NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

GANDHINAGAR

PLANT LAYOUT

Submitted to:
Submitted by:
Mr.Manoj Tiwari

Aryan Singh
Ruchika 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 .
The following factors should be taken into consideration
while planning a layout:
Minimization of manufacturing costs
Efficient work flow
Minimization of work transfer
Provision of future expansion

Selection of Factory Site

Demographic, Infrastructural, Natural and Social factors
should be considered before selecting a location for a factory
site.
Demographic

and

Infrastructural

analysis

is

all

about

understanding population age groups, per capita income,

education level, occupational structure and availability of
skilled and non skilled manpower, technically qualified and
trained supervisors and managers, transportation cost, link
roads, nearness to railway station, airport or sea port,

banking

and

financial

institutes..

Natural and social factors like climatic conditions, pollution,

public hazards, political problems, local laws and regulations,
medical services, public utilities, civic amenities and means
of communication should also be analysed before selection
of the layout.
Layout of the Plant
Layout of the plant is decided based on process sequence,
building structure, shop floor transportation, type of layout
(product or process based or a combination of both) and
arrangement of machines. The aim of every layout is to
maximize utilization of available space in order to speed up
the material flow. Highly specialized machines and small
parts assembly may be configured with a line arrangement
for

final

assembly.

Factors to be considered for designing an effective layout

include number of workers both male and female, number of
machines (size, weight by models), entrance, exit and
passages (size, width, position, number of each of them) for
production as well as administrative wing, change room,
lunch room, lavatories, medical emergency room and
provision for those governed by local laws. Utilities like
boiler, air compressor, vacuum pumps, generator, electric
panel, air conditioning machine, underground water storage
tanks for boiler and washing machines, water softening
plant, waste water recycling plant, drainage system are also

equally

important.

Other factors that need attention before laying out the

factory plan include ceiling height (3-3.5 metres from floor),
lighting (large windows of 2 or 3 stages) and illuminance
levels (600 Lux for production and 800 Lux for inspection
areas) besides ventilation. Also, the workplace should have
sufficient number of mens and womens toilets and drinking
water outlets in the vicinity.

Objective: To set up a manufacturing unit producing 3500

womens 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 Material

Specification

Consumption/ga

rment
Body Fabric
Poplin
1.81 m
Interlining
Microdot
0.42 m
Button
Plastic (14 L)
16 pcs
Thread (Ticket Spun Polyester 35 m
No. 25)
Thread (Ticket Spun Polyester 38 m
No. 50)
Thread (Ticket Spun Polyester 195 m
No. 100)
Paper Printed -

1 pc

tag
Printed Paper
Main Label
Wash
Care

1 pc
1 pc
1 pc

Label

STORES DEPARTMENT

Process flow chart :

Stores
Receipt of Bill Of Materials
Package verification against packing list for weight & no of packages

Materials received

Lab test

Trim card for accessories

To be inspected

Yes

No

Inspection process

pass

Rejected

Inspection fail
Quality checking
Conditionally approved by buyer

Rejected

Storage of passed material

Storage in rejected Area
Update status to production

Issues of fabric to cutting section based onIssues

lay record
of trims to production
Receipt of left over materials from production
Receipt of end bits from cutting section

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.

Accessorie

Require

Dimensi

on

Amount

box

for

No.

of

pcs

Volum Require

of that can be e

15 (inches)

of d

accommodat box(in

volume

ed

cubic

(in cubic
inch)
6360
9800

Button
Thread(Tk

days
840000
183750

l*b*h
3*2.5*2
8*8*2.5

2000
30000

inch)
15
160

No. 25)
Thread(Tk

0
199500

8*8*2.5

30000

160

10640

No. 50)
Thread(Tk

0
102375

8*8*2.5

30000

160

54600

No. 100)
Printed

00
52550

4*3*2

100

24

12612

Paper Tag
Printed

52550

16*16*1

200

256

67264

5 Dia*2
5 Dia*2

375
375

157
157

22000
22000

Paper
Main Label 52550
Wash Care 52550
Label

205276
Therefore total required volume (in cubic inch)

Dimension of racks for accessories = 34*21*66(inches)

