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PLANT LAYOUT

ARCHITECTURAL BRIEFASSIGNMENT NO. 3

Submitted by:-

Devesh Kumar (09)

Himanshu Kumar (11)

Mohd. Nawaz Khan (16)

Rajani kant Gautam (24)

DFT 7

COMPANY PROFILE

Type Of Garments:- Men’s Formal shirt

Type of company:- Export oriented and domestic as well

Daily Production capacity:- 3000 garments/day

Factors Considered for plant layout & Construction

Man

Machinery and equipment

Material handling and movement

Product type

Inventory

Service

Building

Operation Breakdown of the garment

S.NO. OPERATION SEAM TYPES MACHINE

PREPARATORY PROCESS

FRONT LEFT

1. Sew front fly on left front Superimposed SNLS

2. Fold right front edge Superimposed SNLS

3. Sew button & button holeButton hole m/c

4. Fold pocket mouth Folding m/c

5. Top stitch pocket mouth Superimposed SNLS

6. Sew pocket on left front Superimposed SNLS

YOKE & BACK

7. Fold upper yoke

8. Crease brand label

9. Sew size label to brand label Superimposed SNLS

10. Sew brand label to under yoke Superimposed SNLS

11. Sew yoke to back Superimposed DNLS

12. Counter stitch yoke lapped SNLS

SLEEVE & PLACKET

13. Sew under sleeve placket to sleeve

Superimposed SNLS

14. Fold upper sleeve placket

SNLS

15. Sew upper sleeve placket to sleeve

Superimposed SNLS

17. Top stitch to placket Lapped SNLS

COLLAR

18. Fuse fusible interliningFusing Machine

19. Sew keeper to fusible increase interlining Superimposed SNLS

20.Fuse fusible increase interlining on fusible interlining

Fusing Machine

21. Fuse fusible interlining on upper collarFusing machine

22. Run stitch collar SNLS

Superimposed

23. Cut collar point & turn collar Superimposed Collar

Turning m/c

24. Press collar point Pressing m/c

25. Form collar

26. Topstitch collar Superimposed SNLS

27. Cut collar bottom

28.Fuse fusible interlining on upper collar band

Fusing Machine

29. Fell collar band bottom Superimposed SNLS

30. Sew collar band to collar Superimposed SNLS

31. Turn and fold collar band

32. Topstitch collar band lapped SNLS

CUFF

33. Fuse fusible interlining on upper cuffFusing Machine

34. Fell upper cuff bottom Superimposed SNLS

35. Run stitch cuff Superimposed SNLS

36. Turn cuffCuff Turning Machine

37. Fold & form cuff

38. Top stitch cuff Superimposed SNLS

39. Sew button hole on cuffButton Hole Machine

ASSEMBLY

40. Sew shoulder lapped SNLS

41. Counter stitch shoulder Lapped SNLS

42. Sew sleeve Superimposed SNLS

43. Counter Stitch sleeve Superimposed SNLS

44. Sew side & Under SleeveMulti Needle chain Stitch

45. Hem Bottom Lapped SNLS

46. Sew Collar Lapped SNLS

47. Counter Stitch Collar Superimposed SNLS

48. Sew Cuff Superimposed SNLS

49. Turn body

50.Sew Button hole on Top of Front and Sleeve Placket

Button hole M/c

51.Sew Button to Top of Front & Sleeve Placket

Button Hole m/c

Production system followed : PROGRESSIVE BUNDLE SYSTEM

In PBS production, sewing operations are broken down by management into a number of distinct Progressive bundling and separate operations depending on the complexity of the garment. Management assigns an expected sewing time or “standard” (in minutes) for each operation such that the amount of effort required to sew a standard minute is equivalent across tasks. Workers are paid based on individual piece rates according to the standard set for the operation they undertake. In addition to the piece rate standard, workers also receive an hourly wage, or variance pay, when work is interrupted.

