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Final pl doc

  1. 1. 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 BANGALORE1|P a g e
  2. 2. PLANT LAYOUT ARCHITECTURAL BRIEF 20112|P a g e
  3. 3. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 Introduction about the companyProduct:• Formal Jacket• Formal TrouserOutput:• Trouser : 1000 pieces/day/line• Jacket: 500 pieces/day/lineNo. of Production Line:• Trouser: 05• Jacket: 04Total Output:• Trouser: 5000 pieces/day• Jacket: 2000 pieces/dayWorking per day: 08 Hours or 480 min. with a break of 30 min for Lunch.Work Timing: 9 a.m to 5.30 p.mWork Days: Monday to SaturdayTotal Plant Area: 287077 sq. feetGross Built-Up Area: 180164 sq. feetFAR: 0.633|P a g e
  4. 4. PLANT LAYOUT ARCHITECTURAL BRIEF 2011TABLE 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 DEPARTMENTS4|P a g e
  5. 5. PLANT LAYOUT ARCHITECTURAL BRIEF 2011OBJECTIVES: 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 flow5|P a g e
  6. 6. PLANT LAYOUT ARCHITECTURAL BRIEF 2011AR CHART:Activities Spreading & Cutting Merchandising Maintenance Warehouse CAD room Sampling Finishing IE- Dept. Accounts IT-Dept. Quality Sewing StoresStores A O U U O U U U U U U ESpreading & A A O U U U U I U U O UcuttingSewing O A A U X U O U O O O UFinishing U O A A U U O U O O O OWarehouse U U U A U U U U U U U UMerchandising U U X U U A U O O O X ASampling U U U U U A U O O O X IQuality U U O O U U U O U U X XCAD room U I U U U O O U U U X AIE- Dpt. U U O O U O O U U O O UAccounts U U O O U O O U U O X EMaintenance U O O O U X X X X O X UIT-Dpt. E U U O U A I X A U E UKEYSA: Absolutely necessary E: Especially important I: ImportantO: Ordinary closeness OK U: Unimportant X: Undesirable6|P a g e
  7. 7. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 DIFFERENT SECTION OF DEPARTMENTS FABRIC STORE WARE HOUSESTORAGE SEWING TRIMS STORE PACKING TRIMS STOREPRODUCTION CUTTING SECTION PREPARATORY SECTION ASSEMBLY SECTION FINISHING SECTION PACKING SECTIONSUPPORT SAMPLING SECTION CAD ROOM IE-DEPT.OFFICE IT-DEPT. ACCOUNTS & FINANCE PURCHASE DEPT. PRODUCTION ROOM PPC OFFICEHR DEPARTMENT HR MEDICAL ROOM TRAINING SECTION CRECHE REST ROOM MEETING ROOM + COUNSELLING ROOM CLOAK ROOM STAFF TOILET CANTEEN OPERATORS TOILETMAINTENANCE BOILER ROOM MAINTENANCE + MC STORAGE COMPRESSOR ROOM POWER HOUSEADMIN BLOCK MEETING ROOMS GM OFFICE BOARD ROOM MD OFFICE GUEST ROOM MERCHANDISING SECTION ACCOUNTS RECEPTION EXECUTIVE TOILETSFRONT SECTION PARKING SECURITY ROOM7|P a g e
  8. 8. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 keeping8|P a g e
  9. 9. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 record9|P a g e
  10. 10. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 flowchart10 | P a g e
  11. 11. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 available11 | P a g e
  12. 12. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 PROCESS CHART SEWING DEPT. Process ActivitiesSewing methods a) Proper work station b) Proper work aidBundle control sheet follow up a) Check listBundle follow up a) Bundle reportSerial maintenance a) Serial maintenance sheetQC records a) Quality reportsPlanning follow up a) Loading follow upCut clearance a) Cutting reportChecker quality records a) Quality checker evaluation sheet FINISHING DEPT.Trimming methods a) Trimming reports b) Operator trimming productivity chartChecking methods a) Proper work aid b) Proper work stationInline audit records/ procedures a) Inline audit sheetPressing methods a) Pressing defect sheetFolding methods a) Operator wise productivity reportsPacking methods a) Presenting quality reports PACKING DEPT.Carton dimension checking a) Checking carton dimensionPacking ratio a) Packing ratio reportFinal auditing a) Checking packing quality b) Final auditing12 | P a g e
  13. 13. PLANT LAYOUT ARCHITECTURAL BRIEF 2011ARTITECTURE 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.13 | P a g e
  14. 14. PLANT LAYOUT ARCHITECTURAL BRIEF 2011FOUNDATION: 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 beengiven 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 cracksVENTILATION: The places requiring more ventilation are fusing, finishing and ironingsection.  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 lux14 | P a g e
