The National Institute of Fashion Technology Gandhinagar

Plant Layout
Assignment IV

Submitted to
Prof. PavanGodiawala Department of Fashion Technology

Submitted by
AbhijitBiswas MFTech - II Batch 2010-12

Factory Area

217 x 83 = 3000 formal shirts

18,011 sq. ft.

Daily production : Departments : Stores Sampling Cutting Maintenance Sewing Packaging

: : : : : :

73 x 40 23 x 53 23 x 9 63 x 43 15 x 8 15 x 8 15 x 15 15 x 8 15 x 8 15 x 8 30 x 20 10 x 7 10 x 7 12 x 8 12 x 8 28 x 20

= =

2,920 sq. ft. 1219sq. ft. 2,576 sq. ft. 207 sq. ft. 6,032 sq. ft. 2,709 sq. ft.

92 x 28 = = 116 x 52 = =

Administration (offices) Human Resource Cutting & IE Conference Room Quality Room Final Inspection Room Final Dispatch Room Cafeteria Restrooms Security Room Community Center Locker Rooms Parking Area : = 120 sq. ft. = 120 sq. ft. Marketing/Merchandizing/Planning : : : : : : : : : : : :15 x 8 = = = = = = = = = = =

120 sq. ft. 225 sq. ft. 120 sq. ft. 120 sq. ft. 120 sq. ft. 600 sq. ft. 70 sq. ft. 70sq. ft. 96 sq. ft. 96 sq. ft. 560 sq. ft.

Loading / Unloading Zones/Temporary storage

Assumptions
Wastage per shirt So, wastage for 3000 shirts : : 5% 3150

Stores
Stores Area : 73 x 40 = 2,920 sq. ft.

Capacity required calculations for 1 month (30 days)

One roll has total meter age Fabric Width Diameter of Fabric rolls with poly packing Length of the roll with poly packing and allowance Fabric inventory for 30 days So, No. of rolls Number of rolls in one shelf So, number of shelves required Number of shelves in one rack Number of racks required (meters)

: : : : : : : : : :

300 5 1 6 139860 466 9 52 4 14

Manpower Requirement
Store In-charge Fabric inspector Helpers Total man power : : : : 1 1 1 3

Additional requirement for stores department

Fabric weighing machine Accessory weighing machine Fire extinguishers Fabric inspection machine Office working tables : : : : : 1 1 2 1 2

Fabric Racks
Rolls are stacked vertically in the racks Heightof one shelf 12 for the diameter of fabric roll 4 allowance for free movement of the roll 2.5 for thickness of the plank Number of shelves in one rack Dimensions Height of one rack Length of a rack Total Length 3 + 12+3+12+3+12+3+12+3+12+3 = : : 78(6.5) 3( 0.25) 12( 1) : 122(10.21) : 4 : = 12+12+4+2.5 30.5 (2.54)

Moving space between two rolls Diameter of one roll Length Width of rack Total width Width of the fabric roll Allowance for free movement :

11 meters (considering 4 racks and 2 aisles ) 64(5.3 ) 60(5) 4 (0.33)

= : :

Trims Racks
Length Width Height : : : 5 meter (16.40) 3 meters (9.84) 2.3 metres(7.5 feet) 1 meter (3.28)

Space of the aisles Office

Area

15 x 16

240 sq. ft.

Machine and Waste

Area : 15 x 17 : 255 sq. ft.

Inspection & Sorting Tables

Number of them Dimensions Length Width Height : : : 13 6.5 3.48 : 4

Trims required Inventory

NO OF PIECES REQUIERED NO OF FOR PCS IN 1 NO OF BOXES STACKING BOX REQUIRED
11340000 189000 94500 94500 94500 378000 94500 94500 94500 94500 94500 94500 94500 189000

No. TRIMS/ ACCRESSORIES 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Threads Button Felts Kimble Brand Card Business Price Card Shirt Pins Butter Paper Outer Collar Board Inner collar PVC Butterfly Back body Cardboad Polybags Packing boxes Labels + Washcare labels

VOLUME OF ONE BOX DIMENSION (cubic OF THE BOX inches) 16" x 23" x 6" 5" X 5" X 5" 8.5" X 7" X 3" 4" X 3" X 2" 4" X 3" X 3" 7" X 5" X 1.5" 16" X 16" X 1" 16" X 1.5" X 3" 20" X 1.5" X 2" 6" X 3" X 4" 14" X 10" X 8" 16" X 11" X 2" 23" X 20" X 2" RADIUS = 1.5 2208 12.5 178.5 24 36 52.5 256 72 60 72 1120 352 920 6.285

VOLUME REQUIRED (cubic inches) 208656 2362.5 3391.5 22680 34020 3990 121088 68040 56700 68040 529760 332640 869400 3167.64 2323935.64

24 1000 5000 100 100 5000 200 100

95 189 19 945 945 76 473 945 945 945 473 945 945 504

100 100 200 100 100 375 Total volume to stack

in Feet 15 4 7.5 450 2.98860036

Storage rack for accessories Length Width Height Volume that can be stacked Hence numbe of racks required Taking allowance into consideration we will take 3 racks

* at every 15 inches there is a partition in the rack of 2 inches

No.

