PLANT LAYOUT

SUBMITTED TO: SUBMITTED BY:

Mr. Pavan Godiawala TAMANNA

M.FTECH 2010-12

1

FACTORY LAYOUT

1. GROUND FLOOR

a. Raw material storage department

b. Cutting department

c. Sampling department

d. Warehouse

e. Operator Canteen

f. Maintenance department

g. Boiler room

h. Training department, utility room, medical room, executive parking, labour parking

2. FIRST FLOORa. Director Cabinb. Administrative department & H.R departmentc. Production floord. Conference Roome. I.E. Departmentf. Q.A. Departmentg. Compliance departmenth. Display Roomi. Finishing departmentj. Staff Canteen

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WORKING IN AN INDUSTRY

3

BUYER

PRODUCT DEVELOPER

RESEARCH & DEVELOPMENT

SPREADING

PACKING & FINISHING

SAMPLING

MERCHANT

PRODUCTION

TESTING

FABRIC

MARKER PLANNING

FINISHING & PRESSING

WASHING

BUNDLING & TICKETING

CUTTING

PRODUCT DEVEVELOPEMENT

PROCESS FLOW OF INTERNAL DESIGNING

MOCK OR SAMPLES WILL BE PREPARED FOR SELECTION

IF SELECTED THEN MEETING SAMPLES WILL BE MADE

COSTING AND NEGOTIATIONS

SALESMAN SAMPLE

GRADING

ORDER CONFIRMATION

FURTHER TO PD IT PASSED TO MERCHANDISING DEPT

4

EXTERNAL DESIGNING

LINE ADOPTION WITH BASIC DETAILS

SAMPLES WILL BE MADE (2 Pcs)

APPROVAL/COMMENTS

BUYER SENTS A TECH PACK

THEN AGAIN PROTO SAMPLE MADE (3 Pcs)

FIT SAMPLES MADE (3 Pcs)

APPROVAL/COMMENTS

BUYER WILL SENT FIT SAMPLE SPECIFICATIONS

SIZE SET ARE MADE

APPROVAL

REVISE FIT OR SEALER SAMPLE IS MADE

ORDER CONFIRMATION

5

MERCHANDISING

PROCESS FLOW OF MERCHANDISING DEPARTMENT

6

Start

Obtain tech pack from buyer

Sampling

Analyze fabric consumption from CAD

Analyze cost of trims and fabric

Obtain general sewing data from IED

Prepare cost sheet from sample

Develop sample as per the tech pack

Develop proto sample

Cost sheet & sample sent to buyer for approval

Approval

Cost sheet reworked

Confirmation of order

Obtain PCD & details from production unit

Source trims & fabric from

concerned dept.

Book washing & embroidery capacity if required

Obtain GSD from IED

Execution of order by entering details in ERP

Prepare sample as per buyer requirements

Forward the sample to buyer for approval

Approval

Comments received from buyer should be incorporated and fit sample reworked

Hold pre production meeting with the production unit

Execute bulk order

Costing

Follow up with production departments & update the buyer

Submit required documents to documentation dept

Offer garments for final inspection. Truck out

Follow up on the payments for goods

End

NoYes

NoYes

7

SAMPLING

STEPS OF SAMPLING:

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PROTO TYPE SAMPLE MADE

FIT SAMPLE MADE

PP SAMPLE MADE

TOP SAMPLE MADESIZE SET MADESHIPPMENT SAMPLE MADE

FABRIC SOURCING

Fabric requisition from merchandiser

Order placed

Fabric receive invoice/challan

Unloading after checking

9

Tally with supplier invoice for quantity

Send bill to gate for entry

Receive fabric in store

Forward fabric for inspection

Inspection report sends to the concern merchant or sourcing dept.

After comments reentry in the system with final comments if rejected or accepted

If accepted

Relocation in store

Issue against job order

FLOW FOR ORDER PROCESSING

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RECEIVE PO FROM MERCHANDISER

PREPARE A FABRIC REQUISITION

RAISE THE REQUISITION TO VENDORS

RECEIVE SHADE APPROVAL

SEND GOODS FOR DYEING

RECEIVE DYED GOODS

SOURCE OUT THE GOODS SEND YARDAGE FOR INTERNAL TESTING

SUBMIT FOR BUYER’S APPROVAL FOR COLOR AND QUALITY

BULK FABRIC IN - HOUSE

SEND FOR REDYEING, WASHING

ETC

NO

YES

NO

YES

FABRIC STORE

PROCESS FLOW OF FABRIC STORE:

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FABRIC DISPATCHED FROM SUPPLIER

GRIEGE FABRIC

FABRIC RECEIVING

SOLID/YARN

DYED/PRINTED

LAB DIPS PREPARED AT DYEING UNIT IN NEAREST SHADE

FINALIZE THE VENDORS

PLACE THE ORDER

FIRST LOT IN - HOUSE

SAND LAB DIPS FOR SHADE APPROVALBY THE BUYER

SUBMIT FOR APPROVAL TO MERCHANT

LAB TESTING

APPROVED

APPROVED

RE-ORDER

READY FOR ISSUE

FABRIC INSPECTION

12

100 % CHECKING (4 POINT SYSTEM)

LOT MAKING AND SEND IT TO THE MERCHANDISING

QUALITY CHECKING FOR DEFECTS

BACK TO INHOUSE AFTER DYEING OR PRINTING

SEND IT FOR PROCESSING

METER CHECKING BY SECURITY GUARDS

KEPT IN STORE

Receive fabrics

Start

Conduct shrinkage test on minimum 2 bits/bale or minimum 10 bits of consignment

Forward one meter of each consignment for lab test

Verify whether quantity received match with quantity ordered

Inform to stores and prepare goods received note (in case of imported fabric)

Inspection based on four points system. Match bulk with approved dye lot, width of fabric etc.