  15. 15. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 Source: ILO standardsSAFETY NORMS AND FACTORY ACTSome of the important laws that must be considered while designing a new plant layout are asfollows:15 | P a g e
  16. 16. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 OPERATIONAL DPARTMENTS16 | P a g e
  17. 17. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 OperatorSL.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 17 | P a g e
  18. 18. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 5 HIGHLEAD GC-188-MD S/N LOCK STITCH 4 3 12 4 1.5 6 6 PFAFF 1183 S/N LOCK STITCH 4 3 12 4 1.5 6 7 PFAFF 1183 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 11 HIGHLEAD GC-188-MD S/N LOCK STITCH 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/FEET218 | P a g e
  19. 19. PLANT LAYOUT ARCHITECTURAL BRIEF 2011PERSONNEL CALCULATION:DESIGNATION NO.SAMPLING Executive 1Pattern Master 2Cutting Master 1Supervisor 2Cutting Operator 2Sewing Operator 22Helper 6Ironing Operator 4FURNITURE:FURNITURE DESCRIPTION QUANTITYComputer Table 6Executive Table 1PM Tables 2Inspection Table 2Executive Chair Dimension (2 * 2) 9Normal Chairs Dimension (1.5 * 1.5) 22Flooring Material: Epoxy Coated Hardened FloorWorking Area:The working area will include all the PM tables with the inspection tables. It will also havethe storage area for paper & wastes. It will also include the space for the followingequipments & machines:  Stitching M/Cs  Iron/ Steam PressIt will also include the space for the following personnel with their computer tables:  Supervisors19 | P a g e
  20. 20. PLANT LAYOUT ARCHITECTURAL BRIEF 2011  Cutting MasterThe 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 theseparate cubic’s with computer table for each of the personnel mentioned below:  Pattern MasterThe partition should be done in a way that working area will be supervised from thesection/partition only. So, it should have one side transparent windows/ glasses, 4.5 feetabove 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 ofSAMPLING Executive. It will be furnished with an Executive table and computer table. Itshould also have 3 extra chairs along with an executive chair for the officer.20 | P a g e
  21. 21. PLANT LAYOUT ARCHITECTURAL BRIEF 2011PM & CAD DEPARTMENTThe purpose of the CAD department is to generate pattern for the garment and thus producethe production marker for the same. The CAD department also requires producing costingmarkers for the merchandisers. Following are the activities and assets required in thedepartment.  Plotter  Digitizer  Marker making  Marker Preparation  Costing marker  Bundle preparation report21 | P a g e
  22. 22. PLANT LAYOUT ARCHITECTURAL BRIEF 2011GENERAL OVER VIEW- AREA CALCULATION: Operator No. Of M/c M/C M/C Operator Space OperatorSL.NO Description M/C Length Width Area Space(Length) (Width) Area1 pm table 4 6 5 120 6 2 482 Plotter 2 8 3 48 7 2 28 computer3 table 5 5 3 75 3 2 30 Inspection4 Table 4 6 3 72 6 2 485 Digitizer 1 6 1.5 9 6 2 12 pattern6 cutter 1 6 5 30 6 2 12 Pattern Total Storage O/P7 Rack 1 6 3 18 Space 178 Paper8 Storage 2 3 3 18 Waste Paper9 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/FEET222 | P a g e
  23. 23. PLANT LAYOUT ARCHITECTURAL BRIEF 2011PERSONNEL:DESIGNATION NO.CAD Executive 1CAD Pattern Master 2Junior Pattern Master (manual) 2Costing Executive 1Costing Engineer 1Plotting & digitising Master 2Helper 3MACHINE:M/C DESCRIPTION QUANTITYComputer IBM 5Plotter Gerber 2Digitizer Gerber 1Pattern Cutter Gerber 1FURNITURE:FURNITURE DESCRIPTION QUANTITYComputer Table 5Executive Table 1PM Tables 4Inspection Table 4Executive Chair Dimension (2 * 2) 5Normal Chairs Dimension (1.5 * 1.5) 7Flooring Material: Epoxy Coated Hardened FloorWorking Area:The working area will include all the PM tables with the inspection tables. It will also havethe storage area for paper & wastes. It will also include the space for the followingequipments & machines:  Plotter  Digitizer  Pattern CutterThe total window area must be equal to the 1/6th of the total floor area.23 | P a g e
