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 men’s and women’s toilets and drinking water outlets

in the vicinity.

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 Material Specification Consumption/garment

Body Fabric Poplin 1.81 m

Interlining Microdot 0.42 m

Button Plastic (14 L) 16 pcs

Thread (Ticket No.

25)

Spun Polyester 35 m

Thread (Ticket No.

50)

Spun Polyester 38 m

Thread (Ticket No.

100)

Spun Polyester 195 m

Paper Printed tag - 1 pc

Printed Paper 1 pc

Main Label 1 pc

Wash Care Label 1 pc

Stores

Receipt of Bill Of Materials

Package verification against packing list for weight & no of packages

Materials received

Lab test Trim card for accessories

No

To be inspected

Rejected Inspection process Yes pass

Quality checking

Storage of passed material

Update status to production

Issues of fabric to cutting section based on lay

record

Issues of trims to production

Receipt of end bits from cutting section

Receipt of left over materials from production

Inspection fail

Conditionally approved by buyer

Rejected

Storage in rejected Area

STORES DEPARTMENT

Process flow chart :

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.

Accessories Required

Amount

for 15

days

Dimensio

n of box

(inches)

l*b*h

No. of pcs that

can be

accommodated

Volume

of box(in

cubic

inch)

Required

volume

(in cubic

inch)

Button 840000 3*2.5*2 2000 15 6360

Thread(Tk

No. 25)

1837500 8*8*2.5 30000 160 9800

Thread(Tk

No. 50)

1995000 8*8*2.5 30000 160 10640

Thread(Tk

No. 100)

10237500 8*8*2.5 30000 160 54600

Printed

Paper Tag

52550 4*3*2 100 24 12612

Printed

Paper

52550 16*16*1 200 256 67264

Main Label 52550 5 Dia*2 375 157 22000

Wash Care

Label

52550 5 Dia*2 375 157 22000

Therefore 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

Fabric Interlining

Required length for 15

days (m)

95025 22050

Length in a roll (m) 300 100

No. of rolls req. 317 220

Diameter of roll (inch) 12 6

Length of roll (inch) 64 40

No. of rolls in one

shelf(assumed)

7 10

Length of the rack(as per

given rolls/shelf) (inch)

84 60

Ease of roll movement

lengthwise (inch)

5 5

Final Length of

shelf(inch)

89 65

Ease of roll movement

heigthwise (inch)

6 6

Distance b/w two

successive shelfs (inch)

18 12

Required no. of shelves 45 22

Height of the rack(inch) 90 75

No. of shelves in one

rack

5 6

Width of the rack 69 45

Dimension of the

rack(inches)

89*69*90 65*45*75

Dimension of the

rack(meters)

2.26*1.75*2.28 1.65*1.14*1.90

No. of racks required 9 4

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 Marker inspection

Lay inspection

Cut 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) 1.52

Components of garments 28

Cut capacity/day 3500

Marker Length(m) 7.15

No. of garments in a

marker

4

Av. Fabric

consumption(m)

1.81

No. of plies in lay 135

No. of lays 7

Av. Time for laying

/lay(mins)

140

Av. Time for cutting

/lay(mins)

100

Total time for cutting &

laying (mins)

240

Total no. of tables for

laying & cutting

4

Av. Tim for sorting 1

garment/person(min)

1

Av. Time for sorting 500

garments(min)

500

Sorting and bundling

tables

2

No. of fusing machines

(3.3 x 1.6 mt)

2

Band knife machine s 1

(2.25 x 1.5)

Fusing assisting tables 2

Trolleys

In cutting dept. there will be fabric temporary storage.

Calculation of Fabric Temporary Storage

Fabric

Cutting days inventory 1.5

Required fabric

length(m)

9502

Length in a roll (m) 300

No. of rolls req. 31

Diameter of roll (inch) 12

Length of roll (inch) 64

No. of rolls in one

shelf(assumed)

2

No. of rolls in a rack 15

No. of racks 2

Ease for roll

movement(inches)

6

Length 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 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

of machines required for each operation has been found out.

Line Layout:

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 a 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’.

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

Presentation checking

Measurement checking

Folding

Tagging

Poly bag packing

To packing section

FINISHING SECTION

S.No. Operation SAM Pcs/min Required People

1 Thread Trimming 0.43 2.33 3.13

2 Primary Inspection/ 0.64 1.55 4.70Spotting

4 Ironing 0.64 1.56 4.67

5 Measurement Check/ 0.85 1.18 6.19Final Check

6 Final Ironing 0.96 1.05 6.97

Total 3.52 25.66

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 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

Service

Illumination

(Lux)

Reflectance

Contrast

usually low

(Lux)

Errors will

have serious

consequence

s (Lux)

Rask of

short

duration

(Lux)

Storage area and plant room with

no continuous work

150 - - -

Casual work 200 - - -

Rough work, rough machining and

assembly

300 500 500 300

Demanding work, inspection of

medium machining

500 750 750 300

Fine work: Colour discrimination,

textile processing and fine

machining

1000 1500 1500 750

Very fine work: hand engravings,

inspection of fine machining and

assembly

1500 3000 3000 1000

Minute work, inspection of very

fine assembly

3000 3000 3000 1500

Levels specific to garment industry:

Operations Lux level

Sewing 300 - 500 for normal

1000-1500 for critical operations

Embroidery 700

Processing 150

Packing 150 – 300

Inspection 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

Others

500 Cubic feet for every employees

Disposal of Wastes and effluents

Room Temperature

Lighting facility

Trees on factory campus

Safety Guards

Metal Glows on good Condition

Rubber Mat to ironers

Rubber Glows to ironers

Ironers wearing slipper

Motar Guard

Needle Guard

Eye Guard

Scissors and trimmers are tied

Broken Needle Register

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

Fire

Sufficient Fire Extinguisher

Fire Extinguisher all in good Condition

Fire Extinguisher Location List

Fire Extinguisher Service Checklist

Fire Extinguisher kept in 3 feet

Fire Signage in English & Local Language.

Usage Guide in dual language

Fire Extinguisher Color Background Marking

Space beneath marked

Space beneath kept empty

Refilling Service Done

Fire Certified persons photo

Evacuation Drill (External) Every Six Month

Evacuation Drill (External) File

Evacuation Drill (Internal) Every Three Month

Evacuation Drill (Internal) File

Fire safety trained employees name & Photo List

Fire Buckets to Diesel Storage Area with Water and Sand

Fire Buckets to Boiler Room with Water and Sand

Fire Buckets to Generator room with Water and Sand

Diesel Storage area floor filled by sand

Evacuation Plan in all Floor / Area

Emergency Exit

Emergency Exit on Open

Emergency Exit Signage

Emergency Exit with outside open facility

Emergency Light to All room / Area Adequate

Emergency Light to All staircase

Emergency Light to All Exit & Emergency Exit

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

Security

Adequate Securities

Lady Guards

Staff Movement Register

Visitors Note

Others In-Out Register

Material Inward Register

Material Outward Register

Vehicle Movement Register

Visitor Pass

Visitor Slip

Guards Knowledge about their Roles & Responsibilities

Securities Personnel File

Securities Uniform/Cap/Shoe/Belt etc.

Securities Knowledge about Fire Evacuation & Fire Safety

Security Agreement file (If outsourced)

Security Salary register file (If outsourced)

Security ESI, PF Challan (If Outsourced)