Final pl doc

PLANT LAYOUT ARCHITECTURAL BRIEF 2011

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

Spreading & Cutting

Merchandising

Maintenance
Warehouse

CAD room
Sampling
Finishing

IE- Dept.

Accounts

IT-Dept.
Quality
Sewing
Stores

Stores A O U U O U U U U U U E
Spreading & A A O U U U U I U U O U
cutting
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
FABRIC STORE
WARE HOUSE
STORAGE 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
a) Incoming goods
b) Fabric inspection area
c) Inspected goods Ok
IDENTIFICATION d) Rejected Goods area
e) Stickers of pass and reject
f) Colour codification shade and shrinkage
g) Bin Card
a) Physical check for length, width of
FABRIC RECIEPT received e.g. invoice
b.) Communication of excess/shortage goods
e.g. receipt
a) Adequate light
b) 4 point system for visual inspection
report (10 %)
FABRIC INSPECTION c) Shade segregation
d) Approvals of shade and ratio
e) Trims & Fabric approvals
f) Fabric Lab Test Report

a) Issue record to be maintained
b) Fabric issue must be
FABRIC ISSUE shade/shrinkage/width wise
c) Pass rolls must be identified with green
stickers.
a) Fabric Defect Standard
b) 4 point system chart
c) Face side/nap direction/ grain line of the
DISPLAY fabric
d) Shade approved
e) Store layout
f) Process flowchart
a) Fabric issue record
b) Inward record
OTHERS c) Outward record
d) Handling /House keeping

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PROCESS CHART
CUTTING
PROCESS ACTIVITIES
a.) Plaid matching requirement
b.) Grain line, centre/feature line
APPROVED REFERENCE SAMPLE requirement
c.) Nap/design direction
d.) Fusing standard / requirement
e.) Trim requirement
a.) Approved face side display
b.) Approved shade band
c.) Fabric receipt
FABRIC d.) Fabric inspection report
e.) Fabric relaxation tag on roll
f.) Fabric width report
g.) Fabric Shrinkage report
a.) Display cutting SOP
b.) Approvals (shade etc.)
DISPLAY c.) Fabric face side
d.) Numbering/Stickering/Bundling / tagging
e.) Process flow chart
f.) Layout
a.) Cutting m/c maintenance
PREVENTIVE MAINTENANCE b.) Spreading m/c maintenance card
c.) Band knife m/c maintenance card
d.) Die Click maintenance card
a.) Cut parts must be stored in racks
STORAGE b.) Fabric must be stored shade, shrinkage
c.) Mobile cut parts storage
a.) Cutting CAD markers must be used
b.) Markers must be colour coded in case of
CAD MARKERS 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.
a.) Paper should be used to avoid slippage of
line fabrics.
b.) Relaxation of fabric should be done
LAYING/SPREADING 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
a) Adequate light
b) Display defect standard
CUT PANEL INSPECTION c) Parts replacement to take place from
same rolls
d) End bits must be stored neatly with
identification
a) fusing standard(approved report)
b) fusing must be done 4times a day
FUSING 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
ACTIVITIES
a) incoming goods
PROCESS b) trim inspection area
IDENTIFICATION c) inspected goods ok
d) rejected goods area
e) RTG(return to godown)
f) stickers for paas/reject
g) bin card
a) adequate light
TRIM INSPECTION 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
a) storage PO wise
b) needles must be stored safely lock
OTHERS c) labels must be stored safely locked
d) material issue DC
e) handling
f) house keeping
a) approved trim cards
b) sampling plan
DISPLAY c) store layout
d) process flowchart

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PROCESS CHART
QA DEPT.
Process Activities
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
QUALITY SYSTEM 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
a) Display cutting SOP
b) Approvals( embroidery, shade etc)
DISPLAY c) Fabric face side
d) Numbering/ stickering placement mocks
e) Process flow chart
f) Layout
a) Cutting m/c maintenance chart
PREVENTIVE MAINTENANECE b) Spread m/c maintenance chart
c) Band knife m/c maintenance card
a) Cut parts must be stored in racks
STORAGE 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

