Plant Layout Submitted By- Anil Yadav Kavita Yadav Ridhi Jain G. S. Subramanium Varundeep Singh Umakant
Plant Layout
Submitted By-
Anil Yadav
Kavita Yadav
Ridhi Jain
G. S. Subramanium
Varundeep Singh
Umakant
INDEX
Statement of Study 3
Introduction 3
Factors Considered for Layout Construction 5
Steps in Facility Design 7
1) Procure the Basic Data 13
2) Analyze the Basic Data 13
3) Design the Production Process 20
Operation Break Down For COTTON SHIRT 21
Machine Requirement Calculation 24
4) Plan Material Flow Pattern 25
5) Material Flow for Each Department 31
6) Consider General Material Handling Plan 40
7) Calculate the Equipment Requirements 42
8) Plan Individual Work Areas 45
9) Select the Specific Material Handling Equipment 50
10) Coordinate the Group of Related Operations 57
10) Design Activity Relationships 57
11) Determine the Space requirements 66
13) Determine the Storage requirements 69
14) Allocate Activity Area to Total Space 80
15) Consider Building Types 82
16) MASTER LAYOUT 82
17) Evaluation 83
18) Installation & Implementation 83
Check List 84
Conclusion 85
Statement of the study:
To prepare a plant layout for a shirt manufacturing unit with a capacity of 1250 shirts per
day.
Objective: Preparation of a layout plan for a shirt manufacturing unit.
Need of the study:
Designing an efficient layout helps a lot in reducing the time taken by the material to
travel in the department. It helps in:
Optimum flow of the material through each department
Efficient operation of the various related processes. Increase in efficiency.
Introduction
The design of a process plant is a complex activity that will usually involve many
different disciplines over a considerable period of time.
The design may also go through many stages from the original research and
development phases, through conceptual design, detailed process design and onto
detailed engineering design and equipment selection.
Many varied and complex factors including safety, health, the environment,
economic and technical issues may have to be considered before the design is
finalized.
At each stage it is important that the personnel involved have the correct
combination of technical competencies and experience in order to ensure that all
aspects of the design process are being adequately addressed.
Evidence of the qualifications, experience and training of people involved in
design activities should be presented in the Safety Report to demonstrate that the
complex issues associated with design have been considered and a rigorous
approach has been adopted.
The process design will often be an iterative process with many different options
being investigated and tested before a process is selected. In many occasions a
number of different options may be available and final selection may depend upon
a range of factors.
Factors considered for layout construction
A. Movement
This factor includes inter and interdepartmental transport and handling at various
operations, at storage, at inspections, the type of equipments and methods for material
handling. This remains the most important factor while deciding upon the selection of
layout and utilization of available land.
The various support departments are planned such that they are near to their requisite
sections of the plant, so that lesser material handling takes place as well as time is saved.
The material handling equipments are selected and designed as per department’s
requirement and interdepartmental movement.
B. Product
This factor includes type of product, the range and variety it covers, the quantity in a
shift, the number of shifts, necessary operations and their sequence. The product to be
made is high quality dress shirt for export. There are various variations of the dress shirt
which have been covered while selecting the type of machinery. The operation
breakdown was done along with the time study and the final sequence of operations is
decided by elimination of unnecessary operations.
C. Machinery
This factor includes the process, production equipments / furniture type, special
precautions to be taken, tools - their utilization and service net-work related to the same.
During selection of machinery, the type, productivity, price and service provided by the
supplier was kept in mind, so that no hassles are met in future.
D. Waiting
This factor includes permanent and temporary storage and delays and their locations. The
stores and warehouse are planned such that there is minimum amount of material
handling happening between various departments and the store/warehouse. Proper
amount of inventory storage capacity is planned so that inventory cost never goes higher.
E. Man
This factor includes direct workers, supervision and service help personals,
working hours, safety and manpower utilization method. Standard aisle space for
movement is provided, so that there is no problem in movement or supervision. Proper
amount of area for each workstation is provided so that the direct workers have no
problem while doing the operations or during movement. All the safety precautions are
undertaken while designing the layout like exits, emergency exits, fire extinguishers.
F. Service
This factor includes service relating to employee facilities such as parking, lockers,
rooms, toilets, waiting rooms etc, service related to materials in terms of quality,
production controls, scheduling, dispatching, waste control etc and service related to
maintenance and repair, its schedule, frequency and intensity.
G. Building
This factor includes outside, inside building features, utility distribution, nature of service
integration. The various blocks are planned as per their requirement like of height, inside
features, type of shedding, flooring etc. The final building is to be done in two floors with
Kirby sheds while the administration, canteen and other utilities block would be an RCC
structure.
Steps in facility design
1. Procure the basic data
a) Sales forecast
b) Quantity to be produced
c) Production schedule
d) Inventory policy
e) Production routing
f) Operations to be performed
g) Production time standards
h) Scrap percentages
2. Analyze the basic data
Above data is analyzed by the designer to determine the desired interrelationships and
then preparing for subsequent planning steps. Assembly charts give a quick and early
glimpse of the possible flow of materials.
3. Design the production process
The next is to decide how the raw material would be converted to final part or product.
Herein the production engineer designs an OPERATION SHEET or PRODUCTION
ROUTING, which is the tabulation of the steps involved in the production of a particular
part and necessary details on related items. Information on routing may include:
i. Part names and number
ii. Operation numbers and sequence
iii. Operations name and descriptions
iv. Machine names and numbers
v. Production standards
vi. Number of operators
vii. Space requirements
viii. Material
With the above information along with the Assembly chart, an OPERATION PROCESS
CHART is constructed, which provides a better impression of the potential material flow
pattern.
4. Plan material flow pattern
Overall material flow pattern must be carefully designed to assure minimum movement
and expeditious interrelation of the several components –part flow paths.
Assembly chart and production routing along with data on quantity and frequency of
material movement, a preliminary material flow pattern should be developed, which is
then worked upon keeping in mind the factors affecting material flow to reach to a
finalized pattern of flow of material in a particular unit. Flexibility for future expansion or
any changes
5. Consider general material handling plan
The material handling system converts the static flow pattern into a dynamic flow
of material through the plant.
The ideal system consists of an integrated combination of methods and effective
methods of performing every handling task- from unloading of material to
shipping of the final product. This involves both manual and mechanical methods.
Detailed handling methods should only after individual work stations have been
planned.
6. Calculate the equipment requirements
Any layout is incomplete w/o estimation of how many pieces of each type of
equipment (manufacturing, service and auxiliary) will be required.
Preliminary requirement has been made while tabulating production routing. Here
final decisions must be made as to the quantity of the equipment as a basis for
planning individual workstations and planning space requirements for each
activity area.
Also the number of operators must also be determined.
If final decisions regarding above , have not been made, at least an estimation
should be available.
7. Plan individual work areas
At this point, each operation , work station , area , process etc. must be planned in
detail.
The interrelationships between machines, operators and auxiliary equipment must
be worked out.
Each workstation must be tied into the overall flow pattern and flow through each
work station must be planned as an integral part of the overall plan.
