 30

Final Touchup 30

Elbow Seam Press 30

Lapel Pressing 30

Checking 45

Sleeve Label Attach 30

Packing 80

TOTAL 665

Total Jacket production: 2000 pieces.

So time required for finishing: 2000*665 seconds

= 1230000 seconds

= 369.44 hrs

We have a shift of 8 hrs, with 50% efficiency

So, we require: (370/8)* 2

= 93 operators

Total Trouser production: 5000 pieces.

So time required for finishing: 5000*195 seconds

= 975000 seconds

= 271 hrs


48 | P a g e

We have 5 lines

So, we require: (271/5) hrs

= 54.2 hrs

We have a shift of 8 hrs, with 50% efficiency

So, we require: (54.2/8)* 2

= 14 Operators for a line

= (14*5) = 70 operators

So we have 163 operators for finishing section.

DESIGNATION NO.

FINISHING Executive 1

FINISHING Master 1

Supervisor (TROUSER) 1

Operator (TROUSER) 70

Helper (TROUSER) 10

Supervisor (JACKET) 1

Operator (JACKET) 93

Helper (JACKET) 10


FURNITURE:


Computer Table 4

Executive Table 1



Storage Rack 9



49 | P a g e

EQUIPMENTS:


Computer IBM 4

Spot removing Guns EASTMAN 15


Working Area:

The working area will include all the stitching machines, inspection table & other required

equipments. It will also include the space for the following:


Storage Racks

Steam pipes

Vacuum Pipes







FINISHING Master






FINISHING Executive. It will be furnished with an Executive table and computer table. It



50 | P a g e

FINISHED WAREHOUSE DEPARTMET:

This department stores all the finished orders. Here the orders are stored till they are shipped.

Also the finished goods of a consignment whose production is in process is also stored here.

Following are the various processes:

Cartons are brought in from finishing department

Cartons are stored

Cartons are moved to parking be shipped

Name of Operation Machine

No. of

machines

M/c

Length

M/C

Width

M/C

Area

Operator

Space(Length)

Operator

Space

(Width)

Operator

Area

Metal Detector Metal Detector 2 8 5 80 5 4 40

Carton Storage Area 1 10 10 100

Carton Packing/ Disposal

Area 1 20 15 300

Supervisor Area 1 10 8 80

Total

Area 560

Total Space required for

TRS 7500

Total Space required for

JKT 7500





PERSONNEL:

DESIGNATION NO.

STORE MANAGER 1

Supervisor 1

Operator 2

Helper 10



51 | P a g e

FURNITURE:


Computer Table 3

Executive Table 1





Computer IBM 3

Carton Ticketing machine EASTMAN 5

Flooring Material: Concrete

Working Area:




The total window area must be well equipped in terms of moisture.


It should have a separate, medium sized, cabin for the Office of FINISHING Executive. It

will be furnished with an Executive table and computer table. It should also have 4 extra

chairs along with an executive chair for the officer.



above from the floor. It should have one sided entry and exit.


52 | P a g e

TRAINING DEPARTMENT:

This department trains operators following the purposes

Better Efficiency

Quality Improvement

Defect Reduction

Better material handling

It also provides training programme for new hired operators and new product-type.

GENERAL OVERVIEW- AREA CALCULATION & MACHINE REQUIREMENTS

M/C Make M/C

DISCRIPTION

M/C

LENGTH

M/C WIDTH ARE

A

operator length operator

width

o/p

area

1 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

2 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

3 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

4 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

5 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

6 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

7 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

8 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

9 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6

10 HIGHLEAD S/N LOCK

STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


53 | P a g e


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6

30 PFAFF S/N LOCK

STITCH

4 3 12 4 1.5 6

31 HIGHLEAD O/L 2.8 2 5.6 2.8 1.5 4.2

32 JUKI S/N LOCK

STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6


STITCH

4 3 12 4 1.5 6

TOTAL m/c

SPACE

461.6 total O/p area 232.2



Allowance (150%) 1040.7


PERSONNEL:

DESIGNATION NO.

TRAINING MANAGER 1

Supervisor 1


FURNITURE:


Computer Table 3

Executive Table 1





54 | P a g e

MACHINES:


Computer IBM 3


Working Area:




Data Entry Operator

The total window area must be well equipped in terms of moisture.


It should have a separate, medium sized, cabin for the Office of TRAINING Manager. It will

be furnished with an Executive table and computer table. It should also have 4 extra chairs

along with an executive chair for the officer.



above from the floor. It should have one sided entry and exit.


55 | P a g e

MAINTENANCE DEPARTMENT:

The maintenance room in factory will be allocated around sewing floor as it will be utilizing

maintenance room the most. The maintenance room will consist of about 6 tables (10X4 ft),

part storage area (20X20 ft), small part storage area (4X2.5 ft), which will require almirahs in

walls to store parts and tools, grinding machine (5X4 ft), lathe machine (8X4 ft) which will

require raised platforms to mount machines upon along with some space for wood works and

wood, metal, tools storage.