The advantages of the PBU system can be listed as under: 1. Helps to cope up with frequent style changes2. Helpful for small lot sizes also

3. Allows the garment manufacturer to meet short delivery deadlines

DEPARTMENTS

Merchandising Department

The Merchandising department is directly reporting to the Marketing department. As already stated earlier, the merchandising department, controls and coordinates the activities of the Sampling department as well.

Area Required: 25’x25’

Man Power Required:-

Head Merchandiser – 1 Merchandiser – 3 Asst. Merchandiser – 3 Helpers - 2

Machines Required:-

Computer – 4 (For every merchandiser & one for the head) Processor above 2.0 ghz 1 GB RAM minimum Server Connection and internet connection

Printer – 2 (Connected to Every Computer)

SAMPLING DEPARTMENT

The Sampling Department works out to make the required samples with the given specifications supplied by the buyer. As already discussed previously, the merchandising team for the particular buyer coordinates the sample development process.

Total Area Required:- 20’ x 20’


Pattern Master – 2 CAD (Software) Engineer – 1

CAD Master – 2 CAD Helper – 1 Cutting Master – 2 Sewing Operators – 40 Helpers - 10

Machines Required:-

Single needle lock stitch - 28 Model: SunStar KM-250AU-7S Usage: For thin materials (for general use) Speed: Max. 5500spm (Standard: 5000spm) Stitch length: Max. 4mm Needle: Dpx5 Needle bar stroke: 30.7mm Pressure foot height: Manual: 5.5mm Knee: 14mm Motor: Servo motor

OverLock machine - 4 Model: Juki MO-6900S Sewing Machine: Max.8500 spm Needle: DCx27 #11 Number of Needles: 2 Overedging Width: 4.8 mm

Button attaching m/c - 1 Model: SunStar SPS/D-B1202 Sewing speed: Max. 2500spm (Standard: 2200spm) Needle: DPx17#14 Needle bar stroke: 35 mm Button clamp lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 33 patterns) No of stitches: Max. 10000 stitches Motor: Direct drive AC Servo Motor Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz

Multi needle chain stitch machine - 4 Model: Kansai DFB-1404 PS

No of needles: 2-4 No of threads: 4 needle threads & 4 looper threads Needle: Stitch length: 2-5mm Speed: Max. 4500spm (Standard: 4000spm) Tension set: Mounted type Puller width: 55mm Gauge width: Min. 4.76mm (3/16 inch) 38.1mm (1-1/2 inch) Motor: 3-phase, 2-pole, 400W clutch motor

Button hole sewing m/c - 1 Model: SunStar SPS/B-BH3000-G Stitch Type: Drop feed Usage: General fabrics such as shirt, blouse, working dress, lady's dress, etc Sewing speed: Max. 4000spm Button hole area: Width: Max. 6mm Length: Max. 40mm Length of cutter: 6.4-31.8mm Needle: DPx5#14 Needle bar stroke: 35mm Pressure foot lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 4 patterns) No of stitches: 768(stitches)/1 pattern Motor: Direct drive AC Servo Motor: 1 Pulse Motor: 3 Temperature: 5º C-40ºC Relative humidity: 20%-80% Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz Oil supply: Automatic

Gerber plotter (Cartridge plotter): Black and White plotter - 3 Maximum media width – 1010 mm Maximum cutting area – 920 x 1720 mm Floor space Requirement – 2068mm x 1285 mm Weight – 80 kgs Power Consumption – 160 VA

Computer – 1

2.0 Ghz processor (minimum) 1 GB RAM (minimum)

FABRIC STORES

Assumptions for Fabric Stores:

The fabric is received in form of rolls hence the entrance should be at least 8 feet wide and 12 feet high.

The movement of rolls is done with trolleys and fork lift or with the aid of helpers.

The aisle space for the movement of trolleys and fork lift – 1.5 meters.

Fabric rolls are stored in Racks.

Inventory calculation:

Fabric consumption per day for 2000 gmnt – 2000 x 1.6 mts

Dimension of a roll - approx - 60” x 12”

Dimension of racks - 6’ x 6’ x maximum height possible.