8. Select the specific material handling equipment
Specific methods of material handling must be decided upon for each move of material or
item. Many factors need to need to be considered in the selection of handling methods.
9. Coordinate the group of related operations
Once the workplaces have been designed, interrelationships between the work areas,
related group of operations or activities should also be planned.
LAYOUT PLANNING CHART is a useful technique at this point.
10. Design activity relationships
Production activities need to be inter-related with auxiliary and service activities with
respect to the degree of closeness required by material, personnel and information flow.
11. Determine the storage requirements
Plans should now be crystallized in terms of storage of raw material, WIP and
finished products.
Square foot and cubic foot requirements should be calculated , with thought also
given to the location of the storage areas in the layout.
2 storage location methods-
1. Randomized storage
When an individual SKU can be stored in any available storage location. The
closest available slot is designated as storage location
2. Dedicated storage
When a SKU is assigned to a specific storage location or a set of locations. Fixed
slot is defined.
12. Plan the service and auxiliary activities
(Administration, transportation and storage)
A look at the plant service area planning sheet shows the complexity of this step.
Depending on the size of the plant all of the service activities must be carefully
studied, in order to determine which are needed.
Later, during the space planning and final design aspects of the planning, the
details of many of these service activities must be worked out.
13. Determine space requirements
At this stage, a preliminary estimate of the total space required for each activity in
the facility can be made and cumulatively, designer can arrive at a first estimate of
the total area.
Production space needs are estimated with the aid of a production space
requirement sheet.
Space determinations made at this stage are estimates. So these are on a little
higher side to ensure there is sufficient area. Only the final layout will show
accurately the total space needs.
14. Allocate activity areas to total space
The total space requirement work sheet provides for an area template for each
activity listed.
Activity relationship diagram is helpful in determining the relationships b/w the
different area templates.
Then an Area Allocation Diagram can be made based on the above, which
depicts the inter-relationships between the internal flow of materials and the
external flow-by means of various transportation modes.
It will also depicts the relationship w/ surrounding facilities e.g. power plant,
parking areas, storage places and adjacent buildings.
A preliminary layout has now been established.
15. Consider building types
Building type, construction, shape and number of floors should be considered.
Building usually comes after the layout. The layout should never be squeezed into
or altered to fit into a building, if it can be avoided by designing a layout first. As
imp a building might seem to be, it is the layout that forms the basis for the efficient
operation of an enterprise.
16. Construct the master layout
This step is the culmination of the detailed work and planning done in the preceding
steps. Final Layout is prepared using templates, tapes, etc. to a scale e.g. ¼” = 1 ft.
Two dimensional or three dimensional models are prepared.
17. Evaluate, adjust and check the layout with appropriate personnel
No matter how carefully or scientifically previous steps have been carried out, there
are always personal and judgmental factors to be considered. Facility designer and
his associates should check over their work at this stage before submitting it for
approval. Preliminary checks might also be made with others who have contributed
in designing the layout (production, methods, and personnel safety).
18. Obtain approvals
In the final stages , the layout must be formally approved by certain plant officials,
depending on plant facilities and procedures.
19. Install layout
A layout designer should carefully supervise the necessary work involved in the
installation of the layout to make sure all work is done according to the plans in the
approved layout. Any changes, if desired, should be carefully investigated and
approved by the concerned authorities.
20. Follow up on implementation of layout
Just because layout has been installed as planned, there is no guarantee that will
work as planned. No plant layout is 100% perfect and layout designer must
continually take note of how the layout is affecting the production operations. Scope
should be improvement must always be kept and incorporated if found desirable.
1. Procure basic data
2. Analysis Of Basic Data
a. Product Information
b. Tech – Pack
c. Factory Information
i. Foundation
ii. Location
iii. Electric Supply
iv. Nearness to Labor Supply
v. Proximity to external Economies Of Scale
vi. Reputation Of Area
vii. Transport and Communication Services
viii. Government Support
ix. Opportunities For Expansion
x. Development Agencies And Inward Investment
xi. Building Typology
xii. Construction Details
xiii. Description Of Floors
xiv. Area Of Factory- Department-wise
xv. Government And Industry Compliances
Product information:
Sketch (front) Sketch (back)
TECH PACK
BUYER ADDRESS :GENUINE GARMENT EXPORT COMPANY, NEW DELHI
product ID 01126357 Product name Full sleeve Men’s
cotton shirt
Order Quantity 1250 Group Plain
Season summer Brand Local
Size M gender MALE
Fabric 100 % cotton Date 6/4/11
fabric weave Plain GSM 180
COLOUR DETAILS :-
Base Fabric checks blue
Stitching Thread DTM
Button White colored Shell button
TABLE OF MEASUREMENT FOR SIZE SET
S. No Description M Tolerance(+ / - )
1 Neck line length 43 .5
2 Distance b/w Shoulder 45.5 .5
3 Total Sleeve length 67.5 .5
4 Armhole height from Neck point 29 .3
5 Sleeve width 21.5 .3
6 Bottom Sleeve width 11.8 .1
7 Chest Width 55 .5
8 Bottom Width 55 .5
9 Total Length from HSP 78 .5
10 Back yoke height at neck point 9.8 .1
11 Front cross (at ½ arm) 41.5 .3
12 Back cross (at ½ arm) 44.5 .3
13 Cuff height 8.5 .1
14 Sleeve placket length 14.5 .1
15 Sleeve placket width 3.5 .1
16 Sleeve placket Box height 3.5 .1
17 Collar Point 6 .1
18 Collar Height 4 .1
19 Collar band Height 3 .1
20 Shoulder Slope 4.8 .1
21 Shoulder forward 2.5 0
FACTORY INFORMATION:
Foundation:
The foundation will be built by digging 6 ft. down. Firstly a base of plain concrete
cement is there for 6 inches and then a reinforced concrete cement block of 1 ft.
The column foundation starts after that and the plinth and normal ground level are
the same.
IMT Manesar Gurgaon
IMT Manesar Area is under Haryana State Industrial Development Corporatation
(HSIDC).The Export House is situated in the Township (IMT) in Manesar, 17 km from
Gurgaon.
The reasons for Manesar's popularity are not hard to find. "It is located on the main
Jaipur-Delhi highway and is extremely well-connected to Delhi. The international airport
is just 32 km away, while Connaught Place is 45 km. It takes about an hour and a half to
reach Connaught Place which is the center of Delhi.
There are various garment manufacturing units like Modelama, Innovation com, Remya
Fashions - Manufacturer and Exporter of Hi-Fashion Garments etc. in this area.
The following could all be considered as important but for setting up the garment unit,
some of the factors will be more important than others.
Electricity supply:
Some firms require either a certain type of power/energy source or particular amounts to
be able to operate effectively. This means that one consideration for location is
somewhere that has relatively easy access to such sources. This might be particularly
relevant for a garment unit that uses sufficient amounts of power in the production
process. In simple terms, the location has to be in a position to be able to supply the
amount of power that the unit might need.
In this example of the garment unit, the production processes involved in this industry
require an optimum amount of electricity. The electricity supply to the unit is continuous
and the rates are cheap.