The total minimum space requirement of the maintenance room is 4835 along with machine

and aisle allowances. The flooring should be concrete cemented and not tiled to provide

better grip and avoid slippage during work, tiles has a demerit of being cracked as the work

operated in maintenance room is with heavy metal equipments and machines, so using tiles

not advisable.

The function of the maintenance room will be-

• To keep all machines in facility in normal working conditions,

• To keep production with minimum machine delays or downtimes

• To ensure availability of all parts and fixtures that may be required to repair in maintenance

room.

Maintenance Department

Table 6 10 4 240

Parts storage area 1 20 20 400

small parts storage box 20 4 2.5 200

Grinding machine 2 5 4 40

Lathe Machine 2 8 4 64

Wood work Space 1 20 20 400

Wood & metal storage area 1 25 20 500

Tool box 20 3 1.5 90

TOTAL 1934


PERSONNEL:

DESIGNATION NO.

MAINTENACE MANAGER 1

MAINTENACE ENGINEER 2

MAINTENACE WORKER 10


56 | P a g e

FURNITURE:


Computer Table 3

Executive Table 1


MACHINES:


Computer IBM 3



57 | P a g e

UTILITY DEPARTMENT:

Generators placed upon raised concrete platform and under shed outside factory building,

placed according to nearness with electric supply boards for different buildings.

Transformers placed upon raised platform too and near to generators or according to

requirement of the industry.

GENERAL OVERVIEW- AREA CALCULATION

UTILITY

SL.N

O

M/C Make Machine Model

No

M/C

DISCRIPTION

NO. of

M/C

M/C

Length

M/C Width M/C Area

1 CATTER PILLER

500KVA

3412 DICTTA Generator 4 12 8 384

2 KESER CSD102T COMPRESSOR 4 5 3 60

3 KPRS KPRS Transformer 2 6 6 72

4 Fork Lift VYOMA Lift 1 8 6 48

5 AUTOMATIC

ELECTRIC

FT265M STABILAZER 2 4 3 24

6 THERMAX CPD 50/10.54 5 TON BOILER 2 20 20 800

7 ELGI ELGI AIR

COMPRESSOR

2 5 3 30

8 BLUE STAR BLUE STAR WATER

COOLER

10 4 3 120

9 AMBASSADOR AMBASSADOR AIR COOLER 16 3 2 96

10 AMBASSADOR AMBASSADOR EXHAST FAN 20 3 2 120

11 LG LG AIR

CONDITIONER

39 2.5 1.5 146.25

12 HAFFMAN VACCUM 7 3 2 42

13 FORESIGHT 20KVA UPS 9 5 4 180

14 DUEX DPS24000 DEHUMIDIFIE

R

7 3 2 42

TOTAL 2164.25


PERSONNEL:

DESIGNATION NO.

UTILTY MANAGER 1

UTILITY ENGINEER 1

WORKER 5


58 | P a g e

FURNITURES:


Computer Table 2

Executive Table 1


MACHINES:


Computer IBM 2



59 | P a g e

ADMINISTRATION BLOCKS


60 | P a g e

GENERAL OVERVIEW

Department Dimensions No Area

General Manager 15*20 1 300

DGM 15*20 1 300

Factory manager 15*15 1 225

Department Manager 15*10 9 1350

Merchandising

Cubics 8*8 6 384

Design room 30*20 1 600

Sourcing

Cubics 8*8 5 320

IE department

Cubics 8*8 10 640

Quality Assurance 30*20 1 600

Finance

Cubics 8*8 5 320

Purchase

Cubics 8*8 5 320

HR department

Cubics 8*8 10 640

Counselling Room 10*8 1 80

Stationery Storage

Area 20*20 1 400

Board Room 25*15 1 375

Conference hall 30*20 2 1200

Guest Room 25*20 1 500

Reception 25*20 1 500

Crèche 30*20 1 600

Medical room 25*15 1 375

Documentation dept

Cubics 8*8 6 384

IT DEPARTMENT

Cubics 8*8 8 512

Server 3*3 10 90

PPC

Cubics 8*8 6 384

File store room 15*12 1 180

TOTAL SPACE 11579


61 | P a g e


Allowance (150%) 17368.5


PPC DEPARTMENT:

This department serves the purpose of production planning & following-up the production

targets:

PERSONNEL:

DESIGNATION NO.

HEAD 1

ANALYST 2

FOLLOW-UP OFFICERS 3

FURNITURE:


Computer Table 5

Executive Table 5


MACHINES:


Computer IBM 5

Flooring: Tiles.