With divisions after every 3 feet.

Total Area Required:- 50’x66’


Store Manager – 1 Assistants – 3

Machine Required:-

Computer – 1 2.0 Ghz processor (minimum) 1 GB RAM (minimum)

Inspection table – 1

ACCESSORIES AND TRIMS STORE

Assumptions for the Trims & Accessories Store: Trims are received in cartons and are inspected for quality issues and counts. Trims are already lab tested and only physical verification is done in the stores

Along with the trims /accessories / packaging materials the stores also keeps stationery required for the unit.

The list of trims and accessories which are stored is as listed: Thread (sewing) Buttons Shirt folding pieces Back support Paper collar Collar traveler Tag pin Fusing (of Different width) Poly-bag Tissue paper Label Cartons Stickers (Bar code, size etc.)

Total area Required:- 10’ x 16’


Store Manager – 1 Assistants – 2

Machine Required:-


SOURCING & PURCHASE DEPARTMENT

The fabric sourcing department sources the fabric and other raw material required. These are responsible for the sourcing of:-

Fabric Threads Trims Accessories Packing materials New sewing, cutting, finishing, embroidery machines and workstations

Non production related equipments like- Stationery Other equipments



Manager – 1 Asst. Manager -1

Machine Required:-


CENTRAL IE DEPARTMENT

The Central IE department is responsible for the preparation of the

Operation Breakdown GSD analysis Thread Consumption

of the styles provided to them by the Merchandising.

Each new style requires to be timed so that the cost to the company can be calculated as well as the capacity can be allotted to the various floors. It also maintains the production details for the floor.

Total Area Required: - 20’ x 20’


IE Head – 1 IE Manager -2 Asst. Manager – 2 Helper – 2 Sewing Operators – 10

Machine Required:-

Computer – 2

2.0 Ghz processor (minimum) 1 GB RAM (minimum)

Single needle lock stitch - 3 Model: SunStar KM-250AU-7S Machine Specifications: Usage: For thin materials (for general use) Speed: Max. 5500spm (Standard: 5000spm) Stitch length: Max. 4mm Needle: Dpx5 Needle bar stroke: 30.7mm Pressure foot height: Manual: 5.5mm Knee: 14mm Motor: Servo motor

Button attaching m/c - 1 Model: SunStar SPS/D-B1202 Machine Specifications: Sewing speed: Max. 2500spm (Standard: 2200spm) Needle: DPx17#14 Needle bar stroke: 35 mm Button clamp lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 33 patterns) No of stitches: Max. 10000 stitches Motor: Direct drive AC Servo Motor Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz

Multi needle chain stitch machine - 2 Model: Kansai DFB-1404 PS Machine Specifications: No of needles: 2-4 No of threads: 4 needle threads & 4 looper threads Needle: Stitch length: 2-5mm Speed: Max. 4500spm (Standard: 4000spm) Tension set: Mounted type Puller width: 55mm Gauge width: Min. 4.76mm (3/16 inch) 38.1mm (1-1/2 inch) Motor: 3-phase, 2-pole, 400W clutch motor

Button hole sewing m/c - 1 Model: SunStar SPS/B-BH3000-G Machine Specifications: Stitch Type: Drop feed Usage: General fabrics such as shirt, blouse, working dress, lady's dress, etc Sewing speed: Max. 4000spm Button hole area: Width: Max. 6mm Length: Max. 40mm Length of cutter: 6.4-31.8mm Needle: DPx5#14 Needle bar stroke: 35mm Pressure foot lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 4 patterns) No of stitches: 768(stitches)/1 pattern Motor: Direct drive AC Servo Motor: 1 Pulse Motor: 3 Temperature: 5º C-40ºC Relative humidity: 20%-80% Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz Oil supply: Automatic

OverLock machine – 3 Model: Juki MO-6900S Sewing Machine: Max.8500 spm Needle: DCx27 #11 Number of Needles: 2 Overedging Width: 4.8 mm

TOTAL QUALITY ASSURANCE DEPARTMENT

The TQA department is responsible for the quality assurance at each stage of the product. The stages are that of raw material, Work In Progress and the Finished Materials.