Nearness to a Supply of Labor:
All businesses need labour to operate. In some cases, this labour has to have high levels
of skill. Some areas have concentrations of industry in a region and have become known
for having a pool of skilled labour available. In such cases, it can save a firm both time
and cost locating near to the supply of labour. This can be extended if the local labour
supply is relatively cheap.
In the vicinity of the IMT Manesar, cheap labour can be easily found. The nearness to
the villages like Bhiwadi , Khandsa and Manesar fulfills the requirements of labour.
Proximity of Other Businesses - External Economies of Scale:
Where industry becomes concentrated in an area, there are generally a number of
supporting or ancillary units set up. In some cases, these units supply specialised services
or products to other firms in the industry. For example, fabric dyeing, printing, agencies
for fabric sourcing/ accessories sourcing, buying houses etc. are also in IMT manesar.
These benefits can result in lower average costs (costs per unit). This is called external
economies of scale.
The Reputation of an Area:
Certain areas of the country have a reputation for particular types of business - this might
often be due to its industrial past or the density of the similar kind of industries.
There are too many export houses in this area and it is reputed as a hub for garment
manufacturing. Whilst this factor may be seen as being less important it can still be a
factor that a unit might consider.
Transport and Communication Services:
Units that rely on good communications networks either for information transfer or
distribution may well look to locate in areas where such facilities exist. This may include
high quality road networks, access to trains, airports, ports and so on. Many new
industrial estates have been built in out of town areas and major new trunk roads linking
these estates with major road networks make locating in these areas worthwhile for some
firms.
For other firms, speed of information may be the crucial factor in their business. Many
city areas were the first to have access to high speed data networks, broadband, cable and
satellite services and so on. For a firm in the City, having high speed data access is
essential to the transaction of their business.
The IMT manesar is well connected to the highway for the transport of the materials. The
information services are also satisfactory.
Government support:
The availability of low rent premises, faster planning permissions, employment subsidies
(a sum of money given for every job created), grants etc. can make a difference to a
company that decides to locate in that area.
Opportunities for Expansion:
Many businesses might be looking for opportunities to expand in the future. Access to
land, and the ease with which the business can expand if necessary, might therefore be
something that a business will want to find out before making a location decision, or at
least as part of a location decision. In some areas of the country, planning permission may
be difficult to get - there may be restrictions on expansion into the countryside, various
policies to encourage use of derelict land and so on. Whilst this may be of benefit to
society as a whole, it is not necessarily the most cost-effective solution for a business.
In some areas of the country, land and rental prices can be significant factors in location
decisions. IMT manesar can be considered a perfect location for the expansion.
Development Agencies and Inward Investment:
Regional policy in recent years has changed its emphasis. The approach is to have a co-
ordinated policy to help each region achieve its full economic potential but at the same
time to allow decision-making to be devolved to the lowest level, where possible. This
means that the regions themselves will take a lead in encouraging economic development
and supporting businesses in their region.
To this end, there is now a network of regional development agencies (DAs) focusing
their attention on improving the economy of particular regions.
IMT manesar Industries Association is the main association involved in the development
of this area
Govt. & industry compliances:
Labour Laws
Human rights
ILO Compliance
Vendor Compliance
Government Policies and State Government Laws
Minimum Wages
3) Design production process
The production process of various sections involved in the production process is designed
using the analyzed data along with the consultation with concerned experts and
consultants
The next is to decide how the raw material would be converted to final part or product.
Herein the production engineer designs an OPERATION SHEET or PRODUCTION
ROUTING, which is the tabulation of the steps involved in the production of a particular
part and necessary details on related items. Information on routing may include:
i. Part names and number
ii. Operation numbers and sequence
iii. Operations name and descriptions
iv. Machine names and numbers
v. Production standards
vi. Number of operators
vii. Space requirements
viii. Material
OPERATIONAL BREAKDOWN FOR COTTON SHIRT
Sleeve
PLKT MARKING
TACK @ V NOTCH
ATT SMALL PLKT
PLKT MARK AND CUT
FINISH BIG PLKT
ATT BIG PLKT
Collar
N/B HEM
PRESS N/B
T/S ON CLR
PRESS CLR
CLR PRESS
CLR ATTACH TO N/B
Front
TACK B/H PLKT
SEW B/H PLKT
SEW BUTTON PLKT
PRESS B/H PLKT
FRONT CHECKING
Back
LABEL MARKING
LABEL MAKING
YOKE ATTACH
PLEAT MAKING
BK CHECKING
LABEL ATTACH
SHOULDER T/S
NO SET FRNT & BACK
JOIN FNT AND BK
COLLAR ATTACH
COLLAR FINISH
ATT SLV TO BODY
T/S PLKT
SLV CHECKING
Sew Cuff
Turn & Iron Cuff
CLR RAW EDGE TRIM
CLR CHECKING
CUFF CORNER TACK
LEGEND
SEWING OPERATION
IRONING
CHECKING
HELPER
No. SET
TRIMMING
SIDE SEAM ATTACH
S/S LABEL ATTACH
S/S TOP STITCH
CUFF ATTACH
CUFF T/S
YOKE LABEL ATTACH
BOTTOM HEM
TRIM
FINAL CHECKING
ARM HOLE T/S
ARM HOLE CHECKING
SEW CUFF PLEATS
GARMENT READY
MACHINERY REQUIREMENT CALCULATION Formal Shirt Operational Breakdown
FOR ONE LINE
Target output = 1250 pc/day for 4 lines
Sewing SAM 26.2
shift time = 480 min
Helper SAM 6.4
operator efficiency = 65%
Finishing SAM 2.27
Sr.No. Code OPERATION SAM HELPER ACTUAL
TIME MACHINE
W/S
Calculated
W/S
Req.
Actual
W/S
Req.
NO.of
M/C
Req.
Actual
M/C
Req.
Cal Prod.