The section is partitioned into cubic with wooden structure.


62 | P a g e

HR DEPARTMENT:

It serves all the purpose of HR activities.

PERSONNEL:

DESIGNATION NO.

HEAD 1

OFFICERS 9

It should also have the space for conference room.

CONFRENCE/ COUNSCELLING ROOM:

It should be equipped with a conference table & 6 executive tables. It should also have the

space for projection on the wall.

FURNITURE:


Computer Table 10

Executive Table 10

CONFRENCE Table Dimension (6 *4)

1


MACHINES:


Computer IBM 10

Flooring: Tiles.



63 | P a g e

MARKETING AND MERCHANDISING DEPARTMENT:

This department caters to the marketing and sourcing of the product and its components. The

marketing and merchandising departments also requires a list of workstations and cabins for

officers and managers. Following are the list of activities that are carried out in this

department.

Material Planning

Initial Costing

Purchase Orders

Sample development

Approval/Rejection

PERSONNEL:

DESIGNATION NO.

HEAD 1

ANALYST 2

FOLLOW-UP OFFICERS 3

FURNITURE:


Computer Table 5

Executive Table 5


MACHINES:


Computer IBM 5

Flooring: Tiles.



64 | P a g e

FINNANCE DEPARTMENT:

It serves all the financial activities of the organisation, like year budgeting.

PERSONNEL:

DESIGNATION NO.

HEAD 1

OFFICERS 4

MACHINES:


Computer IBM 5

FURNITURES:


Computer Table 5

Executive Table 1


Flooring: Tiles.



65 | P a g e

PURCHASE DEPARTMENT:

This department is responsible for the purchasing activities and all other related activities.

PERSONNEL:

DESIGNATION NO.

HEAD 1

OFFICERS 4

MACHINES:


Computer IBM 5

FURNITURE:


Computer Table 5

Executive Table 5


Flooring: Tiles.


OFFICES OF DIFFERENT MANAGERS:

The cabin/ offices of GM, DGM, Factory Manager & other Department Heads should have

an executive table, computer table and executive chair. It should have 4 spare chairs in front

of the table. It should also have file storage rack. It should also have all the equipments

required for executive need.

FLOORING: TILES


66 | P a g e

IE DEPARTMENT:

It serves the following purposes

Calculation of machine requirement for an order

Thread consumption calculation.

Operation Breakdown

Line Balancing

It should have separate cubic for different personnel equipped with computer table. The head

of department should have an executive table also.

It should also have display board for targets.

FLOORING: TILES

IT DEPARTMENT:

It serves the purposes of IT needs of the organisation. Main activities are following:

Connectivity between different departments

Up gradation of software used by organisation.

Training programme for new software & technology.

It should have separate cubic for different personnel equipped with computer table. The head

of department should have an executive table also.

It should also have display board for targets.

FLOORING: TILES

BOARD ROOM:

It is used for the meetings of board members of organisation. It should have a display for

projection of presentations. It should be equipped with a large size table, placed at centre of

room, & executive chairs, around the table, for the board members to attend the meeting.

FLOORING: TILES

CONFERENCE HALL:

It is used for the conferences/ discussions at organisation. It should have a display for

projection of presentations. It should be equipped with a medium size table, placed at front of

room, & chairs for the employees to attend the meeting.

FLOORING: TILES


67 | P a g e

SAFETY DEPARTMENT/ MEDICAL ROOM

The department caters to the maintenance of safety assets of the organization:

Installation and maintenance of fire extinguishers

First aid Kit installation and Maintenance

Personnel

Designation Number

Nurse 1

Furniture Number Description Dimension (ft)

Bed 2 5*6

Stretcher 1 3*7

Furniture


Chair 1 1.5*1.5

FLOORING: TILES

GUEST ROOM:

It should be furnished with bed, a lamp table, sofa set, table, and computer desk. It should

also have an attached bathroom. It should have a large size window.

FLOORING: Tiles

DESIGN STUDIO:

It should have 3-4 display boards on the wall. It should be equipped with 4 computer table

and an executive table for head designer. It should also have a mid size table for working.

FLOORING: Tiles


68 | P a g e

RECEPTION:

Reception is where all the people, buyers, contractors etc will be received when they visit.

Reception

Designation Number Description Area (sqft)

Receptionist 1 60

Visitor's Lobby 150

Machine

Machine Number Description Dimension (ft)

Computer 1 IBM 3*5

Furniture


Computer table 1 IBM 3*5

Tables 1 4*4

Sofa 3 4*6

Chairs 5 1.5*1.5

FLOORING: TILES


69 | P a g e

OTHER SUPPORTING DEPARTMENTS & STRUCTURES:

1. PARKING:

Here all the vehicles of both operators and officials will be parked. Also parking is the place

where the trucks and other vehicles for transport will be received. This will also be taken care

by security department who will see to it from the entrance gate that rules are abided by

people. Operators will be allowed to park cycles only.