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

Fabric
Required length for 95025

Interlining
22050

15 days (m)
Length in a roll (m)
300
No. of rolls req.
317
Diameter
of
roll 12

100
220
6

(inch)
Length of roll (inch)
64
No. of rolls in one 7

40
10

shelf(assumed)
Length
of

60

rack(as

per

the 84
given

rolls/shelf) (inch)
Ease
of
roll 5

movement
lengthwise (inch)
Final
Length
shelf(inch)
Ease
of

of 89
roll 6

65
6

or

movement
heigthwise (inch)
Distance b/w two 18
successive
(inch)
Required
shelves
Height

12

shelfs
no.
of

of 45

22

the 90

75

rack(inch)
No. of shelves in one 5

rack
Width of the rack
69
Dimension of the 89*69*90

45
65*45*75

rack(inches)
Dimension of

1.65*1.14*1.90

the 2.26*1.75*2.28

rack(meters)
No. of racks required 9

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 cutting

Receipt of cut file & pattern ( CAD Process)

Plan for cutting based on basic cutting plan & fabric allocation

Release lay record

Receipt of fabric

Laying & spreading

Lay inspection

Cut parts inspection

Numbering

Panel checking

Marker inspection

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)

1.52

Components

of 28

garments
Cut capacity/day

3500

Marker Length(m)

7.15

No. of garments in a 4
marker
Av.

Fabric 1.81

consumption(m)
No. of plies in lay

135

No. of lays

Av. Time for laying 140

/lay(mins)
Av.

Time

for 100

cutting /lay(mins)
Total

time

cutting

&

for 240
laying

(mins)
Total no. of tables 4
for laying & cutting
Av. Tim for sorting 1 1
garment/person(min
)
Av. Time for sorting 500
500 garments(min)
Sorting

and 2

bundling tables
No.

of

fusing 2

machines (3.3 x 1.6

mt)

Band knife machine 1

s (2.25 x 1.5)
Fusing
assisting 2
tables
Trolleys

In cutting dept. there will be fabric temporary storage.

Calculation of Fabric Temporary Storage
Fabric
days 1.5

Cutting
inventory
Required

fabric 9502

length(m)
Length in a roll (m)
300
No. of rolls req.
31
Diameter
of
roll 12
(inch)
Length of roll (inch) 64
No. of rolls in one 2
shelf(assumed)
No. of rolls in a rack 15
No. of racks
2
Ease
for
roll 6
movement(inches)
Length
of 66
rack(inches)
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 section

Receipt of machine layout
Study of layout & set the batch
Load pilot run lot
Approval of pilot run
Load bulk cutting
Monitor production as per target
End line checking

Total SAM = 23.27 minutes

Total operations (including ironing, marking) = 48
Total time available = 480 minutes
Total pieces required = 3500
Pieces per minute = 3500/480
= 7.30 pieces
Operation breakdown and line balancing has been done
keeping in mind the pieces required and the SAM of the
individual

operations.

Accordingly,

number

required for each operation has been found out.

Line Layout:

of

machines

The layout that has been chosen for the line is the most
common method of arranging machines with centre table
option; here all operators are facing in one direction. For one
column of workers the centre table is on left, while for the other
column of operators the centre table is on right, hence
differential ease of bundle pickup and disposal. Centre table on
the left side of the operator is always better for larger
component.

For

operations

involving

two

component

assembly where picking has to be done from both right and left
of the operators, the service table at right is advisable, this is
because additional extension space can be created at left side
with comparative ease but creating additional space at right
side of machine is difficult. Generally wiring is done underneath
the centre table, and sewing machine motor is on right side of
sewing machine table, so wiring for one column of sewing
machine is cumbersome. Material movement in this type of
layout is lateral/vertical/zigzag. Light source has to be separate
for two columns of machine, thus infrastructure cost for lighting
will be more. As operators are facing same sides (regimental
seating) they are less prone to talk. The arrangement is
vaastu-friendly.

FINISHING SECTION

Receive garments from sewing section

Middle checking

AQL inspection

Receipt of poly packing approval

De dusting with blower

De dusting & removal of cut thread

Pressing

Measurement checking

Folding
Tagging
Poly bag packing
Presentation checking
To packing section

S.No.