COLLAR PREPARATION
1 A1 Mark Collar 0.31 Y 0.477 Helper table 0.31 0.5 1 0 0 503
2 A2 Make Loop 0.12 N 0.185 Snls w/ ubt 0.12 0.5 1 0.5 1 1300
3 A3 Tack Loop&Attach Loop to
CLR Patch 0.26 N 0.400 Snls w/ ubt 0.26 0.5 1 0.5 1 600
4 A4 Top Stitch on collar with Patch 0.2 N 0.308 Snls w/ ubt 0.20 0.5 1 0.5 1 780
5 A5 Make Collar 0.48 N 0.738 Snls we/c 0.48 0.5 1 0.5 1 325
6 A6
Trim, Turn & Crease Collar 0.31 Y 0.477
Collar turning
machine 0.31 0.5 1 0.5 1 503
7 A7 Topstitch Collar 0.31 N 0.477 Snls w/ ubt 0.31 0.5 1 0.5 1 503
8 A8 Press Neck Band 0.32 Y 0.492 Iron Table 0.32 0.5 1 0.5 1 488
9 A9 Match Band With Collar 0.3 Y 0.462 Helper table 0.30 0.5 1 0 0 520
10 A10 Attach Neckband To Collar 0.48 N 0.738 Snls we/c 0.48 0.5 1 0.5 1 325
11 A11 Trim & Turn Pick 0.32 Y 0.492 Helper table 0.32 0.5 1 0 0 488
12 A12 Ready Cut Collar 0.16 N 0.246 Snls we/c 0.16 0.5 1 0.5 1 975
13 A13 Press Collar 0.47 Y 0.723 Iron Table 0.47 0.5 1 0 0 332
CUFF PREPARATION
1 B1 Mark Cuff 0.32 Y 0.492 Helper table 0.32 0.5 1 0 0 488
2 B2 Hem Cuff 0.29 N 0.446 Snls w/ ubt 0.29 0.5 1 0.5 1 538
3 B3 Make cuff 0.64 N 0.985 Snls we/c 0.65 1 1 1 1 488
4 B4 Trim&turn cuff 0.3 Y 0.462 Helper table 0.30 0.5 1 0 0 520
5 B5 Press Cuff 0.32 Y 0.492 Iron Table 0.32 0.5 1 0 0 488
SLEEVE PREPARTION
6 C1 Notch Sleeve for PLKT 0.32 Y 0.492 Helper table 0.32 0.5 1 0 0 488
7 C2 Attach Down Sleeve PLKT 0.31 N 0.477 Snls w/ ubt 0.31 0.5 1 0.5 1 503
8 C3 Tack Down Sleeve PLKT 0.22 N 0.338 Snls w/ ubt 0.22 0.5 1 0.5 1 709
9 C4 Press Top Sleeve PLKT 0.65 Y 1.000 Iron Table 0.66 1 1 0 0 480
10 C5 Attach Top sleeve PLKT&finish 0.96 N 1.477 Snls w/ ubt 0.97 1 1 1 1 325
FRONT
11 D1 Hem Pocket Mouth 0.24 N 0.369 Snls w/ ubt 0.24 0.5 1 0.5 1 650
12 D2 Press Patch Pocket 0.29 Y 0.446 Iron Table 0.29 0.5 1 0 0 538
13 D3 Make Button Placket 0.3 N 0.462 Snls w/ ubt 0.30 0.5 1 0.5 1 520
14 D4 Attach Top Plkt 0.62 N 0.954 Snls w/ ubt 0.63 1 1 1 1 503
15 D5 Make Button Hole placket 0.65 N 1.000 Kansai 0.66 1 1 1 1 480
16 D6 Mark front For Pocket
Placment 0.31 Y 0.477 Helper table 0.31 0.5 1 0 0 503
17 D7 Attach Pocket To Front 0.79 N 1.215 Snls w/ ubt 0.80 1 1 1 1 395
BACK
18 E1 Match Yoke to Back 0.32 Y 0.492 Helper table 0.32 0.5 1 0 0 488
19 E2 Attach Yoke To Back 0.47 N 0.723 Snls w/ ubt 0.47 0.5 1 0.5 1 332
20 E3 Topstitch Back Yoke 0.46 N 0.708 Snls w/ ubt 0.46 0.5 1 0.5 1 339
21 E4 Attach Patch to Back 0.48 N 0.738 Snls w/ ubt 0.48 0.5 1 0.5 1 325
22 E5 Press Patchlabel 0.32 Y 0.492 Iron Table 0.32 0.5 1 0 0 488
23 E6 Attach Patch Label to Back With Main
Label 0.64 N 0.985 Snls w/ ubt 0.65 1 1 1 1 488
ASSEMBLY
24 F1 Match Front With Back 0.3 Y 0.462 Helper table 0.30 0.5 1 0 0 520
25 F2 Attach Shoulder 0.61 N 0.938 Snls w/ ubt 0.62 1 1 1 1 511
26 F3 Topstitch Shoulder Panel 0.47 N 0.723 Snls w/ ubt 0.47 0.5 1 0.5 1 332
27 F4 Match Sleeves With Body 0.3 Y 0.462 Helper table 0.30 0.5 1 0 0 520
28 F5 Attach Sleeves 0.87 N 1.338 Snls w/ ubt 0.88 1 1 1 1 359
29 F6 Topstitch Armhole 0.81 N 1.246 Snls w/ ubt 0.82 1 1 1 1 385
30 F7 Tack Wash care Label 0.2 N 0.308 Snls w/ ubt 0.20 0.5 1 0.5 1 780
31 F8 Sew Side Seam 0.79 N 1.215 Foa 0.80 1 1 1 1 395
32 F9 Make Side Slit 0.81 N 1.246 Snls w/ ubt 0.82 1 1 1 1 385
33 F10 Match Collar With Body 0.3 Y 0.462 Helper table 0.30 0.5 1 0 0 520
34 F11 Stay Stitch on Neck 0.29 N 0.446 Snls w/ ubt 0.29 0.5 1 0.5 1 538
35 F12 Attach Collar to body 0.45 N 0.692 Snls w/ ubt 0.45 0.5 1 0.5 1 347
36 F13 Close Collar 0.69 N 1.062 Snls w/ ubt 0.70 1 1 1 1 452
37 F14 Topstitch Collar 0.31 N 0.477 Snls w/ ubt 0.31 0.5 1 0.5 1 503
38 F15 Match Cuff To Body 0.32 Y 0.492 Helper table 0.32 0.5 1 0 0 488
39 F16 Make Pleaet on Sleeve 0.29 N 0.446 Snls w/ ubt 0.29 0.5 1 0.5 1 538
40 F17 Attach Cuff To Body 0.63 N 0.969 Snls w/ ubt 0.64 1 1 1 1 495
41 F18 Topstitch Cuff 0.58 N 0.892 Snls w/ ubt 0.59 1 1 1 1 538
42 F19 Hem Bottom 0.65 N 1.000 Snls w/ ubt 0.66 1 1 1 1 480
43 F20 Mark Front For Button Hole 0.32 F 0.492 Helper table 0.32 0.5 1 0.5 1 488
44 F21 Attach Button on Cuff 0.22 F 0.338 Button Attach 0.22 0.5 1 0.5 1 709
45 F22 Make Button Hole on Cuff 0.21 F 0.323 Button Attach 0.21 0.5 1 0.5 1 743
46 F23 Make Button Hole 0.65 F 1.000 Button hole 0.66 1 1 1 1 480
47 F24 Mark Front For Button Att 0.24 F 0.369 Helper table 0.24 0.5 1 0.5 1 650
48 F25 Attach Button on Front Placket 0.63 F 0.969 Button Attach 0.64 1 1 1 1 495
TOTAL 26.2 40.308 26.45 39.5 61.0 30.5 44.0 325
S.NO MANUAL QTY
S.NO SEWING MACHINES QTY
S.NO FINISHING QTY
1 Helper table 14
1 Snls w/ ubt 30
1 Button Attach 3
2 Collar turning machine 1
2 Snls we/c 4
2 Button hole 2
3 Iron Table 6
3 Sncs 0
TOTAL 5
TOTAL 21
4 FOA 1
5 Kansai 1
TOTAL 36
4) Plan material flow pattern
One of major activity during plant layout design is the planning of the flow pattern. It is
on the flow pattern that the layout design depends upon. So selection of the best flow
pattern as per the given constraints from various available options is very important for
the success of the final layout.