Parking area: 3030sqft

PARKING SPACE

Total No. Length Width Area

Loading Truck

Area

4 15 6 360

Oficial Car Area 50 6 4 1200

Bike/ Cycle Area 200 4 1.5 1200

Bus Parking Area 3 15 6 270

TOTAL 3030

Assumption

O/P

Level Male Female

Sewing 1200 60 1140

Toilets 2 for 50 female

worker cutting 120 36 84

2 for 50 male worker

finishing 100 30 70

1 for every next

50

warehouse 15 10 5

Mntc 20 15 5

Urinals 2 for 50 worker Store 30 20 10

1 for 50 worker

Utility 15 12 3

1 for every next

50

Total 1500 183 1317

Toilet Requirements 32 5 27

Washing Place – 1 for every 20

person

Washing Place 31 5 26

1 for next 15

EXE LEVEL

1 for next 15

Office 100 50 50

1 for next

100 Toilet Requirments 4 2 2

1 for next 5o Washing Place 6 3 3

Canteen Assumption

1/3 of people sit at a time

Total 1550

1/3 of people 517


70 | P a g e

Table Dimension 6*4

No. of People at a

table 6

No. of table needed 87

TOILET


operator 32 6 4 768

exec 4 8 6 192

TOTAL 960

WASHING


operator 31 2 2 124

exec 6 2.5 2 30

TOTAL 154

Canteen


Table 87 6 4 2088

Chair 517 2 2 2068

Counter 2 8 3 48

Kitchen 1 25 20 500

Storage 1 10 10 100

Washing Place 12 2 2 48

TOTAL 4852

REST ROOM


Male 1 25 10 250

Female 1 50 20 1000

TOTAL 1250

CLOAK ROOM


1 30 10 300

TOTAL 300


71 | P a g e

2. CANTEEN

Canteen is common for all but there will be different timings for operators and officials.

Meals will only be offered to officials. Operators will be offered lunch, snacks and tea at

subsidized cost.

PERSONNEL

Designation Number

Canteen Supervisor 1

Cooking room 1

Cooks 4

Helpers 10

SECURITY DEPARTMENT:

This department comes under administration. Following are the various requirements:

Security cabins

Parking Maintenance

Security Department

Personnel

Designation Number Description Area (sqft)

Security Head 1 200(at gate)

Security Guards 8

Machine

Machine Number Description Dimension (ft)

Computer 1 IBM 3*5

Furniture


Computer table 4 IBM 3*5

Stool 7 1*1


72 | P a g e

3. TOILET:

FLORING: TILES

It should be finished in a way that it will not support the water to stay at floor. The height of

urinals must be according to average heights of Indian population. It should be equipped with

latest technology.


73 | P a g e

ANNEXURE:

AREA CALCULATIONS:

1. SPREADING & CUTTING

JACKETS

Daily production= 2000pcs

Avg. consumption of fabric for jacket= 2.8 mtrs

Buffer for cutting section= 3%

So total pcs. required to be cut= 2000 + (2000*3)/100

= 2000 + 60

= 2060

So total fabric required to be spread & cut for a day= (2.8*2060)

=5768 mtrs

~5800 mtrs

Automatic spreading & cutting:

(Maximum speed of pull off machine, Blue Jay™ Spread & End Cutting System= 60

mtrs.)

Let assume the efficiency of machine= 60%

Then operating speed of machine= 36 mtrs/ minutes.

Customized length of Pull= 6.00 mtrs

So for better efficiency we spread the ply of length= 5.72(2% considered as end loss+ 6mm

end cutting tolerance)

Time taken to spread 1 ply= 0.16 minutes

Time taken to cut the end of ply= 0. minutes

So, total time to spread 1 ply= (0.16* 2+ 0.1) = 0.33 minutes

Avg. no plies in a lay= 30 plies

Total time to spread a lay= 30*0.33~ 10.0 minutes

Avg SMV of cutting for a garment= 3 seconds

Total time required for cutting= (60* 3) = 180 seconds= 3.0 minutes


74 | P a g e

Total time for spreading & cutting a lay= 13.0 minutes

Allowances= 7 minutes

Avg. time for spreading & cutting a lay= 13.0+7.0= 20 minutes

Hence, for a day we need= 35 lays

For automatic spreading & cutting we need 2 automatic CNC cutters (conveyor system)

with 50 feet length.

