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NATIONAL INSTITUTE OF FASHION TECHNOLOGY, GANDHINAGARPLANT LAYOUTSubmitted to: Submitted by: Mr.Manoj Tiwari Aryan SinghRuchika Tripathi Swati Singh DFT- 7 Plant layout is the spatial arrangement and configuration of departments, work stations, machinery and equipment used in the conversion process. Layout of an apparel production plant directs the flow of materials and work-in-process from start till its completion and integrates material handling and equipment. An efficient layout has the flexibility to be changed to meet requirements of the product line, delivery schedules, and anticipated volume. Safety is a major consideration in plant layout. Fire and safety codes, emergency and accessible exits, open traffic areas, etc. must all be a part of layout plans. ,[object Object],Objective: To set up a manufacturing unit producing 3500 women’s semi formal shirt per day Plot Area: (22*100) 2200 sq m FSI – 1.2 Ground Coverage: 80% Total area that can be constructed = 2200 * .80 = 1760 sq m Specifications of the style studied Raw MaterialSpecificationConsumption/garmentBody FabricPoplin1.81 mInterliningMicrodot0.42 mButtonPlastic (14 L)16 pcsThread (Ticket No. 25)Spun Polyester35 mThread (Ticket No. 50)Spun Polyester38 mThread (Ticket No. 100)Spun Polyester195 mPaper Printed tag-1 pcPrinted Paper1 pcMain Label1 pcWash Care Label1 pc STORES DEPARTMENT Process flow chart : StoresReceipt of Bill Of Materials Package verification against packing list for weight & no of packagesMaterials receivedLab test Trim card for accessoriesNoTo be inspected Rejected Inspection process Yes passQuality checking Storage of passed material Update status to productionIssues of fabric to cutting section based on lay recordIssues of trims to production Receipt of end bits from cutting sectionReceipt of left over materials from productionInspection fail Conditionally approved by buyer Rejected Storage in rejected Area In stores department we have to keep an inventory of 15 days for the required raw material. Therefore we have to plan the no. of racks required and their dimensions. Racks for Accessories: All the accessories will be kept in a box. Here we have assumed the dimension of the box and approximately the no. of pcs that can be accommodated in the box. AccessoriesRequired Amount for 15 daysDimension of box (inches) l*b*hNo. of pcs that can be accommodated Volume of box(in cubic inch)Required volume (in cubic inch)Button8400003*2.5*22000156360Thread(Tk No. 25)18375008*8*2.5300001609800Thread(Tk No. 50)19950008*8*2.53000016010640Thread(Tk No. 100)102375008*8*2.53000016054600Printed Paper Tag525504*3*21002412612Printed Paper5255016*16*120025667264Main Label525505 Dia*237515722000Wash Care Label525505 Dia*237515722000Therefore total required volume (in cubic inch)205276 Dimension of racks for accessories = 34*21*66(inches) or 0.86*0.53*1.6 meters Total Volume required (in cubic inch) = 205276 Therefore 4 racks will be required. Racks for body fabric and interlining FabricInterliningRequired length for 15 days (m)9502522050Length in a roll (m)300100No. of rolls req.317220Diameter of roll (inch)126Length of roll (inch)6440No. of rolls in one shelf(assumed)710Length of the rack(as per given rolls/shelf) (inch)8460Ease of roll movement lengthwise (inch)55Final Length of shelf(inch)8965Ease of roll movement heigthwise (inch)66Distance b/w two successive shelfs (inch)1812Required no. of shelves4522Height of the rack(inch) 9075No. of shelves in one rack56Width of the rack6945Dimension of the rack(inches)89*69*9065*45*75Dimension of the rack(meters)2.26*1.75*2.281.65*1.14*1.90No. of racks required94 There will be two fabric inspection machines in stores department of dimension 2.43*1.82 meters CUTTING DEPARTMENT Receive fabrics from stores Sample cutting Approval of sample cuttingReceipt of cut file & pattern ( CAD Process) Plan for cutting based on basic cutting plan & fabric allocation Release lay record Receipt of fabric Laying & spreadingMarker inspection Lay inspectionCut parts inspection Numbering Panel checking Re