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T-Shirt Manufacturing - Plant Layout
1. National Institute of Fashion Technology,
Chennai
Presented By:
Abhishek Raj
Sarthak Sagar
Shriya Arora
Pammi Kumari
DFT-VII
Plant Layout
Plan for T-Shirt Manufacturing Unit
Department of Fashion Technology
2. Product Description
Required Raw Materials
Location Analysis
Proposed Factory Layout
Area Description
Material Flow
Machines and Equipment
Man Power
Contents
10. Brandix India Apparel City (BIAC) is a revolutionary development in the apparel
industry; a unique, integrated apparel supply chain city, managed by Brandix
Lanka Ltd.
Spread over 1000 acres in the port city of Visakhapatnam (or Vizag for short) in
the eastern state of Andhra Pradesh, it brings alive an avant garde 'Fibre to
Store' concept.
BIAC will bring together world class apparel chain partners from the design table
to consumer brands in flawless integration.
Overview
11. BIAC is first in the world to support a fully integrated vertical supply chain
Fibre to Store Concept
Infrastructure
12. Special Economic Zone
Land Area Covers 1000 acers
Received ISO 14001:2004 EMS certification in 2011
Environment friendly and sustainable campus
Follow CTPAT – Customs-Trade Partnership Against Terrorism
Infrastructure
14. Population (Census Data 2011)
84.66 M in the state
4.28 M in Vizag district
Employable Population:
Within 20 minutes of BIAC
Population 260,000
Employable 45,000
Within 45 minutes of BIAC
600,000 (Age: 18-35)
105,000 Employable (18%)
65% literacy rate
Two Universities in Vizag
Human Resource Availability
15. Cotton production in India
35.5 M bales (Cotton year 2012)
2nd largest Cotton producer in the world with 21% global share
Cotton production in Andhra Pradesh
3rd largest Cotton producing state
12% of the country’s production
Cotton with long staple fibres
Energy
Natural gas supply from Godavari Basin
Ample supply of coal from neighbouring states
Water
Perennial water supply: Godavari River
Natural Resource Availability
19. Presently running Companies in BIAC campus:
Ocean India - fabric mill for knitting, dyeing and printing
Screenline Printing - printing services
Shore to Shore- Manufacturing tags and labels
Vardhman – Threads Suppliers
Brandix Apparel India- ladies innerwear
Seeds Intimate Apparel- Bras and Brallets
Quantum Clothing - ladies innerwear and men’s shirts
S & S- manufacturing underwires for bras
Pioneer Elastics - China based company manufacturing and dyeing
narrow elastic
Thermax- Providing energy solutions for other manufacturing units
Operational Units
20. Presently running Companies in BIAC campus:
Ocean India - fabric mill for knitting, dyeing and printing
Screenline Printing - printing services
Shore to Shore- Manufacturing tags and labels
Vardhman – Threads Suppliers
Internal Suppliers
24. Single Shift
Working Time per day = 420min (7 hours)
No. of working days per week = 6
No. of days working in a month: 25
Output per day @ 60% efficiency : 10,000
Output per month: 2,50,000
Estimated Production Requirement
28. SAM of the T-Shirt:
Crew Neck : 6
No. of m/c for final production= 400
No. of m/c for pilot run = 20
No. of m/c for training room = 20
10% extra, so available m/c=440+44= 484
No. of lines in sewing floor: 40
No. of workstation req. for a T-shirt : 10
No. Machine Required
29. 175 sq. ft.*no. of m/c
=(175*400)sq. ft.
=70,000 sq. ft.
Factory Space Required
30. Total Area – 70,000 sq. ft.
Raw Material Warehouse – 2058 sq. ft.
Finish Goods Warehouse – 3262.5 sq.
ft.
Machine yard – 1406.5 sq. ft.
Production Area – 11,074 sq. ft.
Cutting Area – 3390 sq. ft.
Embroidery – 942.5 sq. ft.
Printing – 942.5 sq. ft.
Office – 426.6 sq. ft. (7 offices)
Staff washroom – 1269.12 sq. ft.
Area Description
Washroom – 977.2686 sq. ft.
Utilities / Crèche – 675.33 sq. ft.
Canteen – 13650 sq. ft.
Medical room – 628.8 sq. ft.
Assembly – 5520 sq. ft.
Parking – 12600 sq. ft.
Front office – 1200 sq. ft.
Green Area – 1925 sq. ft.
31. Length of the roll: 100m
Width of the roll: 5.5 ft
Height of the roll: 1.5 ft
Average consumption per garment: 1 m
Fabric width: 60 inch
Fabric consumption per day:10000m
No. of rolls req. per day: 100 rolls
Inventory: 2 days
Total rolls inventory: 200
Rack dimension: 6ftX 6ftX4ft
No. of shelves: 3
No. of rolls stacked in a height:24
Fabric Store
32. Inspection m/c: 9ftX7ft
Average speed: 6mts/min
Utilization: 90%
Available time: 432min
Inspection per m/c: 2592m
Daily needed fabric:68,544m
M/c req. =3
No. of racks required: 25
No. of shelves: 3
Area required for fabric store: 2058sq. ft
Fabric Store
34. Available time: 480 min
Utilization: 75%
Efficiency: 60%
Average consumption: 2m
Marker length: 4m
Layer length: 4.008m
No. of sizes in a marker: 2
No. of layer: 80
Total garment in a lay: 160
Meter spread: 320.64m
No. of rolls req. :2.14=3
Bundle size: 20
No. of lays req. per day: 40
Cutting room
35. Spreading table length: 15 ft
No. of spreading table req.: 11
Total area : 4314 sq ft
Cutting room
36. SAM of the t-shirt: 5.33
No. of workstation: 400
No. of sewing line: 40
Total m/c:
M/c area per line:122.5 sq. ft.
Open space area per line:105 sq. ft.
Total area required: 7175 sq. ft.
Sewing Room
38. No. of employees: 633
Canteen is with cooking
So area req. per employee is 25 sq ft
So the canteen area is 9750 sq ft
Occupies 320 employees at a time.
So there will be two shifts for employees
Canteen