With these two CNC, we are able to spread

480/20=24*2=48 lays

(480 minutes= total available time for a day,

20 minutes= time taken to spread & cut a lay)

Manual Spreading (Lining):

For better efficiency we spread the ply of length= 5.72 mts (2% considered as end loss+ 6mm


(2 Way Marker)

In a lay we spread 60 plies

Time taken to spread & cut the end of the ply= 1 minutes

Time taken to spread a lay= 60 minutes

Cutting SMV of a garment=15 sec

Total time required to cut 60 plies= 1800 seconds= 30 minutes

Time required to spread & cut a lay= 90 minutes


Total time for a lay= 96 minutes

Required Lay=2060/120= 17.16 ~ 17

We have 480 minutes.

Lay spreaded in 480 minutes= 480/96=5 lays

So we need 4 manual spreading tables.

Pinning table-


75 | P a g e

It is assumed that 20% of orders are of striped formal jackets so we should have 2 pinning

tables for spreading the shell & lining of the striped formal jackets.

It is assumed that 0.25 meter interlining (fusing) is consumed per garment

It is assumed that fusing marker is 22 way

The length of marker= 5.5 meters

The length of a ply= 5.5+0.16=5.7(2% considered as end loss+ 6mm end cutting tolerance)

It is assumed that a ply takes 2 minutes to be spread.

There are 30 plies in a lay


Cutting SMV of a garment fusing =5 sec



Allowances= 7 minutes.


Total lays to be spread= 2060/ (22*30) = 3.12 lays

Time required to lay 3.12 lays= 296.52 minutes= 5 hrs

We require 1 manual spreading/ pinning table for this.

And we should have 1 extra spreading/pinning table. (as recutting table)

INSPECTION

Inspection SMV of a garment= 15 sec

Inspection time for 60 garments= 900 seconds= 15minutes


Total time to inspect 60 garments= 22 minutes

(Total time taken to inspect 2060 garments= 755.33 minutes)

We have 5 cut parts inspector with 60% efficiency

Work content in 1 hr= (60*0.6)*5

= 180 minutes


76 | P a g e

So total time required to inspect 2060 garments= 4.2 hrs

Time taken to inspect a fused collar= 3 sec

Total time taken for inspection of 2060 fused collar=6180 seconds= 103 minutes= 1.72 hrs

We have 1 inspector for this task of capacity 60% efficiency

Work content in 1 hrs= (60*0.6) =36 minutes= 0.6 hrs

Total time required for inspection= 1.72/0.6= 2.87 hrs

Space required for a inspector= 32 sq feet

Space required for 6 inspectors= 192 sq feet

Table dimensions= 12 feet* 8 feet= 96 sq feet

Total table required= 192/96 = 2 tables

TICKETING & BUNDLING

The parts ticketed and bundled for the preparatory line

Ticketing & bundling SMV of a jacket= 150 seconds

Total time to ticket & bundle 2060 garment parts= 309000 seconds

= 5150 minutes

Let assume that we have 20 ticketing & bundling operators having efficiency of 60%

Now with 60% efficiency,


= 720 minutes.

Total time required to finish the work= 5150/720

= 7.15 hrs

Total space required for a ticketer = 10 sq feet

Total space required for 20 operators= 10* 20= 200 sq feet




77 | P a g e

TROUSERS

Daily production= 5000pcs

Avg. consumption of fabric for jacket= 1.4 mtrs

Buffer for cutting section= 3%

So total pcs. required to be cut= 5000 + (5000*3)/100

= 5000 + 150

= 5150

So total fabric required to be spread & cut for a day= (1.4*5150)

= 7210 mtrs

Automatic spreading & cutting:

(Maximum speed of pull off machine, Blue Jay™ Spread & End Cutting System= 60

mtrs.)

Let assume the efficiency of machine= 60%

Then operating speed of machine= 36 mtrs/ minutes.

Customized length of Pull= 6.00 mtrs

So for better efficiency we spread the ply of length= 5.72(2% considered as end loss+ 6mm

end cutting tolerance) (4 way marker)

Time taken to spread 1 ply= 0.16 minutes

Time taken to cut the end of ply= 0.1 minutes

So, total time to spread 1 ply= (0.16* 2+ 0.1) = 0.33 minutes

Avg. no plies in a lay= 30 plies

Total time to spread a lay= 30*0.33~ 10.0 minutes

Avg SMV of cutting for a garment= 1.5 seconds

Total time required for cutting= (120* 1.5) = 180 seconds= 3.0 minutes

Total time for spreading & cutting a lay= 13.0 minutes


Avg. time for spreading & cutting a lay= 13.0+7.0= 20 minutes


78 | P a g e

Hence, for a day we need= 42 lays

For automatic spreading & cutting we need 1 automatic CNC cutters (conveyor system)

with 50 feet length.