cutting Embroidery / printing / fusing Fusing inspection Sorting Storage Issue to sewing Dimension for cutting room furniture Length=Marker length + allowance for fabric rolls We have taken marker length (4 way marker) = 7.15m Allowance = 1.5 m Total length = 8.65 m Width =Width +Allowance Width=1.52 m Allowance=0.3 m Total width =1.82m Dimension of cutting table for fabric =8.65*1.82*0.84 meters No. of tables required Total no. of minutes=480 Width(m)1.52Components of garments28Cut capacity/day3500Marker Length(m)7.15No. of garments in a marker4Av. Fabric consumption(m)1.81No. of plies in lay135No. of lays7Av. Time for laying /lay(mins)140Av. Time for cutting /lay(mins)100Total time for cutting & laying (mins)240Total no. of tables for laying & cutting4Av. Tim for sorting 1 garment/person(min)1Av. Time for sorting 500 garments(min)500Sorting and bundling tables2No. of fusing machines (3.3 x 1.6 mt)2Band knife machine s (2.25 x 1.5)1Fusing assisting tables2Trolleys In cutting dept. there will be fabric temporary storage. Calculation of Fabric Temporary Storage FabricCutting days inventory 1.5Required fabric length(m)9502Length in a roll (m)300No. of rolls req.31Diameter of roll (inch)12Length of roll (inch)64No. of rolls in one shelf(assumed)2No. of rolls in a rack15No. of racks2Ease for roll movement(inches)6Length of rack(inches)66 Therefore the dimensions of the rack = 66*60*42 inches or 1.32*1.2*0.84 meters SEWING DEPARTMENT Receipt of cut parts from cutting sectionReceipt of machine layout Study of layout & set the batch Load pilot run lotApproval of pilot runLoad bulk cutting Monitor production as per targetEnd line checking Total SAM = 23.27 minutes Total operations (including ironing, marking) = 48 Total time available = 480 minutes Total pieces required = 3500 ,[object Object]

= 7.30 piecesOperation breakdown and line balancing has been done keeping in mind the pieces required and the SAM of the individual operations. Accordingly, number of machines required for each operation has been found out. Line Layout: ,[object Object],FINISHING SECTION Receive garments from sewing sectionMiddle checking AQL inspectionReceipt of poly packing approvalDe dusting with blowerDe dusting & removal of cut thread PressingPresentation checking Measurement checking Folding Tagging Poly bag packing To packing section S.No.OperationSAMPcs/minRequired People1Thread Trimming0.432.333.132Primary Inspection/0.641.554.70Spotting4Ironing0.641.564.675Measurement Check/0.851.186.19Final Check6Final Ironing0.961.056.97Total3.5225.66 LIGHTING DIAGRAM Definition A light source emits a flow of energy measured by a unit of power called a lumen. The density of light that falls on a surface is measured in foot candles, or lux. A foot candle is one lumen of light density per square foot. A lux is one lumen of light density per square meter. The foot candle is an older British measurement that is largely being replaced by the metric-based lux. Lumen: a unit of luminous flux equal to the amount of light given out through a solid angle of 1 steradian by a point source of 1 candela intensity radiating uniformly in all directions Outdoor light levels, as measured by a light meter, can range from 107,527 lux in bright sunlight to 107 lux on a very dark day. Recommended light levels (in lux) for indoor work spaces are 500 for personal computing work; 750 for supermarkets; 1,500 to 2,000 for detailed drawing work; and 10,000 to 20,000 for visual tasks in extremely low contrast using small-sized objects. Direct, intense lighting is required for the latter tasks. Activity Illumination(lux, lumen/m2) Public areas with dark surroundings 20 – 50 Simple orientation for short visits 50 – 100 Working areas where visual tasks are only occasionally performed 100 – 150 Warehouses, Homes, Theaters, Archives 150 Easy Office Work, Classes 250 Normal Office Work, PC Work, Study Library, Groceries, Show Rooms, Laboratories 500 Supermarkets, Mechanical Workshops, Office Landscapes 750 Normal Drawing Work, Detailed Mechanical Workshops, Operation Theatres 1,000 Detailed Drawing Work, Very Detailed