Name shade lot as ABC

Send to merchant for buyer’s approval

If approvedForward to cutting dept.

End

Reject lot

If No

If No

If No

If Yes

If Yes

If Yes

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TESTING LAB

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Start

Fabric Sourcing

End

Accessory stores Merchandising

Test Test

Count

Construction

Color fastness to washing

Color fastness to crocking

Dimensional stability to washing

Fabric Strength

Fabric Weight

Buttons

Lining fabrics

Carry on test on fabric and garment as per buyer requirement

On meeting buyer requirement, samples to be sent to external lab to get approval

ACCESSORIES STORE

WORK FLOW OF ACCESSORIES STORE

Merchandiser prepares swatch card

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Swatch card is send to the purchase dept.

Accessories purchased by purchase dept.

Accessories received by receiving dept.

Testing of accessories is done

Storing of accessories in accessory store

Issuing accessories to the sampling and production dept.

TYPES OF ACCESSORIES

LABELS AND TAGS: Main label, size label, wash care label, price tag & hand tag THREADS: Sewing threads. BUTTON INTERLINING AND FUSING MATERIAL: Shoulder pads paper foams etc. NEEDLES STATIONARY: Record books, role paper, pens etc.

PROCESS FLOW OF INDUSTRIAL ENGINEERING DEPARTMENT:

Receiving sketch/garment from merchant construction enquiry – sampling dept.

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Prod. Friendly solution

Calculate SMV merchandising dept. PPC dept.

Prod. Cost prod. planning

Tech analysis before fit stage-suggest amendments(stamp) merchandising dept. incorporate in sampling

start thinking innovation tool room

Receive sample for thread consumption

Make opern bullttin & calculate T.C merchandising. dept

Receive red tag sample thread order

In depth style study & construction engineered way develop customized folders tool room

(innovate)

Prepare opern bullttin prepare R & D report

Update SMV & finalize reports

Factory IE discuss & collects reports

Prepare work station layout m/c & work aid REQMT to maintenance↓↓

Line setting according to IE reports procure from maintenance

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Capacity check analysis & feedback R & D analysis and feedback IE dept

Prod. Studies to increase efficiency

Improve methods rebalance line

Achieve target

MACHINE MAINTENANCE

FUNCTION OF MAINTENANCE DEPARTMENT:-

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Care of the fittings

Adjusting settings

Oil changing

Graph maintenance

Outward/inward reports

Needle weekly reports.

Machine configuration chart

History card

Needle log cards.

:

CAD DEPARTMENT

PROCESS FLOW OF CAD:

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Receive spec sheet form

WORK FLOW OF SPREADING AND CUTTING:

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SPREADING

Receive patterns from pattern

Digitize pattern to feed in

Pattern correction

Pattern grading

Cut ratio planning

Market planning according to the cut plan ratio

Output mini marker to printer

Output marker to plotter

Send to cutting room for cutting

Send to merchandiser for costing

Output to Graphtec plotter

Pattern sent to merchandiser for sampling

WORK FLOW IN CAD

DEPARTMENT

SPREADING

PROCESS FLOW OF SPREADING:

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RELAXATION FOR 8 HR.

TICKETING

CUTTING MANUAL/AUTOMATIC

BUNDLING

CHECKING

FUSING

TRANSFER TO PRODUCTION

FABRIC IS LOADED ON SPREADING MACHINE

\

PROCESS FLOW OF CUTTING DEPARTMENT:-

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TRANSFERRED TO THE CUTTING

PAPER IS SPREAD ON SPREADING TABLE

MANUAL SPREADING IS DONE

PROPER TENTION IS MAINTAINED WHILE

RELAXATION FOR 8 HR.

MARKER IS SPREAD OVER IT AND PASTED BY TAPE

Acquire fabric from fabric store

Cutting package from production

manager

Yes

No

Yes

NO

No

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Cut sample to check

Require Checkin

g

Cut for initial size set

Assemble and check

Require changes

Issue job order

Bulk cutting Sorting

Cut plan

Bundling Issue

Send to CAD for Change

Receive changed pattern from CAD

PRODUCTION PLANNING & CONTROL

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Start

On receiving the orders, allocate the same to units based on line openings and buyer’s ratings

Provide details to the respective units on PCD, order quantity & sample

Confirm the above details given to concerned units in consultation with GM & FM

Confirm in consultation with embroidery, washing departments

Confirm order plan with merchandising team

Provide MIS report to management every fortnight

Planning follow up with factory till order execution

End

Take inputs from IED on productivity based on garment analysis

SEWING DEPARTMENT

Production floor follows Assembly Line system. Following are steps to start a production line:

To study the production file.To study operation bulletin and set line accordingly.Manpower – tailors and helpers.Load and feeding lines.To arrange buffer or work-in-progress.Manufacturing.To make daily production and to achieve targets accordingly.To understand bottlenecks stage of production.