With this CNC, we are able to spread

480/20=24 lays

(480 minutes= total available time for a day,

20 minutes= time taken to spread & cut a lay)

Manual Spreading (Lining):

For better efficiency we spread the ply of length= 5.72 mts (2% considered as end loss+ 6mm


In a lay we spread 60 plies

Time taken to spread & cut the end of the ply= 1.3 minutes


Cutting SMV of a garment= 16sec





Required Lay=2650/240= 11

We have 480 minutes.

Lay spreaded in 480 minutes at a table = 480/150= 3.2 lays

So we need 4 manual spreading tables.

Pinning table-

It is assumed that 20% of orders are of striped trousers so we should have 2 pinning tables

for spreading of the striped trousers.

It is assumed that 0.25 meter fusing is consumed per garment

It is assumed that fusing marker is 22 way


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The length of marker= 5.5 meters

The length of a ply= 5.5+0.16=5.7(2% considered as end loss+ 6mm end cutting tolerance)

It is assumed that a ply takes 2 minutes to be spread.

There are 30 plies in a lay


Cutting SMV of a garment fusing =5 sec



Allowances= 7 minutes.


Total lays to be spread= 5150/ (22*30) = 7.8 lays

Time required to lay 4 lays= 296.52 minutes= 5 hrs

We require 2 manual spreading/ pinning table for this.

INSPECTION

Inspection SMV of a garment= 7.5 sec

Inspection time for 120 garments= 900 seconds= 15 minutes


Total time to inspect 120 garments= 20 minutes

(Total time taken to inspect 5150 garments= (5150/120)*20= 858.33 minutes)

We have 5 cut parts inspector with 60% efficiency


= 180 minutes

So total time required to inspect 5150 garments= 858.33/180= 4.77 hrs

Time taken to inspect a fused part= 1.2 sec

Total time taken for inspection of 5650 fused part=6780 seconds= 113 minutes= 1.88 hrs

We have 1 inspector for this task of capacity 60% efficiency


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Work content in 1 hrs= (60*0.6) =36 minutes= 0.6 hrs

Total time required for inspection= 1.88/0.6= 3.13 hrs

Space required for a inspector= 32 sq feet

Space required for 6 inspectors= 192 sq feet



TICKETING & BUNDLING

The parts ticketed and bundled for the preparatory line

Ticketing & bundling SMV of a jacket= 60 seconds

Total time to ticket & bundle 5150 garment parts= 309000 seconds

= 5150 minutes

Let assume that we have 20 ticketing & bundling operators having efficiency of 60%

Now with 60% efficiency,


= 720 minutes.

Total time required to finish the work= 5150/720

= 7.15 hrs

Total space required for a ticketer = 10 sq feet

Total space required for 20 operators= 10* 20= 200 sq feet



REMARKS

And we should have 2 extra spreading/pinning table (as 1 recutting table for jacket & 1

recutting table for jacket).


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2. SAMPLING DEPARTMENT:

JACKET

SAM 71.51

pitch time 71.51/116 0.616465517

per day production 779

Actual 500

efficiency 64.22 ~ 64

the sampling section is to be placed near the production line and the m/c of production floor (which are

not present in sampling dept) will be used by SAMPLING Dept.

10% allowance

PRODUCTION

REQUIRED 100 JKT

ACTUAL

TIME

46.9% to be

incorporated

FOR

100

JKT

NO.

OF

M/C ACTUAL

SNLS 21.34 33.35 52.32 5231.83 10.90 5

ZIGZAG 2.34 3.66 5.74 573.67 1.20 1

BASTING m/c 1.81 2.83 4.45 444.59 0.93 1

Bartack 0.85 1.33 2.09 209.39 0.44 1

Sddle Stitch 0.85 1.33 2.08 208.43 0.43 1

SNLS (Drop Feed) 8.72 13.62 21.37 2136.90 4.45 1

Corosel Press 2.06 3.21 5.04 503.87 1.05 1

Steam press 3.35 5.23 8.20 820.34 1.71 1

Sleeve Attach 3.34 5.22 8.19 819.39 1.71 2

other m/c 5.77 9.02

other manual activity 17.5 27.34

total of other m/c,

manual, trimming,

inspection 36.36

SAM 77.51

% of SAM 46.91

TROUSER

The sampling section is to be placed near the production line and the m/c of production floor (which

are not present in sampling dept) will be used by SAMPLING Dept.

10% allowance

PRODUCTION

REQUIRED 100 TRS

ACTUAL

TIME

43% to be

incorporated

FOR

100

TRS

NO.