Mechanical Works 1500 - 2000 Performance of visual tasks of low contrast and very small size for prolonged periods of time 2000 – 5000 Performance of very prolonged and exacting visual tasks5000 - 10000 Performance of very special visual tasks of extremely low contrast and small size 10000 – 20000 Lux requirements in the industry: Task GroupStandard Service Illumination (Lux)Reflectance Contrast usually low (Lux)Errors will have serious consequences (Lux)Rask of short duration (Lux)Storage area and plant room with no continuous work150---Casual work200---Rough work, rough machining and assembly300500500300Demanding work, inspection of medium machining500750750300Fine work: Colour discrimination, textile processing and fine machining 100015001500750Very fine work: hand engravings, inspection of fine machining and assembly 1500300030001000Minute work, inspection of very fine assembly3000300030001500 Levels specific to garment industry: OperationsLux levelSewing300 - 500 for normal1000-1500 for critical operationsEmbroidery700Processing150Packing150 – 300Inspection700 for routine1000 for critical/minute inspection COMPLIANCE REQUIREMENT: Exemptions 75 hour O.T. ExemptionExemption for Time CardExemption for AmbulanceExemption for CreachBuildingName 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 blockHealthDrinking 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 a local languageLocate from 20 feet away from toiletLocate maximum 50 meters distance from work spotDrinking Water vessels 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 cleanliness Suggession Box RegisterToiletsToilet 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 Accommodation Min. 61 cm for every 50 employees upto first 500Urinal Accommodation 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 providedAdequate Water TabsNo smoking Sign in Gents ToiletAwareness Quotes in ToiletsLadies / Gents Toilet Name Sign in Dual Language and PictureSpittoonsAdequate SpittoonsSpittoons filled by Sand or Suitable disinfectantSpittoons covered by bleaching powder layerSpittoons scrapped or cleaned at least once in every day Others500 Cubic feet for every employeesDisposal of Wastes and effluentsRoom TemperatureLighting facilityTrees on factory campusSafety GuardsMetal Glows on good ConditionRubber Mat to ironersRubber Glows to ironersIroners wearing slipperMotar GuardNeedle GuardEye GuardScissors and trimmers are tiedBroken Needle Register Dining HallDining Hall with sufficient SpaceDining Hall with Sufficient Chair/TableWater FacilityAmbulance RoomDoctor VisitNurseMedicinesMedicines Issuing RecordCreachFireSufficient Fire ExtinguisherFire Extinguisher all in good ConditionFire Extinguisher Location ListFire Extinguisher Service ChecklistFire Extinguisher kept in 3 feetFire Signage in English & Local Language.Usage Guide in dual languageFire Extinguisher Color 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) FileFire 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 Generator room with Water and SandDiesel Storage area floor filled by sandEvacuation Plan in all Floor / AreaEmergency ExitEmergency Exit on OpenEmergency Exit SignageEmergency Exit with outside open facilityEmergency Light to All room / Area AdequateEmergency Light to All staircaseEmergency Light to All Exit & Emergency Exit H.R.Personnel File to AllApplication FormPassport Size PhotoEducational Qualification CertificateAge ProofI.D. ProofAddress ProofTechnical CertificatePrevious Company Experience/Relieving orderOld Salary SlipESI Nomination Form 1PF 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 CounselingMeetingsPerformance appraisalLeave CardFull & Final SettlementExit InterviewGratuityBonusSalary BreakupSalary on DateInduction ProgrammerInduction Register ManpowerManpower Department wise Male/Female Strength ReportAttendance 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 TimeAny unwanted deduction for employeeUnpaid salary are reversedPay Cover Availability SecurityAdequate 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)

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