Working steps of production dept:

Shrinkage production pattern is issued to production floor from CAD dept.Ready patterns are made as per the requirement of production room.Cutting receives from cutting dept.Cross checking of cut panels with patterns.Bundling of cut panels is done.Operation wise feeding of cut panel into the line.Inline checkpoints.Output of line.Final checkpoints.Auditing of checked pieces.

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PROCESS FLOW OF PRODUCTION DEPARTMENT

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Start

Bulk Production

Cut parts received from cutting

End line checking & AQL audit

Assembly

Sewing process begins

Button & button hole/ Bar tack

Rough checking

Ironing

Final checking

Tagging

Packing

FSA Audit

Measurement checking

Auditing by buyer QA

Truck out End

In-Line checking

Washing

Start

Washing Normal wash

N

Hydro Extraction

Drying

Inspection (Random)

Accounting & despatch to different units

End

WASHING

PROCESS FLOW:

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FINISHING

PROCESS FLOW OF FINISHING

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GARMENT COMES FROM PRODUCTION

PRESENTATION/FINAL IRONING

MEASUREMENT

FINAL CHECKING

WASHING

THREAD CUTTING

INITIAL CHECKING AND SPOTTING

ALTERATION

REIRONING

SENT FOR PACKING

PACKAGING

PROCESS FLOW OF PACKAGING

PACKING NORMS

Packages are sent under licensing rules for shipment. The rules are also specified by the individual buyer and are universal for their respective order. Some of such norms include:

All garments packed in individual poly bags.Poly bag sticker on poly bags, which may be printed by the factory.Order must be completed (packed, ready for shipment) prior to bulk orders.Order must be inspected and audited by the factory 100%.Order must be of first quality, no repair or ungraded garments should be in license shipments.Order must be shipped 100% complete otherwise notified.The packed goods are now ready to be passed through the

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GARMENTS COMES FROM INSPECTION

DETAILS ARE PASTED ON CARTON

IT IS THEN FOLDED

1 OR 2 ARE PACKED TOGETHER

ALL PIECES PUT IN TO CARTONS

SENT FOR SHIPMENT

LOADED INTO TRUCKS

CARTON IS SEALED

CALCULATION FOR PLANT AREA

Given Parameter:-

Plant size = 120*100 sq. mt

FSI =1.2

G.C = 40%

Front margin = 5 mt

Side margin = 5 mt

Total space = 120*100 = 12000 sq. mt

FSI = 1.2*12000 = 00 sq. mt (Maximum available floor space)

Ground coverage = .65*3600 = 2340 sq. mt

Available floor space = (60-12) * (60-21)

= 48*39 sq. mt

= 1872 sq. mt

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SPACE ALLOCATION FOR EACH DEPARTMENT IN EACH FLOOR

GROUND FLOOR :

DEPARTMENTS AREA (in sq mts)

TOTAL NO. OF LIGHTS

TOTAL NO. OF FANS

AIR CONDITION

EXCUTIVE PARKING 353.5 sq mts. 1 halogen - -

TIME OFFICE 13.77 sq mts. 1 1 -

MAIN ENTRY 15 mts. - -

UNLOADING AREA 91.8 sq mts. 2 3 -

STORE MANAGER 13.77 sq mts. 1 1 1

TRIMS AREA 12.39 sq mts. 1 1 -

REJECTED ROLLS 16.06 sq mts 1 1 -

TESTING LABS 23.87 sq mts. 2 2 1

LABOURWASH ROOMS 6.88 sq mts. 1 2 -

UTILITY ROOM 17.90 sq mts. 1 1 -

CRECHE 17.9 sq mts. 1 2 -

LOCKERS 35.8 sq mts. 1 - -

SUPERVISOR 3.67 sq mts. - - -

WASTE ROOM 18.36 sq mts. 1 1 -

REMENENT 18.36 sq mts. - 1 -

CAD 28.4 sq mts. 2 1 1

CUT PANEL AREA 112.02 sq mts. 3 - -

PATTERN MAKING 48.2 sq mts 2 - -

MANAGER 28.12 sq mts. 1 1 1

MEDICAL 28.12 sq mts. 1 1 -

EXECUTIVE WASH ROOM

4.59 sq mts. 1 1 -

EXECUTIVE CANTEEN 22.95 sq mts. 1 1 -

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CONFERENCE 27.54 sq mts. 2 2 1

RECEPTION 20.66 sq mts. 1 1 1

PPC 27.54 sq mts 1 1 1

GM 20.66 sq mts 1 1 1

MD 21.34 sq mts 1 1 1

STUDIO 27.54 sq mts 2 1 1

PURCHASE 20.66 sq mts 1 1 1

EXPORT 20.66 sq mts 1 1 1

ACCOUNTS 20.66 sq mts 1 1 -

MIS 20.66 sq mts 1 1 1

HR 30.99 sq mts 1 1 1

LOGISTICS 13.77 sq mts 1 1 -

MERCHANDISER 27.54 sq mts 1 1 1

SENIOR MERCHANDISER

13.77 sq mts 1 2 1

WORKER PARKING 91.5 sq mts - - -

FIRST FLOOR:

DEPARTMENTS AREA (in sq mts)