Different sections of the unit
The new manufacturing unit will consist of following sections / departments:
A. Production Related
• Fabric Stores
• Sewing Trims & Accessories Store
• Spreading and Cutting Section
• Sewing Section
• Finishing Section
• Merchandising Department
• Sampling & Technical Department
• Quality Department
• CAD Section
• IE Department
• Maintenance
• Warehouse
B. Administration and other departments
• CEO Office
• Accounts Department
• HR Department
• Medical Room
• Training Department
• Conference Room
• Reception
• Generator, Boiler, Compressor and other utilities Room
• Security Room
• Toilets
• Parking
Material Flow Pattern
• Receipt of palletized fabric to store: Palletized fabric is received at the unloading
dock and is transferred to the fabric store through the articulated fork lifter.
• Issue of fabric to cutting section: The required amount of fabric is issued to the cutting
section through fork lifter or the power pallet truck as per requirement.
• Transfer of cut parts to parts section:
The cut parts are transferred to the parts section through a vertical trolley system. The cut
parts would be lifted by the help of a trolley to the parts section from where it would be
fed to the respective lines. In the parts section, material is handled via bins, or racks as
per requirement.
• Transfer of panels to assembly section:
From parts to assembly garments are transferred through use of various bins, racks or
trolleys. And in the assembly section, garment panels move on a mover system.
• Transfer of garments to finishing section:
Garment is transferred to the finishing section through the stairs using gravity. There
would be slider provided in the stairs for easy movement of the bins on the stairs. In the
finishing section garments will move on mover system and racks.
• Transfer of packed garments to warehouse:
The packed and/or palletized cartons are transferred to the warehouse through the
articulated fork lifter or the power pallet truck.
• Shipment of palletized cartons:
Eventually palletized cartons are shipped and loaded in the container at the dock with the
help of fork lifter and the power pallet truck.
Start
Obtain tech pack from buyer
Sampling
Analyze fabric
consumption from
CAD
Analyze cost of
trims and
fabric
Obtain general
sewing data from
IED
Prepare cost sheet
from sample
Develop sample as
per the tech pack
Develop proto
sample
Cost sheet & sample sent to buyer for approval
Approval Cost sheet
reworked
Confirmation
of order
Obtain PCD &
details from
production unit
Source trims &
fabric from
concerned dept.
Book washing &
embroidery capacity if
required
Obtain GSD
from IED
Execution of order by entering details in ERP
Prepare sample as per buyer requirements
Forward the sample to buyer for approval
Approval Comments received from buyer
should be incorporated and fit
sample reworked
Hold pre production
meeting with the
production unit
Execute
bulk order
Costing
Follow up with
production
departments &
update the buyer
Submit required
documents to
documentation
dept
Offer garments
for final
inspection.
Truck out
Follow up
on the
payments
for goods
End
No Yes
No Yes
PRODUCTION ROUTING- MERCHANDISING DEPARTMENT
Tech pack received from merchant
Develop patterns
Costing CAD
marker
Develop sample
Develop fit/proto sample
Revise Fit/Proto
sample
PP sample
Revise PP sample Size set sample
Incorporate buyer
comments
Sealer sample
Incorporate buyer
comments
Bulk production
(shrinkage to be added
if it’s a wash program)
If no comments
If no comments
If no comments
If no comments
If any comments
comments
If any comments
comments
If any comments comments
If any comments
comments
Workflow of sampling
FABRIC SOURCING:
Start Sampling
Technical analysis. Vendor
evaluation/selection of
vendor
Placement
D/L
Submit to buyer
If Ok
Sampling yardage/
lab tests
Final approval by
buyer
Redo D/L
If not Ok
Placement, lab
dips/strike offs
submission to buyer
Rate finalisation,
sampling yardage,
lab tests
Final submission to
buyer
End
Receiving order, technical analysis/
process starts for technical
development, vendor selection
Rate quotation from different mills
TNA/Execution plan/placement of
order for production
On line
inspection
If Ok If not Ok
Lab testing as per buyer
requirement
Mending/cleaning/washing
Despatch to vendor’s godown
Technical monitor/
corrective
measures
Process
If required
Sanforising/dyeing/prints/OXO/
washing/wet processing
Lab test as per buyer
requirement
Third party inspection as per
buyer standards
Third party inspection as per
buyer standards
If not required
Pass Pass
Vendor evaluation/
feedback to vendor End
Reject
If not Ok
Bulk
Receive fabrics
Start
Conduct shrinkage test
on minimum 2
bits/bale or minimum
10 bits of consignment
Forward one meter of
each consignment for
lab test
Verify whether quantity
received match with
quantity ordered
Inform to stores and prepare
goods received note (in case of
imported fabric)
Inspection based on four
points system. Match
bulk with approved dye
lot, width of fabric etc.
Name shade lot as ABC
Send to merchant for buyer’s
approval
If approved Forward to
cutting
department
End
Reject lot
If No
If No
If No
If Yes
If Yes
If Yes
FABRIC AUDIT:
Start
Accept & receive materials against documents
Prepare PRE GRN
Verify materials against invoice/ Delivery challan & packing list
Carry out quality & quantity inspection as per AQL 1.5
Allocation of trims based on the nature of the item
Prepare GRN & do the bill entry. The same is
forwarded to accounts for payment
PROCESS
SELECTION
PRODUCTION
ISSUES
Prepare work order
Prepare delivery challan
Forward trims along with
documents for processing
Identify trims which have been
approved by merchants
Prepare delivery challan & keep trims
ready to issue to the factories
Materials to be issued after
inspection by security against
DC
End
ACCESSORY STORES:
Receive patterns
from pattern
Digitize pattern
to feed in
Receive spec
sheet form
Pattern grading
Cut ratio
planning
Market planning
according to the
cut plan ratio
Output to
Graphtec plotter
Pattern sent to
merchandiser for
sampling
Pattern correction
yes
No
Output mini
marker to
printer
Output marker
to plotter
Send to cutting
room for cutting
Send to
merchandiser for
costing
WORK FLOW
IN CAD
DEPARTMENT
Cutting package
from production
manager
Acquire fabric
from fabric store
Cut sample to
check
Cut for initial size
set
Assemble and
check
Send to CAD for
amendment
Receive
amendment pattern
from CAD
Yes
NO
No
Require
amendm
ents
Issue job order
Bulk cutting
Sorting
Cut plan
Bundling
Issue
WORK FLOW IN
CUTTING DEPARTMENT
PRODUCTION DEPT:
Start
Bulk Production
Cut parts received from
cutting
End line checking & AQL
audit
Assembly
Parts preparation
Button & button hole/ Bar tack
Rough checking
Ironing
Final checking
Tagging
Packing
FSA Audit
Measurement checking
Auditing by buyer QA
Truck out End
In-Line
checking
Washing
5) Material flow pattern plan
Specific methods of material handling must be decided upon for each move of material or
item. Many factors need to need to be considered in the selection of handling methods.
Material handling equipment is selected based on the requirement with consideration for
various factors like cost, service etc.
