Final plant layout

N A T I O N A L I N S T I T U T E O F F A S H I O N T E C H N O L O G Y , C H E N N A I .

Layout of a Shirt Manufacturing Unit

P R E S E N T A T I O N B Y :

N A V E E N K U M A R

N I L A S H A T A N D O N

P A Y A L B A R D A N

R A V I A D I T Y A

Plant Layout – End Term Jury

Structure of the Manufacturing Unit

AutoCAD 2D Layout

AutoCAD 3D Layout

Departments Present in the Unit

Spreading and cutting (110’ x 90’)

Fabric inspection dept (100’ x 25’)

Research and development dept (30’ x 25’)

Human resources dept (60’ x 50’)

Reception (50’ x 20’)

Crèche (45’ x 15’)

Locker room (50’ x 15’)

Card swiping area (30’ x 15’)

Toilets (30’ x 15’)

Departments Present in the Unit

Medical room (50’ x 15’)

Power supply dept (80’ x 15’)

Maintenance dept (80’ x 50’)

Industrial engineering dept (30’ x 15’)

HOD cabin (30’ x 15’)

Sewing floor area (320’ x 90’)

Canteen (70’ x 30’)

Effluent Treatment Plant (180’ x 20’)

Washing area (130’ x 30’)

Departments Present in the Unit

CAD lab (50’x25’)

Finished goods warehouse (50’x80’)

Finishing room (40’x90’)

Packaging department (40’x90’)

Fabric and trims warehouse (80’ x 30’)

Ratio of cutting : sewing : finishing

Locational Analysis

Location Village Vanj, Taluka Choryasi, District: Surat

Type of SEZ Sector Specific SEZ for Apparel. Area: 56 hec.

Status Notified - Functional

Connectivity: Road, Rail, Air and Port

Road Network: 8 km-National Highway (NH8), SEZ is on Navsari- Surat State Highway (SH) ƒ Rail Network: 20 km from SuratRailway St.ƒ Nearest Port: 30 km from Haziraport and 18 km from Magdalla portƒ Nearest Airport: 20 km from Surat Airport

Locational Analysis

Land availability & Lease Rates

Plots allotted to industries @ Rs. 1500 sq. mt.

Available Infrastructure

Internal roads, Power, Water, Drainage system are available in the SEZ

Training Facility Established by ALT Training College, an Apparel Training Centre is present in the SEZ

Proposed industries

All kind of apparel manufacturing industries are permitted

Locational Analysis

Contact Information

Developer Company: Gujarat Industrial Development Corporation (GIDC)

Address:GIDC, Block No. 4, 2Floor, UdyogBhavan, Gandhinagar-382 017

ƒ Contact Person & Designation:Mr. NayanRaval, GM (Projects)

Tel. No.+91-79-23250705

Website: www.gidc.gov.in

Assumptions

Layout: Product specific

Layout Type: Prefabricated

Product: Casual shirt

50% washed & 50% unwashed

Available time: 480min

No. of days working: 6

No. of m/c= 700

10% extra, so available m/c=640

Assumptions

SAM of the shirt: 33.04

No. of lines in sewing floor: 8

No. of workstation req. for a shirt: 80

Output per day @ 60% efficiency:5,712

Output per day with 10% extra: 6,397

No. of days working in a month: 25

Output per month: 1,59,936

Fabric Store

Length of the roll: 150m Width of the roll: 6ft Height of the roll: 1.5 ft Average consumption per garment: 2 m Fabric width: 60 inch Fabric consumption per day:11,424m No. of rolls req. per day: 76 rolls Inventory: 10 days Total rolls inventory: 762 Rack dimension: 6ftX 6ftX4ft No. of shelves: 3 No. of rolls stacked in a height:24 Total rolls inventory in store: 762

Calculation sheet

Fabric store

Inspection m/c: 9ftX7ft Average speed: 6mts/min Utilization: 90% Available time: 432min Inspection per m/c: 2592m Daily needed fabric:68,544m M/c req. =3 No. of racks required: 32 No. of shelves: 95 Area required for racks: 1,142 sq. ft. Area required for fabric store: 2500sq. ft