Operation

SAM

Pcs/min

Required People

1 Thread Trimming

0.43

2.33

3.13

2 Primary Inspection/
Spotting

0.64

1.55

4.70

4 Ironing

0.64

1.56

4.67

5 Measurement Check/
Final Check

0.85

1.18

6.19

6 Final Ironing

0.96

1.05

6.97

Total

3.52

25.66

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
Easy Office Work, Classes

150
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 tasks
5000 - 10000

Performance of very special visual tasks of extremely low

contrast and small size

10000

20000
Lux requirements in the industry:
Task Group

Standard Reflecta

Errors will Rask

Service

nce

have

of

Illuminat

Contrast

serious

short

ion (Lux)

usually

conseque

durati

low

nces (Lux)

on

Storage area and plant room 150

(Lux)
-

(Lux)
-

with no continuous work

Casual work
200
Rough
work,
rough 300

500

500

300

machining and assembly

Demanding work, inspection 500

750

750

300

of medium machining
Fine
work:
Colour 1000

1500

1500

750

3000

3000

1000

3000

3000

1500

discrimination,

textile

processing

and

machining
Very
fine

work:

fine
hand 1500

engravings, inspection of fine

machining and assembly
Minute work, inspection of 3000
very fine assembly

Levels specific to garment industry:

Operations

Lux level

Sewing

300 - 500 for normal

Embroidery
Processing
Packing
Inspection

1000-1500 for critical operations

700
150
150 300
700 for routine
1000 for critical/minute inspection

COMPLIANCE REQUIREMENT:
Exemptions
75 hour O.T. Exemption
Exemption for Time Card
Exemption for Ambulance
Exemption for Creach
Building
Name Sign to All Rooms / Area
Indicators / Direction from Security Gate onwards
Storage above Storage limit Carton Box etc.
Aisle marking
Aisle width minimum 112 cm.
Indicators Arrows in the passage
Aisle without block
Health
Drinking Water
At least4.5 Litres water provided per day per employee
Water Testing Certificate
Drinking water not in plastic pot
Drinking Water, Cup availability
Drinking 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 language

Locate from 20 feet away from toilet
Locate maximum 50 meters distance from work spot
Drinking Water vessels cleaned at least once in a day
Water Reservoir or Tank Cleaned at least once in a week
Water centre cleaning condition
Water Vessal Cleaning log sheet
Water Centre Incharge person with cleanliness
Suggession Box Register
Toilets
Toilet Seat to Every 20 Women
Toilet Seat to Every 20 men upto 100
Toilet Seat to Every 50 men beyond 100
All toilet seat with proper privacy and lock facility
Urinal Accommodation Min. 61 cm for every 50 employees upto
first 500
Urinal Accommodation Min. 61 cm for every 100 employees for
above 500
Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
Dust Bins
Buckets with mug at toilets
Toilet White Washed once in every four month
Tiles/Mosaic floors washed with Detergent or disinfectant once
in four month

Daily Cleaning Log sheet provided

Adequate Water Tabs
No smoking Sign in Gents Toilet
Awareness Quotes in Toilets
Ladies / Gents Toilet Name Sign in Dual Language and Picture
Spittoons
Adequate Spittoons
Spittoons filled by Sand or Suitable disinfectant
Spittoons covered by bleaching powder layer
Spittoons scrapped or cleaned at least once in every day

Dining Hall
Dining Hall with sufficient Space
Dining Hall with Sufficient Chair/Table
Water Facility
Ambulance Room
Doctor Visit
Nurse
Medicines
Medicines Issuing Record
Creach

H.R.
Personnel File to All
Application Form
Passport Size Photo

Educational Qualification Certificate

Age Proof
I.D. Proof
Address Proof
Technical Certificate
Previous Company Experience/Relieving order
Old Salary Slip
ESI Nomination Form 1
PF Nomination Form 2
Gratuity Nomination Form F
Factory Act Nomination Form 34
Track Record
Appointment Order
Insurance
NDA with Signature
Employee Manual
I.d. Card to All
Adequate Swiping machine
Punching Card to All
ESI Card to All
PF Slip to All
Awareness Programme
Stress Relieve Counseling
Meetings
Performance appraisal
Leave Card
Full & Final Settlement
Exit Interview

Gratuity
Bonus
Salary Breakup
Salary on Date
Induction Programmer
Induction Register

Manpower
Manpower Department wise Male/Female Strength Report
Attendance Report
Late Report
Absentism Report
Daily Staff In-Out Register
Is there Under Age
Contract Employees
Punch report
Leave card to each employee
MIR (Material Issue Register)

Salary
Salary date before 7 every month
Bank Salary Account to all
Salary Registers with employees signature monthwise
Minimum Wages
Basic
D.A.
Other Salary Breakups
Over Time

Double Salary to Over Time

Any unwanted deduction for employee
Unpaid salary are reversed
Pay Cover Availability