Operator
Machine Model M/c M/C Operator Space Operator
SL.NO M/C Make No M/C DESCR Length Width M/C Area Space(Length) (Width) 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
SADDLE
8 HENGTAI GK-68 STITCH 4 3 12 4 1.5 6
S/N LOCK
9 PFAFF 1183 STITCH 4 3 12 4 1.5 6
S/N LOCK
10 D/A 272 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
S/N LOCK
12 HIGHLEAD GC-1088-M STITCH 4 3 12 4 1.5 6
S/N LOCK
13 HIGHLEAD GC-1088-MD STITCH 4 3 12 4 1.5 6

14 SINGER 16694101 BARTACK 4 3 12 4 1.5 6
CHAIN
15 HIGHLEAD GK0058 STITCH 4 3 12 4 1.5 6
CHAIN
16 D/A 171 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
Operator
Machine M/C M/c M/C M/C Operator Space Operator
M/C Make Model No DISCRIPTION Length Width Area Space(Length) (Width) 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 O/P
AREA 180 AREA 90

No. Of O/P Space
Description M/C M/c Length M/C Width M/C Area O/P Space(Length) (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

 ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2

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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:

Operator
No. Of M/c M/C M/C Operator Space Operator
SL.NO Description M/C Length Width Area Space(Length) (Width) Area

1 pm table 4 6 5 120 6 2 48

2 Plotter 2 8 3 48 7 2 28

computer
3 table 5 5 3 75 3 2 30

Inspection
4 Table 4 6 3 72 6 2 48

5 Digitizer 1 6 1.5 9 6 2 12

pattern
6 cutter 1 6 5 30 6 2 12

Pattern Total
Storage O/P
7 Rack 1 6 3 18 Space 178

Paper
8 Storage 2 3 3 18

Waste Paper
9 Bin 1 4 4 16

Total
M/c
Space 406

Sub Total Space 584

Allowance (150%) 876

Total Required Area 1460

 ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2

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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

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

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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 2
requirements.
DATA Entry Operator For maintaining and keeping the 2
records.
Store Supervisor Each for jacket and trouser fabric 2
storage
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

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

INVENTORY
AVG. TOT. REQ. /DAY REQUIREMENT
S.NO. ITEM QTY./PACKAGE (CAP. = 5000 TRS./DAY) (30 DAYS) Length Width Area

pcs. (12gross)
1 Button 1728 / box 20000 11.57407 box 347.22 1.5 1.5 781.25
m (10tubes) /
2 thread(count tubes) 10000 box 1525000 152.5 box 4575.00 0.75 0.5 1715.625
m (150yds.) /
3 tapes(bias/binding etc.) 137.16 roll 5000 36.45378 rolls 1093.61 0.75 0.5 410.105
m (150yds.) /
4 w.b. lining 137.16 roll 6100 44.47361 rolls 1334.21 0.75 0.5 500.3281
m (150yds.) /
5 fusing banroll 137.16 roll 6950 50.67075 rolls 1520.12 0.75 0.5 570.0459
m (150yds.) /
6 zipper tape 137.16 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
sets/pkt (4
8 hook & bar 1000 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

TOT. REQ. /DAY Monthly
AVG. (CAP. = 2000 Consumpti
S.NO. ITEM QTY./PACKAGE JKTS./DAY) on DIMENSION AREA