Progressive bundle system (PBS)
The progressive bundle system (PBS) gets its name from the bundles of garment
parts that are moved sequentially from operation to operation.
Bundles consist of garment parts needed to complete a specific operation or
garment component.
Bundles are assembled in the cutting room where cut parts are matched up with
corresponding parts and bundle tickets.
The sewing operations are laid out in sequence . Each operator receives a bundle ,
does his work , re-ties the bundle and passes it to the next operator .
There is usually a storage facility such as rack, bin or table for storing the inter-
process work between each operation. The work is routed by means of tickets.
Any imbalance in production can be corrected by using utility workers . It is used
in shirt factories, jeans factories , jacket factories, etc
Advantages
Operators perform the same operation on a continuing basis, which allows them to
increase their speed and productivity.
This system may allow better utilization of specialized machines, as output from
one special purpose automated machine may be able to supply several operators
for the next operation.
Small bundles allow faster throughput unless there are bottlenecks and extensive
waiting between operations.
Semi skilled labour can be used.
Disadvantages:
1. Operators who are compensated by piece rates become extremely efficient at one operation
and may not be willing to learn a new operation because it reduces their efficiency and
earnings.
2. Slow processing, absenteeism, and equipment failure may also cause major bottlenecks
within the system.
3. Large quantities of work in process
4. This may lead to longer throughput time, poor quality concealed by bundles, large
inventory, extra handling, and difficulty in controlling inventory.
5. It requires a high level of management skill to arrange the workflow and decide on the
number of operators for each operation .
6) Calculate equipments requirements
MACHINE
TYPE
LENGTH WIDTH AREA PER MC
INCHES FEET INCHES FEET SQ FEET
SNLS 42 3.5 21.2 1.8 6.18
DNLS 42 3.5 21.2 1.8 6.18
DNCS 42 3.5 21.2 1.8 6.18
SNEC 42 3.5 21.2 1.8 6.18
B/H 47 3.9 22.5 1.9 7.34
B/S 47 3.9 22.5 1.9 7.34
B/S feeder 47 3.9 23 1.9 7.51
B/H B/S Tandem without
feeder
48 4 28 2.3 9.33
B/H B/S Tandem with feeder 60 5 40 3.3 16.67
Auto Jig 43 3.6 32.5 2.7 9.70
Front Pressing 52 4.3 45 3.8 16.25
Sleeve plkt Pressing 42 3.5 21.2 1.8 6.18
Contour 35.5 3.0 23.5 2.0 5.79
Collar Notch 42.5 3.5 24.5 2.0 7.23
Kansai 42 3.5 21.2 1.8 6.18
Back Stacker 42 3.5 21.2 1.8 6.18
Cuff Stacker 53.5 4.5 21.2 1.8 7.88
Collar blocking 42 3.5 34 2.8 9.92
Cuff Blocking 24 2.0 33.5 2.8 5.58
Checking table 47 3.9 38 3.2 12.40
Iron Table 1 41 3.4 25 2.1 7.12
Iron Table 2 51 4.3 31 2.6 10.98
Table 48 4.0 31 2.6 10.33
Fusing Machine 175 14.6 62.00 5.2 75.35
Iron Table 60 5 36 3 15
Folding Table 60 5 36 3 15
Thread Sucker 60 5 24 2 10
Collar and Cuff Press 60 5 48 4 20
Collar Press 36 3 24 2 6
Stain Remover 60 5 48 4 20
Needle Detector 72 6 48 4 24
A-type Trimming Table 48 4 36 3 12
Fabric Inspection Mc 120 10 72 6 60
Washing Mc 24 2 18 1.5 3
Dryer 24 2 18 1.5 3
Light Box 28.8 2.4 20.4 1.7 4.08
i. Cutting Section
To cut pieces for 1250 shirts per day, following equipments are required:
Equipments required for producing 1250 pieces per day
Equipment Quantity Quantity available
Fabric Inspection Machine (72” width) 1
Spreading & Cutting Table 2
Pinning, Numbering, Bundling Table 2
Fusing Machine 1 1
Band Knife 84 7.0 60.00 5.0 35.00
Die Cutting Mc 42 3.5 42.00 3.5 12.25
Storage Rack 1 38.4 3.2 157.44 13.1 41.98
Storage Rack 2 38.4 3.2 275.52 23.0 73.47
Table 1 905.28 75.4 78.00 6.5 490.36
Table 2 787.2 65.6 78.00 6.5 426.40
Die Cutter 1 1
Band Knife 1 1
Straight knife 3 3
ii. Finishing Section
TYPES OF EQUIPMENTS Machinery DESCRIPTION /
CAPACITY
1250 pcs
Fork Lift 1 NA
Iron Table 4 Ramson
Thread Sucking 1 Ramson-TSN77 (300Pc/Hr)
Stain Remover 1 Ramson-CL7 (Enough for
1250pc/Day)
Needle Detector 1 Hashima-
HN750G(1250pc/Day)
Boiler 1 Ramson-ROB707
Carton Strapper 1
TOTAL 22
iii. CAD Section
EQUIPMENT DESCRIPTION
/DIMENSION
For 1250 pcs per day
PLOTTER 7ft x 2ft 1
DIGITIZER 3.9x5.9ft 1
TABLE 4 ft x 4 ft 1
COMPUTER 2 ft x 4 ft 3
At this point, each operation, work station, area, process etc. must be planned in
detail.
The interrelationships between machines, operators and auxiliary equipment must
be worked out.
Consideration must also be given to multiple machine operation, principles of
motion economy and material handling to and from the workplace.
Each workstation must be tied into the overall flow pattern and flow through each
work station must be planned as an integral part of the overall plan.
7) Plan individual work areas
Cutting Section:
Pinning, Numbering and Checking table 12 mX1.8 m
\
Workstation Details for Layout Construction
Parts section
Sewing Workstation
Note:
Area consumed by each workstation = 2 sq meters.
feet space is being provided for operator’s sitting and movement.
On right hand side of workstation main aisle of 3 feet is being provided.
Checking Workstation (Supervisor and QC)
1.5 feet is being provided supervisor or checkers sitting and movement.
Area consumed by each workstation = 1.7 sq meters.
On right hand side of workstation main aisle of 3 feet is being provided.
Assembly section
Sewing Workstation
Note:
• Area consumed by each workstation = 1.8 sq meters
• Area consumed by each workstation = 3.5 sq meters
• 2.5 feet space is being provided for operator’s sitting and movement.
• Main aisle of 3 feet is being provided between two lines.
Finishing Section
Trimming Workstation (A-Type Table)
o Area consumed by each workstation = 3.9 sq meters.
o 1.5 feet space is being provided for operator’s sitting and movement.
o Distance between two workstations is 1 feet.
o Garment moves on the mover system.
Pressing Workstation
o Area consumed by each workstation = 2.3 sq meters.
o 2 feet space is being provided for operator’s sitting and movement.
o Main aisle of 3 feet is being provided.
o Garment moves on conveyor
Folding and Bagging Workstation
o Area consumed by each workstation = 2.3 sq meters.
o 2 feet space is being provided for operator’s sitting and movement.
o Main aisle of 3 feet is being provided.