  24. 24. PLANT LAYOUT ARCHITECTURAL BRIEF 2011Administration/ Official Block:There should be a separate wooden partition for the personnel offices, where we will have theseparate cubic’s with computer table for each of the personnel mentioned below:  Costing Executive  Costing Engineer  Plotting & Digitising MasterThe partition should be done in a way that working area will be supervised from thesection/partition only. So, it should have one side transparent windows/ glasses, 4.5 feetabove 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 CADExecutive. It will be furnished with an Executive table and computer table. It should alsohave 3 extra chairs along with an executive chair for the officer.24 | P a g e
  25. 25. PLANT LAYOUT ARCHITECTURAL BRIEF 2011FABRIC STORE DEPARTMENTThis department is required for the storage of fabrics received as raw material.. Following arethe activities carried out in this department.• Raw Material (fabric receipt)• Quality checking• Issue material for production• Weighing machines• Spring balanceFlooring Material: ConcretePERSONNEL:DESIGNATION DESCRIPTION NO.RMQA Executive Operates trim & fabric stores both. 1Store Manager For the Fabric storage. 1MRP 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 storageHelper 6Inspection Supervisor 1Inspector 225 | P a g e
  26. 26. PLANT LAYOUT ARCHITECTURAL BRIEF 2011MACHINEM/C DESCRIPTION QUANTITYComputer IBM 6Fabric Inspection Machine Gerber 2Lifting Machine 1FURNITUREFURNITURE DESCRIPTION QUANTITYComputer Table 6Executive Table 1Executive Chair Dimension (2 * 2) 6Normal Chairs Dimension (1.5 * 1.5) 7Flooring: Epoxy Coated Hardened FloorWorking Area:The working area will include the space for the following equipments & machines:  Fabric Inspection Machine  Lifting Machine  Storage RacksIt will also include the space for the cubic of following personnel:  Store Supervisor  Inspection SupervisorThe total window area must be equal to the 1/6th of the total floor area. It should also have thespace for the storage of excess material.Here, the file storage rack will also be placed.Administration/ Official Block:There should be a separate wooden partition for the personnel offices, where we will have theseparate cubic’s with computer table for each of the personnel mentioned below:26 | P a g e
  27. 27. PLANT LAYOUT ARCHITECTURAL BRIEF 2011  Store Manager  MRP Engineer  DATA Entry OperatorThe partition should be done in a way that working area will be supervised from thesection/partition only. So, it should have one side transparent windows/ glasses, 4.5 feetabove from the floor. It should have 2 sided entry and exit.The administration block should have a separate, medium sized, cabin for the Office ofRMQA Executive. It will be furnished with an Executive table and computer table. It shouldalso have 3 extra chairs along with an executive chair for the officer.27 | P a g e
  28. 28. PLANT LAYOUT ARCHITECTURAL BRIEF 2011TRIM STORAGE DEPARTMENT:This department is required for the storage of trims received as raw material. This departmentalso keeps a record of trims received and issued to the production. Following are the activitiescarried out in this department.• Raw Material (Trim Card)• Quality checking• Issue material for productionGENERAL 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 6314.82928 | P a g e
  29. 29. PLANT LAYOUT ARCHITECTURAL BRIEF 2011  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 77Assume 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 25029 | P a g e
  30. 30. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 Sub Total Space 5000 Allowance (150%) 5988.603 Total Required Area 9981.005PERSONNEL:DESIGNATION DESCRIPTION NO.Store Manager For the Fabric storage. 1MRP 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 storageHelper 6Inspection Supervisor 1Inspector 10FURNITURE:FURNITURE DESCRIPTION QUANTITYComputer Table 16Executive Table 1Executive Chair Dimension (2 * 2) 5Normal Chairs Dimension (1.5 * 1.5) 10MACHINES:M/C DESCRIPTION QUANTITYComputer IBM 6Weighing Machine 530 | P a g e