pcs.
(12gross) / 451.388888 1015.6
1 Button 1728 box 26000 15.05 box 9 1.5 1.5 25
m
(10tubes) /
2 Thread 10000 box 650000 65.00 box 1950 0.75 0.5 731.25
m
tapes(bridal/besom/armhole/s (150yds.) / 2624.67191 984.25
3 atin etc.) 137.16 roll 12000 87.49 rolls 6 0.75 0.5 2
sh. Pads(no. weighing at
4 present - need broad platform 500 pairs/box 2000 4.00 box 1.2
weighing m/c) 120 2 5 300
0.2
5 Label 1500 pcs./pkt 4000 2.67 pkts. 80 0.5 5 10
0.2
6 Tags 100 pcs./pkt 2000 20.00 pkts. 600 0.5 5 75
hanger (no. weighing at
7 present - need broad platform 150 pcs./box 2000 13.33 box 0.7
weighing m/c) 400 1.25 5 375
bund 0.7
8 Polybags 1000 pcs./bundle 2000 2.00 les 60 1.25 5 56.25
bund 0.2
9 sticker(polybag/carton) 100 pcs./bundle 2000 20.00 les 600 0.5 5 75
bund 0.2
packing cartons 5 pcs./bundle 320 64.00
10 les 1920 4.25 5 2040
5662.3
TOTAL 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

operator
Surface area of shelf 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 2
requirements.
DATA Entry Operator For maintaining and keeping the 2
records.
Store Supervisor Each for jacket and trouser fabric 1
storage
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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Flooring: Epoxy Coated Hardened Floor

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.

31 | 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

MACHINE
M/C MODEL NO OF M/C M/C OPERATOR OPERATOR O/P
MAKE NO M/C DESCR MACHINES LENGTH WIDTH AREA LENGTH WIDTH AREA
low-ply CNC
EASTMAN Eagle™ conveyor 2 50 8 800 50 2 200
Power
Cradle
EASTMAN 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
Spread and End
EASTMAN Blue Jay™ Cutting System 4 1.5 8

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

32 | P a g e


2. TROUSER
Machine M/C No of M/C M/C operator operator
M/C Make Model No DISCRIPTION Machines LENGTH WIDTH AREA length width o/p area
low-ply CNC
EASTMAN Eagle™ conveyor 1 50 8 400 50 2 100
Power Cradle
EASTMAN 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
Spread and End
EASTMAN Blue Jay™ Cutting System 4 1.5 8

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

Sub Total Space 8706
Allowance (150%) 13059
Total Required Area 21765

* 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

33 | 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 of the total floor area.



 Cutting Master

 Data Entry Operators


34 | P a g e


CUTTING 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.

35 | 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
Operat
Operator
S. OPERATION MACHINE M/C MAKE & M/c M/C M/C or
Space(Len Operator Area
NO. DESCRIPTION TYPE SERIAL Length Width Area Space
gth)
(Width)

PREPARATORY

Loading Table 5 4 20 5 2 10

1 4 3 12 4 1.5 6
Durkopp Adler 0272-
W/B Extension SNLS
990103-272-140342
2 4 3 12 4 1.5 6
Back Pocket Auto Facing Durkopp Adler 0271-
3 6.5 4.5 29.25 6.5 1.5 9.75
Facing Attach 992001-271-992001
4 6.5 4.5 29.25 6.5 1.5 9.75
Front Pocket Auto Facing Durkopp Adler 0271-
5 6.5 4.5 29.25 6.5 1.5 9.75
Facing Attach 992001-271-992001
6 6.5 4.5 29.25 6.5 1.5 9.75

7 Hilead GM288-302 2.8 2 5.6 2.8 1.5 4.2

8 Front Pocket O/L 3T O/L 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 5 4 20 5 1.5 7.5

11 5 4 20 5 1.5 7.5
Front Pocket
Manual
Turning
12 5 4 20 5 1.5 7.5

13 5 4 20 5 1.5 7.5

36 | P a g e


14 4 3 12 4 1.5 6

15 4 3 12 4 1.5 6
Durkopp Adler 0271-
Front Pocket TS SNLS
990103-271-140342
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 4 3 12 4 1.5 6
Stitch Side Pocket SNLS w Durkopp Adler 0275-
to Front Differential Feed 990103-275-140342
21 4 3 12 4 1.5 6
Side Pocket Macpi 558-00-2058-
22 Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
Ironing 00
23 4 3 12 4 1.5 6
Side Pocket Edge Durkopp Adler 0271-
SNLS
Stitch 990103-271-140342
24 4 3 12 4 1.5 6