Material

Consumption For 3150 per shirt shirts Fabric (meter)

For 1 month (30 days)

1 2

Shell Fabric Fusing Trims and Accessories

1.48 0.4

4662 1260

139860 37800

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Buttons Button Felts Threads Kimble Brand Card Business Price Card Shirt Pins Butter Paper Outer Collar Board Inner collar PVC Butterfly Back body Cardboard Polybags Packing boxes Labels + Washcare labels

16 2 120 1 1 1 4 1 1 1 1 1 1 1 2

50400 6300 378000 3150 3150 3150 12600 3150 3150 3150 3150 3150 3150 3150 6300

1512000 189000 11340000 94500 94500 94500 378000 94500 94500 94500 94500 94500 94500 94500 189000

Cutting

Cutting Area

92 x 28

2,576 sq. ft.

Fabric Storage Racks

Stitching Cutting capacity Required fabric inventory So, storage capacity required Fabric consumption of 1 shirt Fabric for 10800 shirts Number of rolls in one rack Diameter of one roll Total number of racks Total number of rolls required So, no of shelves required There will be 4 racks of two shelves Dimensions of Fabric racks Length : 6 : : : : : : : : : : : 3150 shirts per day 3600 shirts per day (20% extra) 3 days 10800 shirts 1.48 meters 15984 meters 5 12 8 52 14

- 5 one roll placed length wise - 1 allowance for placement Width : 4 (1.21 m)

- 2 rolls placed over 3 rolls, of diameter 12, distance between 2 rolls 3 Height : 2.3

Spreading and Cutting Tables Inspection Tables Bundling and Ticketing tables Fusing Table Band Knife Fusing Machine Main Inspection and Sorting Table

: : : : : : :

3 2 3 1 1 1 1

One lay of 1 ply of No. of shirts in 1 ply One lay We require shirts to be cut No. of lays would be 3600/400 Time taken to spread one lay

: : : : : : :

100 plies 7 meters 4 400 shirts 3600 shirts 9 2 hours

Spreading & cutting table

Length of the table (two of them 7.5 meters each put together) Width Height : : 2 meter (6) 1.06 meter ( 3.48) : 49

Inspection& Sorting table

Dimensions Length Width Height : : : 13 6 3.48

Bundling & Ticketing Table

Dimensions Length Width Height : : : 6.5 5.6 3.48

Band Knife Machine table

Dimensions Length Width Height : : : 7 5 3.48

Preparatory Fusing Table

Dimensions Length Width Height : : : 6.5 5.6 3.48

Fusing Machine Table

Dimensions Length Width Height : : : 6 3.8 3.48

Fusing Inspection table

Dimensions Length Width Height : : : 8 5 3.48

For carrying the cut bundles there will be Trolleys

No. 1 2 3 4 5 6 7 8 9 10 11 Manpower Requirement Cutting master Supervisor Spreaders Band knife operator Straight Knife operator Sorting personnel Fusing, laying & cutting Teflon placing & soldering Inspection Stickering Bundling Helper for transportation Total No. of Personnel 1 3 12 3 4 6 6 4 6 3 5 8 61

Machine List in the Cutting Department S. No. Machines Number 1 Straight Knife 3 Specification : Eastman Co. Blade length 8 inches 2 Band Knife 1 3 Fusing machine 1 4 Hot Notcher 1 5 Driller 1

Other Requirements
S. NO. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 Requirements Big Clamps Small Clamps Fabric weights Pair of cutting gloves Soldering machine Trolleys for moving cut parts Stickering guns Scissors 14 inches Scissors 12 inches Glass pencil for marking Measuring tape Pattern hanging system Manual spreading roll stands T-scales, rulers, hip curves, etc. Brown cellophone tape No. 30 30 30 1 3 2 2 8 6 4 packets 10 1 3 Lump sum Lump sum

Sewing
Area of the sewing department Sewing shifts 1 shirt takes Minutes Available : : : : 116 x 52 = 2 27 minutes 480 6,032 sq. ft.