8. SELECTION OF SPECIFIC MATERIAL HANDLING
EQUIPMENTS
Material handling is undertaken at every stage of logistics activity, and is an integral part
of the other elements of logistics function. Material is handled during the production
process, warehouses or storage, in transport, during packing and when goods are returned
by the customer for one reason or the other. This would insure cost reduction in the
operation of the overall material handling function and increase productivity.
Material handling equipment is all equipment that relates to the movement, storage,
control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. Material handling equipment is
the mechanical equipment involved in the complete system.
Material handling equipment is generally separated into four main categories:
A. storage and handling equipment,
B. engineered systems,
C. industrial trucks, and
D. bulk material handling.
Material handling equipments were chosen on the basis of following three criteria:
1. Material Characteristics
2. Move Requirements
3. Method (Equipment) Capabilities
There are various kinds of equipments available for material handling. Since the type of
equipment will materially affect the layout, the layout planner should be familiar with the
characteristics and capabilities of each type. Usually the best, most economical and most
efficient handling is accomplished by an integration of different types of handling
equipments.
For the selection of specific material handling equipments following points should be
checked:
Cost of the equipment delivered and installed complete with power and fuel
facilities
Cost of operation
Cost of maintenance
Ability to do a specific job
Safety aspect of material and operator
Effect on working conditions
Dependability of performance
A sound approach to the problem of selecting the most suitable material handling system
for a plant layout must take into consideration not only the engineering aspects of the
handling system but also the economic appraisal of the various material handling systems
that lend themselves to the job to be performed.
A) Storage and handling equipment
Storage and handling equipment is a category within the material handling industry. The
equipment that falls under this description is usually non-automated storage equipment.
Products such as Pallet rack, shelving, carts, etc. belong to storage and handling.
Selective pallet rack is an example of storage and handling equipment.
B) Engineered systems
Engineered systems are typically custom engineered material handling systems.
Conveyors, Handling Robots, AS/RS, AGV and most other automated material handling
systems fall into this category. Engineered systems are often a combination of products
integrated to one system. Many distribution centers will optimize storage and picking by
utilizing engineered systems such as pick modules and sortation systems.
Equipment and utensils used for processing or otherwise handling edible product or
ingredients must be of such material and construction to facilitate thorough cleaning and
to ensure that their use will not cause the adulteration of product during processing,
handling, or storage. Equipment and utensils must be maintained in sanitary condition so
as not to adulterate product.
C) Industrial trucks
Industrial trucks usually refer to operator driven motorized warehouse vehicles, powered
manually, by gasoline, propane or electrically. Industrial trucks assist the material
handling system with versatility; they can go where engineered systems cannot. Forklift
trucks are the most common example of industrial trucks but certainly aren't the extent of
the category. Tow tractors and stock chasers are additional examples of industrial trucks.
D) Bulk material handling
Bulk material handling equipment is used to move and store bulk materials such as ore,
liquids, and cereals. This equipment is often seen on farms, mines, shipyards and
refineries
Different types of material handling equipment can be:
Trolleys, Bins, Pallet, Guides, Conveyor, Fork Lifters, Pallet Truck, Order Pickers,
Manual handling system etc.
We are here discussing the equipments our company uses :-
Features and Benefits of Industrial Trolleys
Powder coated with durable non-slip industrial quality vinyl mats or lipped metal
surfaces
Fitted quality non-marking wheels and castors.
All industrial trolleys come standard with castor mounting plates. Castors are
bolted to these castor mounting plates to allow for ease of castor replacement, or
to allow for changes to castor arrangement.
Available in a large range of models with ability to customise on large orders
Trolleys and Materials Handling Equipment Product Range:
Custom Made Trolleys
Platform Trolleys
Imported Trolleys
Hand Trolleys and Dollies
Hand Trucks
Panel Carts
General Cleaning Equipment
Plastic Containers
Ladders
Stackers
Scissor Tables
Guard Rails
Lifting and Handling Equipment
Pallet Trucks
Wheels and Castors
Conveyors
Some salient features of storage bins are:
Made from Polypropylene Copolymer.
Strong rear lip for use with louvered panel.
Strong heavy duty with reinforced base, sides and stacking rim.
Resistant to most industrial solvents and withstands high temperatures.
Clear access to contents.
All bins with identification card holders.
Incorporates a safety stop feature at the back for use in shelves
Features like bin dividers, louvered panels, shop floor trolleys and rotary stands
are also available.
Complete Line of Products:
Accessory Racks
Clothes Racks
Garment Steamers
Grid wall
Hangers
Mannequins and Forms
Rack Covers and Garment Bags
Shelf Brackets, Hooks and Other Accessories
PALLETS
Wooden Pallets
Widest type selection, best quality Babool/Hard wood with preservative
treatment, optimum design for all applications, flawless workmanship and
very high production capacity.
Mild Steel Pallet
Pressed steel or rolled section rigidly welded pallets for lifetime maintenance
free usage.
Stainless Steel / Aluminum Pallets
For food and pharmaceutical industry, involving autoclave, driers and other
such application.
Box / Cage Pallets
Stackable / non stackable box / cage pallets for storage of small parts and
packages.
Collapsible Pallets
Stackable Box / Cage Pallets that can collapse to a fraction of their volume for
lean period storage or empty return
PU Coated Wooden Pallets
Total water repellency and other resistive properties of polyurethane with
design flexibility, economy and frication safety of wooden pallets.
9. Coordinate the group of related operations
Once the workplaces have been designed, interrelationships between the work areas,
related group of operations or activities should also be planned. LAYOUT
PLANNING CHART is a useful technique at this point. This chart records the major
steps in each operation, forces a consideration of the steps between the operations,
points out the omissions in planning and guiding the further development of an
effective integration of operations.