25 4 3 12 4 1.5 6
Side Pocket Durkopp Adler 0271-
SNLS
Tacking 990103-271-140342
26 4 3 12 4 1.5 6
Back Panel
27 Auto 5T O/L Pegasus EXT5204-02 2.8 2 5.6 2.8 1.5 4.2
Serging
Macpi 558-00-2058-
28 Dart Fusing Buck Press 5 5 25 5 1.5 7.5
00
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
Macpi 558-00-2058-
31 Dart Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
00
32 6 5 30 6 1.5 9
Auto-welt Auto Welt m/c
33 6 5 30 6 1.5 9

34 4 3 12 4 1.5 6
Back Pocket Durkopp Adler 0272-
SNLS
Corner Stitch 990103-272-140342
35 4 3 12 4 1.5 6
Macpi 558-00-2058-
36 Welt Back Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
00
Macpi 558-00-2058-
37 Welt Front Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
00
Back Pocket Loop
38 3.5 3 10.5 3.5 1.5 5.25
Marking Manual+Template
39 4 3 12 4 1.5 6
Back Pocket Loop Durkopp Adler 0272-
SNLS
Attach 990103-272-140342
40 4 3 12 4 1.5 6
Pfaff 1183-8/31-
41 Welt Closing SNLS 900/24-909/04- 4 3 12 4 1.5 6
910/06
42 4 3 12 4 1.5 6
Back Pocket Durkopp Adler 0271-
43 SNLS 4 3 12 4 1.5 6
Pouch Closing 990103-271-140342
44 4 3 12 4 1.5 6
Welt Pocket Durkopp Adler 510
45 Bartack 4 3 12 4 1.5 6
Bartack Premium
Back Loop
46 Bartack Juki LK-1900HS 4 3 12 4 1.5 6
Bartack
Macpi 558-00-2058-
47 Back Loop Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
00
48 Back Loop Stitch SNLS Brother S-7200A-403 4 3 12 4 1.5 6
Durkopp Adler 0173-
SNCS w Roller
49 J Fly Zip Attach 99200 1 AP-173- 4 3 12 4 1.5 6
Feed
142210 AP
YKK Zip Cutting
50 Cut and Gape Zip YKK-2CPSB-78000 4 3 12 4 1.5 6
m/c
Straight Fly Zip Durkopp Adler 0271-
51 SNLS 4 3 12 4 1.5 6
Attach 990103-271-140342
52 2.8 2 5.6 2.8 1.5 4.2
Siruba 737 FS-
Inseam O/L 5T O/L
504M2-04
53 2.8 2 5.6 2.8 1.5 4.2
Siruba 737 FS-
54 5T O/L 2.8 2 5.6 2.8 1.5 4.2
504M2-04
Sideseam O/L
55 Auto 5T O/L 2.8 2 5.6 2.8 1.5 4.2

37 | P a g e


56 5 5 25 5 1.5 7.5
Corosel Press
Seam Press
57 5 5 25 5 1.5 7.5
Corosel Press
Front Panel
58 3T O/L Peagasus 552-134B 2.8 2 5.6 2.8 1.5 4.2
serging
M/C O/P
860 375.625
AREA AREA
TROLL
1.5 47(no. of
TROLLEY 1.5 (L) EY 105.75
(W) Trolley)
AREA
1(No. of AREA
FUSING M/C 6(L) 5(W) fusing (Fusing 30
m/c) M/C)