TOTAL NO. OF LIGHTS

TOATAL NO. OF FANS

AIR CONDITION

SAMPLING 530.3 sq mts. 5 14 -

MAINTAINENCE 123.9 sq mts. 3 4 -

IE 19.2 sq mts. 1 1 -

QUALITY ASSURANCE 1.83 sq mts 1 1 -

SEWING AREA 2107.2 sq mts 1065 59 -

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COMPLIANCE 36.7 sq mts. 1 1 -

TRAINING 31.22 sq mts. 1 1 -

MANAGER ROOM 13.77 sq mts. 1 1 1

STORE 31.22 sq mts. 1 1 -

BOILER 18.36 sq mts. 1 1 -

EXECUTIVE WASH ROOMS

11.01 sq mts 1 1 --

EXECUTIVE CANTEEN 22.9 sq mts 1 2 -

WASTE ROOM 18.36 sq mts 1 1 -

DRINKING WATER 4.59 sq mts. - - -

WASH ROOMS 4.59 sq mts. 1 - -

RACKS 27.5 sq mts. 2 1 -

SECOND FLOOR :

DEPARTMENTS AREA (in sq mts.)

TOTAL NO. OF LIGHTS

TOTAL NO. OF FANS

AIR CONDITION

WASH ROOMS 9.18 sq mts. 1 - -

EXECUTIVE CANTEEN 34.4 sq mts. 1 1 -

LABOUR CANTEEN 385.6 sq mts. 2 11 -

MEASUREMENT & INSPECTION

128.5 sq mts. 65 4 -

AUDIT AREA 80.34 sq mts. 40 2 -

PACKAGING 144.6 sq mts. 50 3 -

DISPATCH AND LOADING

96.4 sq mts. 5 4 -

CARTON STORAGE 18.36 sq mts. 2 1 -

WASHING AREA 146.9 sq mts. 10 5 -

WASHROOMS 4.59 sq mts. 1 - -

DRINKING WATER 4.59 sq mts. 1 - -

SUPERVISOR 2.52 sq mts. - - -

WASHING MANAGER 27.5 sq mts. 1 1 1

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FINISHING MANAGER 27.5 sq mts. 1 1 1

FINISHING ZONE 156.1 sq mts. 78 5 -

WORKFORCE IN DIFFERENT DEPARTMENT

ADMINISTRATION DEPARTMENT:-

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DEPARTMENT NO. OF EMPLOYEES

Executive 2

Accounts and finance 5

Human resources 4

Purchase 3

Export and import 3

MIS 4

Logistics 2

Merchandising 5

PPC 5

IE 3

CAD 5

Maintenance 4

TOTAL 42

SAMPLING DEPARTMENT:

Cutting master 3

Sampling manager 1

Sampling in charge 1

Pattern master 1

Supervisor 2

Tailors 35

Helpers 2

Ironer 3

checker 3

TOTAL 51

STORE DEPARTMENT:-

Fabric store

Store manager 1

Assistant manager 2

Checker 3

Workers/helpers 20

TOTAL 26

35

Trim store

Store manager 2

Assistant manager 2

Workers/helpers 10

TOTAL 14

CUTTING DEPARTMENT:

Production manager 1

Pattern master 2

Assistant pattern master 2

Cutting master 3

Workers/helpers 50

TOTAL 58

SEWING DEPARTMENT:

Production manager 1

Supervisor 4

Quality checker 4

Workers/helpers 268

Male:female(ratio) 70:30

TOTAL 277

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QUALITY ASSURANCE DEPARTMENT:

Quality manager 1

Workers/helpers 5

TOTAL 6

FINISHING DEPARTMENT:

OPERATION WORKER HELPER

Button holing 2 2

Button attaching 2 0

Thread cutting 25 0

Pressing 20 2

Initial checking 15 0

Final checking 2 0

Re final checking 2 0

Spot removal 4 0

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PACKAGING DEPARTMENT

Assistant manager 1

Quality checker 3

Workers/helpers 8

Equipment details of various department

FABRIC INSPECTION MACHINE

Specifications of Fabric Inspection Machine for Fabric up to 3500 mm are:

Speed of Machine: 30meters/minute. 2HP x 1440rpm, 415volts Electric Motor. Reverse - Stop - Forward Arrangements [From Three Sides]. Roll Compact with 5" Dia. M. S. Rubber Striped Rolls: 2 Nos. Adopter for Paper Tube as per your requirement. Revolution type Meter Counter. Batching on Operator Side. Transparent Horizontal Inspection Table with Bottom illumination. Tension Device and Guide Rolls. Cloth Inspection & Winding Unit are completely wired electrically, only main supply is to be

provided.

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Equipment details of testing lab

1. AUTOMATIC TWIST TESTER

Specifications of Automatic Twist Tester:

Yarn test length

: 25mm to 500 mm adjustable (metric unit) OR 1” to 20” adjustable (imperial unit). The test length is automatically taken into account for calculation and final reading is displayed directly in TPM/TPI.

Range : Up to 9999 TPM or 99.99 TPI.

Resolution : 1 TPM or 0.01 TPI.

Elongation Range

: Up to 9999 TPM or 99.99 TPI.

: With tolerance of -15mm or 0.6 inch for movement in other  direction.

Motor Speed : Up to 1500 RPM

: Manual control of rotation is possible by hand.

Clamps : Spring loaded clamps at motor end for easy clamping of yarn.