Room Dimensions: 14ft x 18ft

Man power Requirement:-

TQA Dept. head – 1 TQA Incharge – 4 Quality Checker – 4 Helpers – 4

SREADING AND CUTTING SECTION

Assumptions for the Spreading & Cutting Section:

Aisle space for the movement should be 5 feet.

Aisle space around the computerized cutting machine is 5 feet.

Band knife should be at the corner with the operator facing the wall.

While working on the table (numbering /sorting), every worker is given an area of 25 sq. feet for easy movement and working

Bundled cut parts are stored in bins.

The cut pieces in bins are issued to the sewing department on a trolley.

There are racks present in the section for the storage of cut pieces.

Total Area Required:- 2787 sq.feet


Floor Incharge -1 Spreading Master – 4 Cutting Master – 4 Helpers - 4

Tables Required:-

Spreading and cutting table – 2 432” x 34.75” x 72”

Pin table – 2 96” x 48” x 36”

Machine Required:-

Band Knife Cutter – 2 Model: Eastman EC-900N Cutting Capacity : 180 mm Table size: 1500 x 2100 mm Table height: 720 -790 mm Arm length: 900 mm Variable speed: 570-1440 m/min Motor: AC 220V 750W 1-phase Knife Dimension: 0.45 x 10 x 3960 mm

Straight knife cutter – 6 Model: Eastman Blue streak II Cutting Capacity: 4.5 inch Motor: AC 220V 60Hz 1-Phase Weight: 15.4 kg Stroke: 1.25 inch RPM: 17,000 Blade type: Straight

Fusing Machine – 2 Model: Hashima HP-600LSC Power supply: Single or 3-phase Rated output: heater-7400W

Motor – 90W Fusing Width: 600 mm Pressure: max. 5.0 kg/cm2

Dimensions: 1325x1180x1090mm Net weight: 296 kgs


Ticketing guns – 6

SEWING SECTION

Assumptions for the Sewing Section:

Unit production system is in place.

There are 7 lines for 90% efficiency the daily production of 3,000 shirts. SAM for the garment: 21.8

Total working min in an 8 hour shift: 480

Total number of sewing machines required: 260

Aisle space is 5 feet

Each lines has a sub assembly and an assembly section

Each SNLS is equipped with UBT (Under Bed Trimmer)

Total Area Required:- 3500 sq. feet


Production head – 1 Asst. Production Manager – 1 Pre-Production manager – 1 Asst. Pre-Production manager -1 Sewing Operators – 260 Helpers – 50

Machine Required:-

Single needle lock stitch - 28 Model: SunStar KM-250AU-7S Usage: For thin materials (for general use) Speed: Max. 5500spm (Standard: 5000spm) Stitch length: Max. 4mm Needle: Dpx5 Needle bar stroke: 30.7mm Pressure foot height: Manual: 5.5mm Knee: 14mm Motor: Servo motor

OverLock machine - 4 Model: Juki MO-6900S Sewing Machine: Max.8500 spm Needle: DCx27 #11

Number of Needles: 2 Overedging Width: 4.8 mm

Button attaching m/c - 1 Model: SunStar SPS/D-B1202 Sewing speed: Max. 2500spm (Standard: 2200spm) Needle: DPx17#14 Needle bar stroke: 35 mm Button clamp lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 33 patterns) No of stitches: Max. 10000 stitches Motor: Direct drive AC Servo Motor Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz

Multi needle chain stitch machine - 4 Model: Kansai DFB-1404 PS No of needles: 2-4 No of threads: 4 needle threads & 4 looper threads Needle: Stitch length: 2-5mm Speed: Max. 4500spm (Standard: 4000spm) Tension set: Mounted type Puller width: 55mm Gauge width: Min. 4.76mm (3/16 inch) 38.1mm (1-1/2 inch) Motor: 3-phase, 2-pole, 400W clutch motor