* ALL MEASUREMENTS ARE IN TERMS OF FEET/FEET2

 ASSEMBLY LINE

Loading Table 5 4 20 5 2 10

1 4.25 3.5 14.875 4.25 1.5 6.375
Macpi 558-
W/B Iron Steam Press
00-2058-00
2 4.25 3.5 14.875 4.25 1.5 6.375
W/B Attachment Manual +
3 3.5 3 10.5 3.5 1.5 5.25
Marking Template
Hilead GK-
4 TNCS 4 3 12 4 1.5 6
0058-3
Durkopp
Seat Seam Joining
Adler 0171-
5 TNCS 4 3 12 4 1.5 6
131110-171-
131110
Durkopp
6 4 3 12 4 1.5 6
Beltloop Adler 0272-
SNLS
Attachment 990009-272-
7 4 3 12 4 1.5 6
640642
8 Durkopp 4 3 12 4 1.5 6
SNLS w Adler 0275-
9 W/B Attachment 4 3 12 4 1.5 6
Differential Feed 990013-275-
140342
10 4 3 12 4 1.5 6
Durkopp
Left Extention Adler 0272-
11 SNLS 4 3 12 4 1.5 6
Lock 990103-271-
140342
Extention Turn &
12 Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
Press
Durkopp
Right Extention Adler 0272-
13 SNLS 4 3 12 4 1.5 6
Lock 990012-272-
740642
Thomas
Rt Extention Hook Attaching
14 Walker T- 3.5 2 7 3.5 1.5 5.25
Hook Attach m/c
4000
W/B Center Back Manual + Wax
15 3.5 3 10.5 3.5 1.5 5.25
Marking marker
Lt Extention Bar
16 Manual 3.5 3 10.5 3.5 1.5 5.25
Attach
17 Durkopp 4 3 12 4 1.5 6
Adler 0272-
Front Rise Stitch SNLS
990103-272-
18 4 3 12 4 1.5 6
140342
Durkopp
19 J Stitch Auto J Stitch Adler 0271- 6 5 30 6 1.5 9
992001
YKK
Slider & Brad Slider & Brad
20 FBMST09(S)- 1.5 1.5 2.25 1.5 1.5 2.25
Attach Attaching m/c
78000
21 Durkopp 4 3 12 4 1.5 6
W/B Label Attach SNLS Adler 0271-
22 990103 4 3 12 4 1.5 6
Durkopp
Wash Care & Size
23 SNLS Adler 0271- 4 3 12 4 1.5 6
Label Attach
990103

38 | P a g e


Durkopp
24 J Stitch Bar Tack Bartacking m/c Adler 510 4 3 12 4 1.5 6
Premium
Bar tack Front Brother KE-
25 Bartacking m/c 4 3 12 4 1.5 6
Pocket 4300C-01
Macpi 558-
26 Seat Seam Press Steam Press 4.25 3.5 14.875 4.25 1.5 6.375
00-2058-00
Durkopp
Keyhole Making
27 W/B Button Hole Adler 580 4 3 12 4 1.5 6
m/c
Premium
Durkopp
Back Pocket Button Attaching
28 Adler 530 4 3 12 4 1.5 6
Button Attach m/c
Premium
29 Manual 5 3 15 5 1.5 7.5
Inline Inspection
30 Manual 5 3 15 5 1.5 7.5
Label Fold &
31 SNLS Pfaff 1183 4 3 12 4 1.5 6
Tack
32 4 3 12 4 1.5 6

33 W/B Ditch Stitch SNCS Juki MVI-484 4 3 12 4 1.5 6

34 4 3 12 4 1.5 6
Durkopp
W/B Button Button Attaching
35 Adler 530 4 3 12 4 1.5 6
Attach m/c
Premium
Durkopp
36 Ditch Finish SNLS Adler 0272- 4 3 12 4 1.5 6
990103
Durkopp
Adler 510
37 Belt Loop Down Bartacking m/c Premium, 4 3 12 4 1.5 6
Brother KE-
430C-01
Brother LK3-
38 Bartacking m/c 4 3 12 4 1.5 6
B430E
Belt Loop Up
39 Bartacking m/c Juki Lk-1900 4 3 12 4 1.5 6
Siruba 737
40 Bottom Hem O/L 5T O/L 2.8 2 5.6 2.8 1.5 4.2
FS-504M2-04
Buttom Blind Strobel Blind hem Strobel 103-
41 4 3 12 4 1.5 6
Hem m/c 180
Loiva Button
42 Button Wrapping 4 3 12 4 1.5 6
wrapping m/c
43 3 1.5 4.5