(Total available time * no of machines) / ( processing time) (480 * 36 )/ 27 From 6 lines no. of garments Daily production Number of sewing lines Each sewing line produces Absenteeism = : : : : : 640 garments from one line in 1 shift 3840 3150 shirts 6 640 garments 10%

There will be a progressive bundling system

S. No. Manpower requirement 1 Operators 2 helpers 3 Collar Creasing 4 Pocket creasing 5 In process inspection 6 Final Checking 7 Helpers 8 Production manager Total Manpower requirement

Number of Personnel 240 6 6 6 6 12 12 3 291

S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Operation flow for the stitching department M/c Observe the Operation details Specification time (sec) Collar band / cuff hemming SNLS 80 Collar band and run stitch SNLS 120 Collar turning and creasing Nagaishing 30 Cuff blocking Nagaishing 25 Collar and cuff top stitch SNLS needle feed 100 Band attach to collar SNLS 100 Front kaj placket Kansai spcl 95 Button placket making SNLS 45 Button placket marking Manual Pocket Creasing Iron table Sleeve placket making SNLS 195 Pocket attaching SNLS ubt 90 Pocket and front checking Manual Main label attachment SNLS ubt 60 Yoke and back attachment SNLS 60 Shoulder and front attachment SNLS 90 Top stitch on back shoulder SNLS 60 Attach sleeves SNLS 180 Side seam FOA 110 Attach collar and top stitch SNLS 180 Attach cuff SNLS 180 Bottom hem SNLS 120 Total no. of machines in one line

No. of machines 2 2 1 1 2 2 2 1

3 2 1 1 2 1 3 2 3 3 2 36

There will be a feeding trolley system for cut parts Also trolleys for carrying sewn garments to the packaging department

Preparation tables
Total number of tables Dimensions : : 6 7 x 5 x 3

Shop Floor requisition

Width of the machine Length of the machine Gap between two machines : : : 21 inches 42 inches 30 inches

So one machine will be taking space with allowance around 50 inches : Machines in one line : 50/12 = 4.16 36 machines,

18 machine on either side of the line

Inspection Tables
Number of Inspection tables Dimensions : : 18 4 x 3x 3

End line inspection tables

Total number of tables Dimensions : : 3 9 x 5 x 3

Button Placket Marking Tables

Total number of tables Dimensions : : 3 8 x 6 x 3

Creasing Tables Number of creasing tables Dimensions Other Materials

Scissors

: :

6 6 x 1.5x 3

30

Handling system for inline processing Plastic Baskets Feeding trolleys (one line 10)

: : :

9 x 2 x 6 = 108 30 12

Packaging
Area of packaging department : 63 x 43 : 2,709 sq. ft. Capacity of finishing department would be 3000 shirts per day Button holing and button attaching is done in the finishing room Vacuum table steam press is being used for pressing One boiler per two pressing table is being used Shirt folding is done manually Complete packing for the shirt takes place (viz. pinning, putting collar stand, butterfly, putting cardboard) and then putting in the boxes and finally seating in the carton boxes

Machinery
Button making Button holing Thread sucking machine : : : 3 3 2

Thread Trimming Table

Number of table Dimensions Length Width Height : : : 10 5 3.48 : 3

Thread SuckingMachine
Number ofthem Dimensions : 2

Length Width Height

: : :

3 3 3.48

Final Inspection Table

Number of table Dimensions Length Width Height : : : 6 3 3.48 : 7

Pressing Table
Number of table Dimensions Length Width Height : : : 4 3 3.48 : 12

Folding Table
Number of table Dimensions Length Width Height : : : 8 5 3.48 : 10

Final Packaging Table

Number of table Dimensions Length Width Height : : : 15 5 3.48 : 3

Storage Racks
Number of racks Dimensions Length Width Height : : : 6.5 5.5 7.5 : 9

Furniture Requirement * AQL level followed is 2.5 No. of Tables 3 3 6 12 10 Dimensions (feet) 8x6x3 10x 5 x 3 6x3x3 4x3x3 8x5x3 Operation Time in minutes (approx) 1.7 2.7 4 2 3 People per furniture 4 6 2 1 2

Furniture Button and button hole marking table Thread trimming table Inspection table Pressing table Folding table

Total people 12 18 12 13 20

Administration / Offices

S. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22

Office Requirements Working Tables Chairs Almirah File Folders rack Swatch Folder Rack Calculators Clip boards Paper weight Cellophane tape Stationary Pinking Shears Punch Hole machine Clips and Pins File holder Gum/fevicol Rubber stamp, ink pad Stapler Pedestal fan Phone Trash cans Measuring Tape Emergency light

Number 2 6 2 1 1 2 4 6 2 lump sum 2 2 lump sum 2 lump sum lump sum 3 3 8 15 6 5