: Toggle clamp at spool end for easy, quick and continuous clamping of yarn through spool.

Averaging: Reading of at least 20 samples can be stored and average TPM/TPI value

is   calculated and displayed.

Supply : 230 V AC, 30 Watts.

Size : 1000mm x 150mm x 200mm (approx).

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2. FABRIC ABRASION TESTER

Specifications of fabric abrasion tester:

Standards: GB/T4802.2, GB8690, ASTMD4966, ASTMD4970, ISO12945.2

Friction head: 8 pcs

Sample clip diameter: diameter 38mm and diamter90mm

Diameter grinding platform: diamter 120mm

38mm Sample clip and guide rod total weight: (200 ± 1) g

Hammer: 395g ± 2g, 594g ± 2g

Counter counting range: 1-65535 times preset

Test speed (grinding speed): 50 ± 2r.p.m

Power: 380V ± 5%, 50Hz, three-phase four-wire

Dimensions: 850mm × 600mm × 350mm

Weight: about 80kg

3. FABRIC PILLING TESTER:

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Specifications of fabric pilling tester:

Model: YG502B

Standard: GB/T4802.1-1997

Main technical data: trajectory diameter 40, circular orbit

Brush Height 2-12mm adjustable

Dimensions 520x280x360

Weight 45kg

Power AC220V

4. FABRIC PICK COUNTER

Specification for fabric pick counter:

Y511B Fabric pick counter

Standard: GB/T4668, ISO7211

Magnification 10, 20

Figured scale travel 0~50mm

Dimensions 97×53×35mm

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5. WASHING COLOR FASTNESS TESTER

Specification for washing color fastness

Reciprocating travel 100mm

Rubbing finger pressure 60Times/min

Rubbing finger pressure 9N

Reciprocating times 10 times (automatic stop)

Rubbing head size Circular diameter 16mm

External Dimensions L760×W270×H240mm

Weight 20kg

Power- AC220 50Hz 40W

Manual

Applicable standards: Built according with: AATCC

42

Features: It applies for AATCC standard.

Model Y571M

Testing Times 1-99999

Rubbing Travel 105mm (Can be adjusted)

Rubbing Speed Manual

Rubbing Pressure 9N

Rubbing Head diameter: 16mm

External Dimensions 660×160mm×215mm (L×W×H)

Power Source :NO

6. COLOR ASSESSMENT CABINET

Specification of color assessment cabinet

Brand: JAG

Model: JAG60

43

Configuration: D65, TL84, F, UV (4 light sources)

Weight: 25Kg

Cabinet dimensions (W x D x H): 710x420x570 mm

Packing dimensions (L x W x H): 750x600x350mm

Light Tube Length: 600mm (24")

7. SINGLE FIBER TESTER

Specification of single fiber tester:

Electronic single fiber strength tester

Testing breaking strength; break elongation rate, fixed elongation, etc. of fibers, or thin metal wires.

Standard: GB/T14337, ISO5079, 11566, ASTM D3822, BS4029, AATCC, etc.

Unit: N, CN, KG, LB, IN etc.

Max Strength Range: 100cN, 200cN, 300cN, 500cN.

44

Scale limits: 2-120%

Scale value: 0.01N

Accuracy: <± 0.5%

Sensor Accuracy: <±0.05%FS

Resolution 0.01cN

Minim clamp distance: 10mm Digital setting, automatic fixing

Drawing speed: 2-200mm/min. Scale value: 1 mm/min. Accuracy: 1%

Return speed: 2- 200mm/min. Scale value: 1 mm/min. Accuracy: 1%

Work motion: 100mm. Elongation resolution: 0.01mm

Maximum elongation: 150mm

Host size: L370 × W300 × H550mm

Weight: 85KG

WASHING MACHINE

FABCARE WASHING MACHINE

specifications:

Fabcare 'Washing Machines' are designed for all types of Laundry Jobs, Technical and Enzyme

Washings.

Machines are available with different types and size to cater the need of different Fabrics such as

Denim, Cotton, Rayon, Knitted, Woolen Garments.

Automatic, Auto timed, Auto reverse, Auto Digital temperature control.

Front plate/Inner Basket/Outer Drum all in SS Heavy duty fabrication.

Heating system available in Electric/Steam Direct Injection/Indirect steam through Seamless pipe of

SS 316 quality Coils/Thermic Heat Transfer Fluids, Oil/Gas fired heated.

Available in 20, 35, 70, 140 Kg. Dry weight per charge capacity.

45

46

DRYING TUMBLER

MODEL CAPACITY :SDS 30 CAPACITY DRY WTPEPCHARGE : 30  KG  1:24 BASKET SIZE : Ø950 X850 MOTOR DRIVE BLOWER : 0.75 KW STEAM CONN. : Ø15 (0.5"  BSP)50KG/HR

CONSUMPTION ELECTRIC : 18/24  KW OVERALL DIMENSIONS : 1150 X 1460 X 1980 NET WEIGHT : 560  KG

47

CUTTING ROOM MACHINE DETAILS

TYPES OF MACHINES USED & THEIR SPECIFICATIONS:-

1. BAND KNIFE MACHINES- LF-BK-00850MODEL EC-700220V,50/60 HZ,1PH,3AMPKNIFE SIZE 3500 mm.

2. END CUTTER MODE EC-3LF –EC-00900220 V,50HZ,1 PH,0.5AMPEASTMAN M/C CO.NEW YORK,US

3. STRAIGHT KNIFE

48

Motors110v, 1ph: Weight34 lbs. (15.4kg)Horsepower.65hpBlade Size(inches): 5"(cm): 12.7cm Cutting Capacity(inches):3.5"