  31. 31. PLANT LAYOUT ARCHITECTURAL BRIEF 2011Flooring: Epoxy Coated Hardened FloorWorking Area:The working area will include the space for the following equipments & machines:  Storage RacksIt will also include the space for the cubic of following personnel:  Store Supervisor  Inspection SupervisorIt 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.Here, the file storage rack will also be placed.Administration/ Official Block:There should be a separate wooden partition for the personnel offices, where we will have theseparate cubic’s with computer table for each of the personnel mentioned below:  Store Manager  MRP Engineer  DATA Entry OperatorThe partition should be done in a way that working area will be supervised from thesection/partition only. So, it should have one side transparent windows/ glasses, 4.5 feetabove from the floor. It should have 2 sided entry and exit.31 | P a g e
  32. 32. PLANT LAYOUT ARCHITECTURAL BRIEF 2011CUTTING & SPREADING DEPARTMENT:The department serves the purpose of spreading of the fabric on long tables and cutting thepattern pieces out of it. The critical factor in deciding the area of the department is the lengthof the cutting table. The process of numbering and bundling is also carried out in thisdepartment. The department requires the storage space for the cut fabric rolls, cutcomponents, bundles etc. Following are the requirements for this department.  Spreading Tables  Cutting tables  Numbering tables  Bundling tables  Checking tablesGENERAL 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 118032 | P a g e
  33. 33. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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/FEET2PERSONNEL:DESIGNATION NO.CUUTING Executive 1CUTTING Supervisor 2SPRAEDING Operator 40TICKETING & BUNDLING Operator 40INSPECTION Operator 12CUTTING Operator 16HELPER 10DATA ENTRY Operator 233 | P a g e
  34. 34. PLANT LAYOUT ARCHITECTURAL BRIEF 2011FURNITURE:FURNITURE DESCRIPTION QUANTITYComputer Table 5Executive Table 1Executive Chair Dimension (2 * 2) 5Normal Chairs Dimension (1.5 * 1.5) 4Cut Parts Storage Rack Dimension (8 * 1.5) 10Fabric Storage Rack Dimension (8 * 4) 5Lining Storage Rack Dimension (8 * 4) 3MACHINES:M/C DESCRIPTION QUANTITYComputer IBM 5Straight Knife EASTMAN 16Tagging Punch Machine EASTMAN 40Flooring Material: Epoxy Coated Hardened FloorWorking Area:The working area will include all the spreading & cutting tables. It will also have the storagearea for paper & wastes. It will also include the space for the following equipments &machines with space for storage racksThe total window area should 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 theseparate cubic’s with computer table for each of the personnel mentioned below:  Cutting Master  Data Entry OperatorsThe partition should be done in a way that working area will be supervised from thesection/partition only. So, it should have one side transparent windows/ glasses, 4.5 feetabove from the floor. It should have a sided entry and exit.34 | P a g e
  35. 35. PLANT LAYOUT ARCHITECTURAL BRIEF 2011The administration block should have a separate, medium sized, cabin for the Office ofCUTTING Executive. It will be furnished with an Executive table and computer table. Itshould also have 3 extra chairs along with an executive chair for the officer.35 | P a g e
  36. 36. PLANT LAYOUT ARCHITECTURAL BRIEF 2011SEWING DEPARTMENT:The department serves the purpose of sewing the garment and thus carrying out theproduction. 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  InspectionGENERAL 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 7.536 | P a g e
  37. 37. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 4.237 | P a g e
  38. 38. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 99010338 | P a g e
  39. 39. PLANT LAYOUT ARCHITECTURAL BRIEF 2011 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 Total Required Area 5775.4375 IN TERMS OF FEET/FEET2 No. Of Trouser Line 5 Total Area for Trouser Sewing Dept. 28877.1875 RACK AREA 320 TOTAL AREA 29197.187539 | P a g e

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