Calculation sheet

Cutting room

Available time: 480 min Utilization: 75% Efficiency: 60% Average consumption: 2m Marker length: 4m Layer length: 4.008m No. of sizes in a marker: 2 No. of layer: 80 Total garment in a lay: 160 Meter spread: 320.64m No. of rolls req. :2.14=3 Bundle size: 20 No. of lays req. per day: 40

Calculation sheet

Cutting room

Spreading table length: 5.508m No. of spreading table req.:7 No. of spreader req. :11 No. of spreader allotted:6 No. of spreading team: 6 No. of req. cutter: 5 No. of cutter allotted : 3 No. of allotted cutter: 2 M/c area: 2898 sq ft OP. space area: 1416 sq ft Total area : 4314 sq ft Total area req. :9900

Calculation sheet

Sewing Room

SAM of the shirt: 33.04

No. of workstation: 80

No. of sewing line: 8

Total m/c: 640

M/c area per line: 1063sq ft

Op space area per line:447.5 sq ft

Total area required: 3398.625 sq ft

Calculation sheet

Washing room

50% washed and 50% unwashed

Washing machine

Tumble Drier

Drier

M/c area:1290 sq ft

Op space area: 300 sq ft

Total area req. 3900 sq ft.

Calculation sheet

Finishing Room

Finishing SAM = 4.45 Minutes

Thread Sucker

Press Fold

Spotting M/C

Checking tables

Sub Total Space = 1585 Sq. ft.

Allowance (125%) = 1981.25 Sq. ft.

Total Required Area 3566.25 Sq. ft.

Calculation sheet

Canteen

No. of employees: 900

Canteen is without cooking

So area req. per employee is 12 sq ft

So the canteen area is 2100 sq ft

Two floor canteen

Occupies 350 employees at a time.

So there will be three shifts for employees

Calculation sheet

Sustainable Factory

OBJECTIVES

Efficient management of energy and water resources

Management of material resources and waste

Restoration and protection of environmental quality

Enhancement and protection of health and indoor environmental quality

Reinforcement of natural systems

Analysis of the life cycle costs and benefits of materials and methods

Integration of the design decision-making process

Renewable Sources of Energy in Gujarat

Wind power (capacity=3,187 MW)

Solar power (capacity=856.81 MW)

Adoption of materials and products in buildings and construction that will require less use of natural resources and increase the reusability of such materials.

Sustainable construction also enhances the resilience of the industry as such materials are readily available in the world market.

Steel, other metals, glass and prefabricated parts using combinations of these, as well as recyclable substitutes for concrete are examples of sustainable materials and products.

SUSTAINABLE CONSTRUCTION

To reduce the non-renewable energy (energy expended to process and transport materials) in the building, the main walls are made of compressed stabilized-earth block manufactured forty kilometres from the site.

The machine moulded blocks are made of local soil, sand, and locally manufactured cement. The large size of the blocks minimizes mortar joints.

The walls require no plaster finish; they are simply sealed with varnish on the interior and exterior.

Polycarbonate sheets on roof. Glass strips, running continuously across the

breadth of the roof at regular intervals.

SUSTAINABLE RAW MATERIAL FOR CONSTRUCTION

Windows use imported plate glass and aluminium frames.

Floor finishes include polished concrete tile, rendered and cut concrete, tile, and wood.

Bamboo is used for window blinds and various forms of sunscreen.

Nonhazardous finishes and materials are used throughout the building, ensuring good indoor air quality, which is enhanced by high air-exchange rates.

Stabilizing plants, silt traps, and stormwater-collection ponds were used to prevent soil erosion during construction.

Special mechanisms to recycle construction waste, which reduced the amount of waste that went into landfills.