(cm):8.89cmStroke Size(inches):1.125"

(cm): 2.86cm

SEWING MACHINES DETAILS

TYPES OF MACHINES USED –

1. SINGLE NEEDLE LOCK STITCH

Specifications :

Bed dimensions: Length: 18 3/4" (477 mm) Width: 7" (178 mm) Space to right of needle: 10 5/16" (262 mm) Outside diameter of machine pulley: 2 61/64” (75 mm) effective diameter for V-belt Regular machine: Singer® clutch motor high speed 1/2 H.P. Under bed thread trimmer (U.T.T): Singer® AC servo motor/EC (N.P.) motor Including the operation panel C-30 Needle bar Stroke: For 200A: 1 3/16 " (30 mm) For 300A: 1 3/18" (35 mm) Clearance under presser foot: By hand 7/32 " (5.5 mm) By knee 1/2" (13 mm)

2.DOUBLE NEEDLE LOCKSTITCH :

49

SPECIFICATIONS ;

Max sewing speed -3000rpm Max. stitch length-5mm Needle bar stroke-33.4mm Needle-DPX5 #14. Bed size-517mm*478mm Weight of machine-43kgs Power required- single phase 100,420V,200. Three phase 200,240V/650VA. With automatic UBT.

3 5 THREAD OVERLOCK

SPECIFICATIONS :

Brand: Juki Application: For light-weight materials

Feed Dog: 4-Row

Feed System: Bottom-Feed

Max. Sewing Speed: 7000 rpm/spm

Max. Stitch length: 1.5~4mm

50

Needle Bar Stroke: 24.5mm

Needle System (at time of delivery): DC X 27

Lubrication: Automatic

Lubricating Oil: Juki New Defrix Oil #2(Equivalent to ISO VG32)

Lift of Presser Foot by Hand: 7 mm

Number of Threads: 2/3/4/5 Threads

3. BUTTON STITCHING MACHINE :

SPECIFICATIONS :

Max. sewing speed- 1500 spm. Number of stitches-8, ,16 and 32. Applicable buttons- round shaped ,flat(2 holed,4 holed),shank/snap/metal. Needle bar stroke-48.6 mm Needle size -TQ x 7 #18 ~#20TQ x 1 # 14~#18. Button clamp lifting height / system- >9mm/Automatic System.

3. BUTTON HOLE SEWING MACHINES –

Max. SewingSpeed -3,000 spm Number ofStitches -83~225 (by gear change method). Max lift of work clamp-12 mm (15/32”) Needle bar stroke -34.6 mm Length ofbottom holes -6.4-38.0 mm Needle Size -DP x 5 # 11~ 16

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FINISHING MACHINES DETAIL

1. FUSING MACHINE

Specifications: - CONTINOUS FUSING MACHINE: -

MODELAE-300

POWER SUPPLYSINGLE PHASE

HEATER 3 KW

MOTOR 0.40 KW

CURRENT 17 A

TEMPERATURE 200’ C

PRESSURE 1 KG/CM2

BELT SPEED 8.7 M/MIN

FUSING WIDTH 300 MM

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2. PRESSING

MODELNO. OF

MOTORSPOWER

DIMENSIONS(L*W*H) INCHES

WEIGHT KG.

NX-2429 1 .75 HP, 1 PH/3PH 50*30*36 80

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RAW MATERIAL STORE DEPARTMENT

CALCULATION:-

Total area=390 sq mt

Rack size=7’*6’

Fabric Gsm=220

Fabric weight-100 kg

Fabric width =56”

Capacity of 1 rack=1800 kg.

Fabric diameter=2.5’

Total no. of racks=28racks

Total capacity of racks=28*1800

= 50400 kg.

CUTTING DEPARTMENT

CALCULATION

Total area=694 sq mt

No of pieces cut per day=2000

3% extra=2000*3*2060/100 pcs/day

Avg consumption/t-shirt=0.9 mtr

Avg consumption /t-shirt=220*100/.9*56*2.5=1.4 kg

Marker way=10 way

Total no. of layers=100

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Total garments/cut=10*100=100 pcs/cut

For one cut (assumption)

Spreading:

One lay spreading time=35 sec=30/60=0.50 min

Total spreading for 100 layers=0.50*100

=50 min

Lay preparation time=10 min

Total spreading time for one cut=50+10

=60 min

Total cutting for one lay or cut=100 min

Total required time for one cut finishing=100+60

=160 min

Total no. of cuts/ day=480/160=3 cut

From 3 cut=3*1000

=3000 pcs

Production of cutting department=4*3000

=12000pcs/day

9000 pcs issued to sewing department

In sewing department=4 line

1 line capacity=2000 pcs

4 line capacity=2000*4

=8000 pcs

Thus WIP in cutting department=12000-8000

=4000 pcs/day

Total fabric required per day in cutting room

=9000*1.4

=12600 kg

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COMPLIANCE ISSUES FOLLOWED IN THE INDUSTRY:

Displays

Factory Act AbstractMinimum Wages AbstractThe Payment of Wages AbstractThe Payment of Gratuity AbstractThe Maternity Benefit Act AbstractThe Payment of Bonus AbstractESI AbstractEPF AbstractForm 11Weekly Holiday NoticeNotice Nearest Hospital, Fire Station, Police Station etc.Notice Important Officials Phone NumbersForm V (National & Festival Holiday)Standing Order (Tamil & English)Needle Control PolicyVoluntary Work PolicySexual Harrassment PolicyHealth and Safety PolicyChild labour abolition policyAnti discrimination policyUrgent Business need policyZero abusement policyWorking hours policyBroken needle policySexual harrassment policyHiring / Recruitment policyEnvironmental policySecurity policyBuyers code of conductWorkmen Committee Members Photo with NameHealth & Safety Committee Members Photo with NameCanteen Members Photo with NameTransport Committee Members Photo with NameHarrassment & Discrimination committee Members Photo with Name

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Unit Work FlowOrganisation Chart with manpower detailsWeekly Holiday AnnouncementExcise Certificate

Building

Name Sign to All Rooms / AreaIndicators / Direction from Security Gate onwardsStorage above Storage limit Carton Box etc.Aisle markingAisle width minimum 112 cm.Indicators Arrows in the passageAisle without block

Health

Drinking WaterAt least4.5 Litres water provided per day per employeeWater Testing CertificateDrinking water not in plastic potDrinking Water, Cup availabilityDrinking Water centre (one place to every 150 employees upto 500)Drinking Water centre (one place to every 500 employees above 500)Water Cooler / Heater available at every canteen, dining hall, rest room etc.Drinking Water Signage in English and TamilLocate from 20 feet away from toiletLocate maximum 50 meteres distance from work spotDrinking Water vessale cleaned at least once in a dayWater Reservoir or Tank Cleaned at least once in a weekWater centre cleaning conditionWater Vessal Cleaning log sheetWater Centre Incharge person with cleanlinessSuggessation Box Register

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Toilets

Toilet Seat to Every 20 WomenToilet Seat to Every 20 men upto 100Toilet Seat to Every 50 men beyond 100All toilet seat with proper privacy and lock facilityUrinal Accomodation Min. 61 cm for every 50 employees upto first 500Urnial Accomodation Min. 61 cm for every 100 employees for above 500Effective water Sewage systemSoap/ TowelBathroom LockWater tapDust BinsBuckets with mug at toiletsToilet White Washed once in every four monthTiles/Mosaic floors washed with Detergent or disinfectant once in four monthDaily Cleaning Log sheet providedAdeaquate Water TabsNo smoking Sign in Gents ToiletAwareness Quotes in ToiletsLadies / Gents Toilet Name Sign in Dual Language and Picture

Spittoons

Adequate SpittoonsSipittoons filled by Sand or Suitable disinfectantSpittoons covered by bleaching powder layerSpittoons scrapped or cleaned at least once in every day

Others

500 Cubic feet for every employeesDisposal of Wastes and effluentsRoom TemperatureLighting facilityTrees on factory campus

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Safety Guards

Metal Glows on good ConditionRubber Mat to ironersRubber Glows to ironersIroners wearing slipperMotar GuardNeedle GuardEye GuardSharp ToolsPaddle MatScissors and trimmers are tiedSharp BoxesMaskNeedle disposal once in six monthBroken Needle Register

Human resources

Dining HallDining Hall with sufficient SpaceDining Hall with Sufficient Chair/TableWater FacilityAmbulance RoomDoctor VisitNurseMedicinesMedicines Issueing RecordCreachSufficient SpaceCreach AttenderCreach Children DetailDaily RegisterCradleToysPosturesWash Room FacilityToiletMilkEatables AvailableDrinking Water

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VentilationChairs for mothersShady plaground for older childrenFirst AidFirst Aid Boxes with All medicinesFirst Aid Boxes Location ListFirst Aid Box Daily ChecklistFirst Aid Training employees (20 %)First Aid Trainer Name & Photo ListFirst Box once for 150 employeesFirst Aid StationsFireSufficient Fire ExtinguisherFire Extinguisher all in good ConditionFire Extinguisher Location ListFire Extinguisher Service ChecklistAccess area without hindaranceFire Extinguisher kept in 3 feetFire Signage in Tamil & EnglishUsage Guide in dual languageFire Extinguisher Colour Background MarkingSpace beneath markedSpace beneath kept emptyRefilling Service DoneFire Certified persons photoEvacuation Drill (External) Every Six MonthEvacuation Drill (External) FileEvacuation Drill (Internal) Every Three MonthEvacuation Drill (Internal) FileSufficient Fire Safety trained employeesFire safety trained employees name & Photo ListFire Buckets to Diesel Storage Area with Water and SandFire Buckets to Boiler Room with Water and SandFire Buckets to Genset room with Water and SandFire Buckets to E.B. Panal Board with Water and SandFire Buckets to Motor Room with Water and SandFire Buckets to Appropriate place.Fire Tray with sandDiesel Storage area floor filled by sandEvacuation Plan in all Floor / AreaEmergency ExitEmergency Exit on OpenEmergency Exit SignageEmergency Exit with outside open facilityEmergency Exit Board Light with UPS ConnectionEmergency Light to All room / Area AdequateEmergency Light to All staircase