OF

M/C ACTUAL

SNLS 8.95 15.43 23.61 2361.08 4.92 5

3 OL 0.55 0.94 1.44 143.79 0.30 1

5 OL 2.05 3.53 5.40 540.03 1.13 1


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Bartack 1.35 2.33 3.56 356.49 0.74 1

TNCS 1.47 2.53 3.87 387.02 0.81 1

SNLS (Diif Feed) 1.51 2.61 3.99 398.59 0.83 1

Corosel Press 0.98 1.69 2.58 258.41 0.54 1

Steam press 1.73 2.99 4.57 457.22 0.95 1

other m/c 2.09 3.61

other manual activity 1.99 3.43

trimming 2.04 3.52

inspection 1.34 2.31

total of other m/c,

manual, trimming,

inspection 12.86

SAM 29.61

% of SAM 43.43717995

Efficiency= 58%

SAM 29.61

pitch time 29.61/106 0.28

per day production 1714

Actual 1000

efficiency 58%

3. STORAGE AREA:

JACKET STORAGE

Assumption

Inventory for 31 Days

Aisle Space between 2 racks = 3m = 10ft(approx.)

Main Aisle = 13 feet

Roof Height = 8 mts

Total Yardage = 120 mts

Roll Data

Roll Diameter = 7 inches

Roll Height = 62 inches

Roll Weight = 25 Kg

Fabric Storage Area Calculation without Palletisation

Average Fabric Consumption = 2.8 mts

Total Production per Day = 2000 Jackets

Total Fabric required per day = 2000*2.8 = 5600 mts

Total Yardage of Fabric for 31 Days inventory = 5600 * 31 = 173,600 mts


83 | P a g e

So, Total no. of Rolls = 173,600/120 = 1,445 Rolls (approx.)

Total Roof Height = 8 mts = 315 inches

Ground Clearance = 6 inches

Roof Clearance = 1 feet = 12 inches

Now in the single block of a rack, 21 Rolls will be stored (7*3)

Margins left after the roll storage = 3 inches on top and side

So, Length = 52 inches

Height = 24 inches

Depth = 62 inches

Rail Girdles on all sides = 3 inches

30”

58”

So, Total Blocks required = 1,445/21

= 69

So in 1 column we will have 4 blocks,

Hence we need to have 18 columns (approx.)

Area covered by 1 column = (58*30) = (23 feet *12 feet) = 276 Sq.ft

Area covered by 18 columns = (18*276) = 4968 sq.ft

For the lining we have almost same consumption of fabric, this implies that we need same

space for the lining storage.

So now we require total 9936 sq feet for total fabric storage (lining + shell fabric).

JACKET INSPECTION:

Daily consumption of fabric= (2.8 *2*2060) = 11536 mtrs

20% inspection is required.

2307 mtrs are required to be inspected.

It is assumed that speed of inspection machine 10 m/min.

So we need 231 minutes to inspect the machine.

52 "

52”

24”


84 | P a g e

Now, considering the 50% allowances for the inspection, now the work content is 346.5

minutes.

We have 480 minutes for working.

So we need only 1 inspection machine.

TROUSER STORAGE

Assumption

Inventory for 31 Days

Aisle Space between 2 racks = 3m = 10ft(approx.)

Main Aisle = 13 feet

Roof Height = 8 mts

Total Yardage = 120 mts

Roll Data

Roll Diameter = 7 inches

Roll Height = 62 inches

Roll Weight = 25 Kg

Fabric Storage Area Calculation without Palletisation

Average Fabric Consumption = 1.4 mts

Total Production per Day = 5000 Trousers

Total Fabric required per day = 5000*1.4 = 7,000 mts

Total Yardage of Fabric for 31 Days inventory = 7000 * 31 = 217,000 mts

So, Total no. of Rolls = 217,000 /120 = 1808 Rolls (approx.)

Total Roof Height = 8 mts = 315 inches

Ground Clearance = 6 inches

Roof Clearance = 1 feet = 12 inches

Now in the single block of a rack, 21 Rolls will be stored (7*3)

Margins left after the roll storage = 3 inches on top and side

So, Length = 52 inches

Height = 24 inches

Depth = 62 inches

Rail Girdles on all sides = 3 inches

30”

52 "

52”

24”


85 | P a g e

58”

So, Total Blocks required = 1808/21

= 86

So in 1 column we will have 4 blocks,

Hence we need to have 22 columns (approx.)

Area covered by 1 column = (58*30) = (23 feet *12 feet) = 276 Sq.ft

Area covered by 22 columns = (22*276) = 6072 sq.ft

TROUSER INSPECTION:

Daily consumption of fabric= (1.4 *5150) = 7210 mtrs

20% inspection is required.

1442 mtrs are required to be inspected.

It is assumed that speed of inspection machine 10 m/min.

So we need 145 minutes to inspect the machine.

Now, considering the 50% allowances for the inspection, now the work content is 217.5

minutes.

We have 480 minutes for working.

So we need only 1 inspection machine.

Total inspection machine needed= 2 (each for JKT & TRS)

INSPECTION MACHINE SPACE

Dimension of inspection machine:

6.67* 5.55

Area= 37.02 sq feet

Area required for two inspection machine= 72.04 sq feet.