SUSTAINABLE RAW MATERIAL FOR CONSTRUCTION

Understanding the Lighting Requirement

Lamp Type Rated Life Hours

Full-size fluorescent (T5,high-performance T8)

20,000 to 30,000 - Lumen maintenance % - 92 to 93

General area lighting of allkinds, including open andclosed offices, training classrooms, and high-bay areas. – Sewing, Finishing, Washing Section

Compact fluorescent 6,000 to 12,000Lumen Maintenance - 86 (%)

Incandescent replacements in table andfloor lamps, cans, wall washers, and sconces

Quartz pulse-startmetal halide

20,000Lumen Maintenance – 65 to 75 (%)

Outdoor lighting, high-baylighting, and remote-sourceLighting - Landscape

Ceramic pulse-startmetal halide

20,000Lumen Maintenance - 80 (%)

Where color is critical- example cutting section

Induction 100,000 hoursLumen Maintenance70 at 60,000 hours; 55 at100,000 hours

Where maintenance costsare high like parking, roadways and ware house.

LED 50,000 Lumen Maintenance - 70 (%)

In color-based applications such as exit signs, niche applications such as outdoorsignage, task lamps.

Light Source Upgrade Alternatives

A mix of top- and side-lighting, light shelves, high-reflectance ceilings.

Automatically Control Lighting.

Use of Day Light and Automatic Control Light

Over time, all lighting systems become gradually lessefficient.

Other efficiency losses include improperly functioningcontrols, dirt accumulation on fixture lenses and lumendepreciation.

How to control this ??

Follow a strategic lighting maintenance plan of scheduledgroup re lamping and fixture cleaning.

LIGHTING

Cross- ventilation . Cooling is achieved at the plant primarily by passive design and

secondarily by active systems. Passive design measures include the orientation and massing of

building volumes, controlled fenestration and ventilation, shading of the building and its surroundings, and thermal mass and solar reflectivity of the facades and roofs.

The massing of the building volumes and the positioning and sizing of windows permit daylight to enter as natural illumination without causing substantial heat gain

Thermal roof load, the largest contributor to heat gain and indoor discomfort in the tropics, is controlled by a combination of photovoltaic roofs, and cool roofs.

Indoor thermal comfort

Production spaces and offices are ventilated and cooled by evaporative cooling units. These units draw in fresh air, filter it, and add moisture to lower the dry-bulb temperature.

Indoor air is not recirculated, but extracted by suitably sized exhaust fans to ensure effective moisture and heat removal.

Humidistat in each cooling unit keep the indoor relative humidity at or below 80 percent.

IAQ(Indoor Air Quality)

InfiltrationAir leaks around the frame, around the sash, and through gaps in

movable window parts. Infiltration is foiled by careful design and installation.

ConvectionPockets of high-temperature, low-density gas rise, setting up a circular

movement pattern. Convection occurs within multiple-layer windows and on either side of the window.

RadiationRadiation is energy that passes directly through air from a warmer

surface to a cooler one.Radiation is controlled with low-emissivity filmsor coatings.

ConductionConduction occurs as adjacent molecules of gases or solids pass

thermal energy between them. Conduction is minimized by adding layers to trap air spaces, and putting low-conductivity gases in those spaces.

Window Heat Flow

Window films reduce heat gain due to solar radiation and provide low cost cooling load reduction.

Buildings in sunny areas can benefit from a variety of shading techniques.

Bamboo sheet shade screens reduce heat gain up to 80 % compared to normal glass.

Window Films

Centrifugal fans (A) are the most common fans used.

They are often cheaper but usually less efficient than axial fans (B).

Fan System

The heat-island effect around the building is controlled by shading, by covering parking areas, by using lighter, reflective paving around the building instead of dark, heat absorbent paving, and by shading the courtyards between the building volumes.

The combination of the many passive cooling measures reduces the thermal load to a level that can be handled by environmentally efficient cooling systems instead of power hungry conventional systems

COOLING

Light intensity levels for different departments

ACTIVITY REQUIRED LUX LEVEL

Preparation of cloth 200-300-500

Cutting 500-750-1000

Matching 500-750-1000

Sewing 750-1000-1500

Pressing 300-500-750

Inspection 1000-1500-2000

Hand tailoring 1000-1500-2000

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