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Emergency Light to All Exit & Emergency ExitEmergency Light daily On/Off Log SheetEmergency Light Location ListEmergency Light kept on 6 feet hightSufficient Spare Emergency Light in stockEmergency Electricity Switch off System (floorwise)Signage Emergency Electricity Switch OffNo Hindrance Emergency Switch off Access AreaChemical Users AwarenessMedical Certificate to Canteen employeesCommitteesWorkmen CommitteeWorkmen Committee MeetingWorkmen Committee Meeting File (with Circular, Agenda, Minutes, etc.)Workmen Committee Meeting PhotosHealth & Safety CommitteeHealth & Safety Committee MeetingHealth & Safety Committee Meeting File (with Circular, Agenda, Minutes, etc.)Health & Safety Committee Meeting PhotosCanteen CommitteeCanteen Committee MeetingCanteen Committee Meeting File (with Circular, Agenda, Minutes, etc.)Canteen Committee Meeting PhotosTransport CommitteeTransport Committee MeetingTransport Committee Meeting File (with Circular, Agenda, Minutes, etc.)Transport Committee Meeting PhotosHarrassment & Discrimination CommitteeH & D Committee MeetingH & D Committee Meeting File (with Circular, Agenda, Minutes, etc.)H & D Committee Meeting Photos

Documents

Personnel File to AllApplication FormPassport Size PhotoEducational Qualification CertificateAge ProofI.D. ProofAddress ProofTechnical CertificatePrevious Company Experience/Relieving orderOld Salary SlipESI Nomination Form 1

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PF Nomination Form 2Gratuity Nomination Form FFactory Act Nomination Form 34Track RecordAppointment OrderInsuranceNDA with SignatureEmployee ManualI.d. Card to AllAdequate Swiping machine Punching Card to AllESI Card to AllPF Slip to AllAwareness ProgrammeStress Relieve CounsellingMeetingsPerformance appraisalLeave CardFull & Final SettlementExit InterviewGratuityBonusSalary BreakupSalary on DateInduction ProgrammeInduction RegisterManpowerManpower Departmentwise Male/Female Strength ReportPresentism ReportLate ReportAbsentism ReportDaily Staff In-Out RegisterIs there Under AgeContract EmployeesPunch reportLeave card to each employeeMIR (Material Issue Register)SalarySalary date before 7 every monthBank Salary Account to allSalary Registers with employees signature monthwiseMinimum WagesBasicD.A.Other Salary BreakupsOver TimeDouble Salary to Over Time

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Any unwanted deduction for employeeUnpaid salary are reversedPay Cover AvailabilitySecurityAdequate SecuritiesLady GuardsStaff Movement RegisterVisitors NoteOthers In-Out RegisterMaterial Inward RegisterMaterial Outward RegisterVehicle Movement RegisterVisitor PassVisitor SlipGuards Knowledge about their Roles & ResponsibilitiesSecurities Personnel FileSecurities Uniform/Cap/Shoe/Belt etc.Securities Knowledge about Fire Evacuation & Fire SafetySecurity Agreement file (If outsourced)Security Salary register file (If outsourced)Security ESI, PF Challan (If Outsourced)

Housekeeping

Adequate Housekeeping EmployeesLady Housekeeping employeesGents Housekeeping employeesHousekeeping SupervisorAreawise work allocationHousekeeping Time ScheduleToilet Cleaning Log SheetBrooms AvailabilityBroom Stick AvailabilityWater Mop AvailabilityThread Mop AvailabilityBuckets AvailabilityPhenoil AvailabilityHarpic AvailabilitySoap on All toilet & BathroomTowel on All toilet & BathroomTissues & Hand Wash Shampoo Availability on Visitor RestroomDaily Cleaning ScheduleMSDS for apropriate place.MaintenanceE.B.

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E.B. Service CardElectricity Board Cardonned off from work placeE.B. Meter Reading RegisterE.B. FileRubber Mat to E.B. Panel BoardRubber Mat to All swtich BoardAuthorized Persons Photo Display on E.B. related RoomsCaution board and danger signal on Electricity related RoomsElectrecians FileC or B license certificates of ElectrecianRubber Glows to all ElectrecianSafety instructions Displayed on E.B. Related RoomsBroken WireLoose WireBroken SwitchBoiler roomBoiler room cardonned off from work placeFire Safety Instruments availabilityAuthorized persons Photo listGensetGenset Running NoteGenset FileAMC to GensetGlovesSafety shoesEar MuffTray of SandMachinary Machinary Detail Machinary File (Machinarywise) with purchase, service etc detail.AMC to all machinaryMachinary Service CardMaterial Safety Data Sheet (MSDS)Personal Productivity Equipment (PPE) Issue RegisterPPE Awareness

Logistics

All Staff Bus/Van R.C. Book CopyAll Staff Bus/Van Insurance CopyAll Drivers Licence CopyTransport In - Out Time RegisterTransport Travellers Name ListTransport CommitteeTransport Agreement Copy

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Load Van R.C.Book/Insurance CopyCompany Drivers Licence CopyCompany Van Trip Sheet BookGeneralFixed Asset Stock RegisterDiesel Consume RegisterWhite Petrol Consume RegisterGen Set Usage NoteGen Set AMCElectrical PlanAMC to ComputersAMC to Swiping Machines

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