Button hole sewing m/c - 1 Model: SunStar SPS/B-BH3000-G Stitch Type: Drop feed Usage: General fabrics such as shirt, blouse, working dress, lady's dress, etc Sewing speed: Max. 4000spm Button hole area: Width: Max. 6mm Length: Max. 40mm Length of cutter: 6.4-31.8mm Needle: DPx5#14 Needle bar stroke: 35mm

Pressure foot lift: Max. 13mm No of patterns: Max. 99 patterns (Standard: 4 patterns) No of stitches: 768(stitches)/1 pattern Motor: Direct drive AC Servo Motor: 1 Pulse Motor: 3 Temperature: 5º C-40ºC Relative humidity: 20%-80% Voltages: 1-phase: 100-240V, 3-phase: 200-415V, 50/60 Hz Oil supply: Automatic

Collar Turning Machine - 7 Model: Ngai Shing NS 81 Power: 2600 W Weight – 10Kg Machine Dimension: 100x110x120cm

Pressing Machine with table – 14 Model: Braithwaite M28 Heating element – 1KW Length of cable – 2.5 metre Dimensions of table – 25” x 50”

FINISHING DEPARTMENT

Assumptions for the Finishing Section:

The washing of the garments is outsourced.

Finished garment can be stored in the finishing section.

Folding of the garment is done manually.

Aisle space is 5 feet.

Material handling of cartons takes place through trolleys

Inspection/ Trimming:

Manual Operation

Table dimensions: 5 and half feet by 4 feet

Area/ table: 6 sq feet (approx)

Total Area Required: - 1502 sq. ft.


Finishing Head – 1 Operators – 28 Helpers – 10

Machine Required:-

Thread sucking Machine - 14 Model: WenZhou LG-X530

Shirt Folding Machine-14 Model: Ngai Shing NS -50 Production Rate:- 300 pieces/shift

Spot cleaning gun - 14 Model: Albatross EX-4000 Power: 110-120 V

Pressing Machine with table – 7 Model: Braithwaite M28 Heating element – 1KW Length of cable – 2.5 metre Dimensions of table – 25” x 50”

OTHER DEPARTMENTS

Assumptions for other departments:

Effective arrangements have been made in factory for the treatment of wastes and effluents due to the manufacturing process carried on therein, so as to render them innocuous, and for their disposal.

There is 1 water point for every 25 workers.

Crèche is present for children up to 6 years.

Fire extinguishers are present in each section.

Separate urinals are present for the male and female workers with walls glazed with tiles up to the height of 3 feet.

Boilers /compressor/transformers are situated outside the factory premise and should be managed as per boilers act.

Main security point is at the main door situated at the distance of 12 feet from the factory building.

Parking facility is present inside the main building.

CRECHE:

Man Power Required:- 1


MEDICAL:



SECURITY:



Machine Required:-

Metal Detectors – 6

CONFERENCE ROOM:


Machine Required:-

LCD Projector – 1 Computer -1

RECEPTION:


Machine Required:-

Computer - 1

MD CABIN:


Machine Required:-

Computer – 1

GENERATOR ROOM:


Machine Required:-

High Electric Power Generator Model:- Bliss Kirloskar

BOILER ROOM:


BIBLIOGRAPHY

http://www.hashima.co.jp/english/products.html

http://www.hashima.co.jp/english/products.html

http://www.sewingmachinery.com/pressing/pressing.html

http://www.ngaishinghk.com/english/products.htm

http://www.gerbertechnology.com/default.asp?contentID=8

http://www.juki.co.jp/industrial_e/products_e/all.html

http://www.juki.co.jp/industrial_e/products_e/all.html

http://www.gerbertechnology.com/default.asp?contentID=8

http://www.ngaishinghk.com/english/products.htm

http://www.sewingmachinery.com/pressing/pressing.html

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Documents

spm needle

spm standard

patterns standard

needle threads

spm stitch length

stitches motor

spm button hole area

inch motor