44 3 1.5 4.5

45 3 1.5 4.5
Trimming Trimmer 6 4 24
46 3 1.5 4.5

47 4 1.5 6

48 4 1.5 6

49 Endline 5 3 15 5 1.5 7.5
Inspection (Inside Manual
50 Out) 5 3 15 5 1.5 7.5

51 Endline 5 3 15 5 1.5 7.5
Inspection Manual
52 (Straight) 5 3 15 5 1.5 7.5
M/C
617.85 320.95
AREA O/P AREA
RACK (8*5) 40 (NO.RACKS) 8 RACK AREA 320

Sub Total Space 2310.175
Allowance (150%) 3465.2625
*ALL MEASUREMENTS ARE
IN TERMS OF FEET/FEET2

No. Of Trouser Line 5
Total Area for Trouser Sewing Dept. 28877.1875
RACK AREA 320
TOTAL AREA 29197.1875

39 | P a g e


2. JACKET
 COLLAR SECTION

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

S. M/c M/C Operator Operator Space
OPERATION DESCRIPTION M/C Area Operator Area
NO. Length Width Space(Length) (Width)

COLLAR
5 4 5 3
1 COLLAR MARKING 20 15
ZIG-ZAG STITCH TO ATTACH
UPPER COLLAR WITH UNDER 4.5 3.75 4.5 2.5
2 COLLAR 16.875 11.25
PRERULLING STITCH CREASE
4 3 4 1.5
3 LINE OF UNDERCOLLAR 12 6

4 FUSE COLLAR 4.25 3.5 14.875 4.25 1.5 6.375
4 3 4 1.5
5 COLLAR CORNER LOCK 12 6
4.25 3.5 4.25 1.5
6 TURN, POINT & PRESS COLLAR 14.875 6.375

 SLEEVE SECTION

7 SLEEVE CAP FORMATION 4 3 12 4 1.5 6
TWO PIECE SLEEVE ATTACH
4 3 4 1.5
8 (SHELL FABRIC) 12 6
INTERLINING SLEEVE
4 3 4 1.5
9 ATTACH 12 6
SHELL SLEEVE SEAM FLAT
4.25 3.5 4.25 1.5
10 PRESS 14.875 6.375
4.25 3.5 4.25 1.5
11 PRESS ELBOW, TURN SLEEVE 14.875 6.375
BUTTON MARKING &
4.25 3 4.25 1.5
12 ATTCHING 12.75 6.375
4 3 4 1.5
13 SLEEVE HEAD FULLNESS 12 6

 FRONT SECTION

5 4 5 3
14 FRONT MARKING 20 15
5 4 5 3
15 DART MARKING 20 15
6 5 6 3
16 AUTODART 30 18
4.25 3.5 4.25 1.5
17 FUSE DART 14.875 6.375
4 3 4 1.5
18 CENTRE BACK ATTACH 12 6
4 3 4 1.5
19 SIDE PANEL ATTACH 12 6

20 SIDE PANEL PRESSING 6 5.25 31.5 6 4 24
ARMHOLE TAPE ATT. TO
4 3 4 1.5
21 FRONT & BACK PANEL 12 6
FRONT POCKET FACING
5.5 4.25 5.5 3.25
22 ATTACH 23.375 17.875
4.5 3.25 4.5 2.5
23 FLAP READY 14.625 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
BREAST POCKET FOLD AND
4.25 3.5 4.25 1.5
26 PRESS 14.875 6.375
BREAST POCKET FACING
4 3 4 1.5
27 ATTACH TO POCKET BAG 12 6

40 | P a g e

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