Operator space= 6.67*2*2=26.68 sq feet

TOTAL SPACE FOR FABRIC STORAGE:

4968(JKT shell) + 4968 (JKT lining) + 6072 (TRS fabric) + 72.04 (Inspection M/c) + 26.68

(O/p space) = 16106.72 sq feet

~ 16107 sq feet


86 | P a g e

DEPARTMENTAL AREA CALCULATION

DEPARTMENT AREA

FABRIC STORAGE 11040

TRIM STORAGE 9981.005304

PM & CAD 1460

SAMPLING 1374.5

SPREADING & CUTTING 18695

TRS SEWING 28877.1875

JKT SEWING 58324

TRS FINISHING 3875

JKT FINISHING & PACKING 6300

TRS PACKING 450

WAREHOUSE 39000

MAINTENANCE & UTILITY 10245.625

ADMIN 28947.5

TRAINING 1734.5

CANTEEN, TOILET & MISC 19190.5

TOTAL 239494.8178


87 | P a g e

4. LIGHT CALCULATION

FABRIC STORAGE

(Fluorescent tubes 40 watts) is used for Calculation

Coefficient of utilization (CU) = “coefficient of utilization” is 50% = 0.5

Depreciation factor (DF) =0.91 (as per GE Standard)

Efficiency of tube light (40W tube light) = 3200 lumen

16107 Sq.ft = (16107/13) sq.mt = 1239 sq.mt

Lux required = Illumination *area

= 300 *1239

= 371,700Lux

Lux to be produced = Lux required/CU*DF

= 371,700 /0.91*0.5

=371,700 /0.455

=816,923

No. of Lamps Required = Lux to be produced/lamp watt

= 255 lamps

TRIM STORAGE


Depreciation factor (DF) = 0.91 (as per GE Standard)

Efficiency of tube light (40W tube light) = 3200 lumen(approx)

9981 Sq.ft = 768 sq.mt


= 300 *768

= 230,400 Lux


= 230,400 /0.91*0.5

=230,400 /0.455

=506,374


= 158 lamps

PM & CAD




1218Sq.ft = 94 sq.mt


= 500 *94

= 47,000 Lux


88 | P a g e


= 47,000 /0.91*0.5

=47,000 /0.455

=103,297


= 32 lamps

SAMPLING




1218Sq.ft = 94 sq.mt


= 500 *94

= 47,000 Lux


= 47,000 /0.91*0.5

=47,000 /0.455

=103,297


= 32 lamps

SPREADING & CUTTING





= 750 *1674

= 1255673 Lux


= 1255673/0.91*0.5

=1255673/0.455

=2759721


= 862 lamps

TROUSER SEWING




28877Sq.ft= 2221 sq.mt


= 500 *2221

= 1110654 Lux



89 | P a g e

= 1110654/0.91*0.5

=1110654/0.455

=2440997


= 10 lamps

JACKET SEWING




19429Sq.ft= 1495 sq.mt


= 500 *1495

= 747269 Lux


= 747269/0.91*0.5

=747269/0.455

=1642350


= 513 lamps

TROUSERS FINISHING




3875Sq.ft= 298 sq.mt


= 500 *298

= 149038 Lux


= 149038/0.91*0.5

=149038/0.455

=327557


= 102 lamps

JACKET FINISHING & PACKING






= 500 *485

= 242308 Lux



90 | P a g e

= 242308/0.91*0.5

=242308/0.455

=532544


= 166 lamps

TROSERS PACKING




450Sq.ft= 35 sq.mt


= 300 *35

= 10385 Lux


= 10385/0.91*0.5

=10385/0.455

=22823


= 8 lamps

WAREHOUSE




39000Sq.ft= 3000 sq.mt


= 300 *3000

= 9, 00,000 Lux


= 9, 00,000 /0.91*0.5

=9, 00,000 /0.455

=1978022


= 618 lamps

MAINTENANCE & UTILITY




10245Sq.ft= 788 sq.mt


= 500 *788

= 394038 Lux


91 | P a g e


= 394038/0.91*0.5

=394038/0.455

=866019


= 271 lamps

ADMIN




28947Sq.ft= 2227 sq.mt


= 500 *2227

= 1113347 Lux


= 1113347/0.91*0.5

=1113347/0.455

=2446915


= 765 lamps


92 | P a g e

TRAINING



Efficiency of tube light = 80 lumens per watt



= 500 *133

= 66692 Lux


= 66692/0.91*0.5

=66692/0.455

=146576


= 46 lamps

CANTEEN, TOILET & MISC




19190Sq.ft= 1476 sq.mt


= 300 *1476

= 442846 Lux


= 66692/0.91*0.5

=66692/0.455

=973288


= 304 lamps

Date post:	13-Apr-2017
Category:	Business
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