10. The Activity Relationship Chart
This chart is an ideal technique for planning the relationship among any group of
interrelated activities. It is important for:
1. Preliminary allocation of sequence
2. Relative location of work centres or departments
3. Location of activities
4. Location of work centres
5. Showing which activities are related to each other and why
6. Providing basis for subsequent area allocation
The various activities identified as above may now be arranged in an activity
relationship chart based on their need to be close to each other. Before actually
making the chart, it is necessary to analyze what all departments need to be close to
each other and also the reason for the need of their proximity needs to be known. For
this purpose, an analysis has been
Activity Closeness to
activity
Reason for closeness
STORE
Raw material
Inspection
A The material from stored is issued to inspection
so material movement needs to be minimized
Cutting A The fabric supply from store has to be sent to the
cutting room. This flow must be smooth
Fusing U -
Sewing O The trims need to be moved to the sewing floor
Washing U -
Finishing U -
Merchandising I The merchandisers need to check availability of
certain raw material for sampling purposes
Sampling I The sampling needs a supply of materials from
the stores
Maintenance U -
Industrial
Engineering
U -
Administration U -
Accounts U -
INSPECTION
Cutting O The sequence of flow requires them to be
somewhat close
Fusing U -
Sewing U -
Washing U -
Finishing U -
Merchandising U -
Sampling U -
Maintenance U -
Industrial U -
CUTTING
Sewing E After cutting, cut parts are sent for sewing so
these departments need to be close
Washing U -
Finishing U -
Merchandising U -
Sampling U -
Maintenance and
housekeeping
U -
Industrial
Engineering
O The IE department keeps conducting time
studies for spreading and cutting operations
Production
planning and
Control
O The PPC department needs to be aware of the
available capacity
Administration U -
Accounts U -
Packaging and
Dispatch
U -
Sewing I The sequence of operations needs these activities
to be together
Engineering
Administration U -
Accounts U -
Cutting
Fusing A The pattern parts are fused after being cut so
these activities need to be close by
FUSING
Washing U -
Finishing U -
Merchandising U -
Sampling O The sampling section might need to get parts
fused from the fusing section
Maintenance and
housekeeping
U -
Industrial
Engineering
U -
Production
planning and
Control
U -
Administration U -
Accounts U -
Packaging and
Dispatch
U -
SEWING
Washing E The garments after being sewn need to be sent to
the washing section
Finishing I They need to be close because of sequence of
workflow
Merchandising U -
Sampling U -
Maintenance and
housekeeping
E There are greater chances of sewing room
requiring maintenance people
Industrial
Engineering
O The IE department keeps conducting time
studies for sewing operations
Production
planning and
Control
O The PPC department needs to be aware of the
available capacity
Administration U -
Accounts U -
Packaging and
Dispatch
U -
WASHING
Finishing E The garments from washing need to move to the
finishing department
Merchandising U -
Sampling O The sampling department needs to get samples
washed from the washing
Maintenance and
housekeeping
U -
Industrial
Engineering
U -
Production
planning and
Control
U -
Administration U -
Accounts U -
Packaging and
Dispatch
U -
FINISHING
Merchandising
U -
Sampling U -
Maintenance and
housekeeping
U -
Industrial
Engineering
U -
Production
planning and
Control
U -
Administration U -
Accounts U -
Packaging and
Dispatch
A The garments after finishing need to go in for
packaging
MERCHANDISING
Sampling A The merchandising team coordinates all the
activities in the sampling department
Maintenance and
housekeeping
U -
Industrial
Engineering
I The merchandising department needs some data
from the IE department
Production
planning and
Control
O These departments work in consultation with
each other
Administration U -
Accounts U -
Packaging and
Dispatch
U -
SAMPLING
Maintenance and
housekeeping
O This is necessary in case machinery or other
problems occur in the sampling room
Industrial
Engineering
U -
Production
planning and
Control
U -
Administration U -
Accounts U -
Packaging and
Dispatch
U -
Maintenance and
housekeeping
Industrial
Engineering
U -
Production
planning and
Control
U -
Administration U -
Accounts U -
Packaging and
Dispatch
U -
Industrial
Engineering
Production
planning and
Control
E These two departments work in consultation
with each other
Administration U -
Accounts U -
Packaging and
Dispatch
U -
Production
planning and
Control
Administration U -
Accounts U -
Packaging and
Dispatch
U -
Administration Accounts O They share paperwork amongst them
Packaging and
Dispatch
U -
Accounts Packaging and
Dispatch
U -
ACTIVITIE
S F
AB
RIC
ST
OR
E
TR
IM S
TO
RE
SP
RE
AD
ING
&
CU
TT
ING
S
EW
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FIN
ISH
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ME
RC
HN
AD
ISIN
G
SA
MP
LIN
G
QU
AL
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CA
D D
EP
AR
TM
EN
T
IE D
EP
AR
TM
EN
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FIN
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DE
PA
RT
ME
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M
AIN
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NA
NC
E
EX
PO
RT
DE
PA
RT
ME
NT
P
PC
FABRIC STORE U A O U I U U U U U U O U
TRIM STORE U U O A I O O U U U U O U
SPREADING &
CUTTING
A U A U I O I A I U I U I
SEWING O O A A I O A U A U A U I
FINISHING U A U I I O I U U U O U U
MERCHNADISI
NG
O O O I O A O O U U U U U
SAMPLING O O O I U A I U U U O U U
QUALITY I I I A I O I U U U U U O
CAD
DEPARTMENT
U U A U U U U O U U O U ?
IE
DEPARTMENT
U U I A I U U U U U U U ?
FINANCE
DEPARTMENT
U U U U U O U U U U U O U
MAINTENANC
E
U U A A A U O O O O U U U
EXPORT
DEPARTMENT
O O U U U O U U U U U U U
PPC U U I I U U U O ? ? U U U
A Absolutely
Necessary
E Especially
Important
I Important
O Ordinary
important
U Unimportant
X Undesirable
11. Determine the storage requirements
Fabric Storage Area Calculation:
Rolls to be stored in palletized form
Inventory of 12 days
ASSUMPTIONS
Aisle space between racks = 1 m
Main aisle = 1 m
Roof Height = 15 m
Average fabric consumption per shirt = 1.6m
Total production per day = 1250 shirts
Total fabric required per day = 1250 * 1.6 = 2000 m
Total consumption of fabric for 12 days inventory = 2,000 * 12 = 24,000
Roll Data:
Total yardage = 120 m
Roll diameter = 7 inches
Roll height = 62 inches
Roll weight = 25 Kg
Pallet Data:
Wooden Pallet Weight = 20 Kg
Length = 62 inches
Width = 62 inches
Height = 5 inches
Total rolls in a pallet = 56 rolls (Rows = 7, Columns = 8)
Final Height of palletized rolls = 56 inches
Weight of one pallet = 56* 20 + 20 =1140 Kg (It can sometimes go up to
maximum of 1500 Kg)
Total yardage of fabric in one pallet = 56 * 120 m = 6720 m (It can be maximum
of 7000m)
One block of the rack will be having: Length = 62 inches + 6 inches (allowance) =
68 inches Height = 56 inches + 6 inches (allowance) = 62 inches Depth = 62
inches
Rail Girdles on all sides = 3 inches
Ground clearance = 3 inches
Roof Clearance = 1 feet = 12 inches
Conclusions
• Total number of pallets for storing = 25 pallets
• Max rack height = 7 m = 23 feet = 275 inches (But 7.5 m height racks to be made, so
that smaller size pallets can be stored there)
• In the single block of a rack, 1 pallet needs to be stored. Total blocks required =
Number of pallets
• In one column, we will have 4 blocks.
• Total no of columns= 50
• In a row, we will have 10 such columns.
• Total no of racks = 5
• Total minimum height consumed = 266 inches
• Length of racks = 18m
Other equipments in a store are: Fabric inspection m/c = 2 (7 feet x 6 feet x 2)
• Fabric inspection table = 1 (10 feet x 6 feet)
• Fabric inspection machines = 1 (5 feet x 7 feet)
• Lab = 1 (125 sq feet) Office = 1 (125 sq feet)
• Articulated Fork Lifter = 1
Warehouse Area Calculation (Palletized Cartons
ASSUMPTIONS
• Dimension of a carton = 60 cm x 40 cm x 30
18 shirts per carton
• Peak Total Inventory = days
Roof Height = 8 m
• In a single pallet 18 cartons would be there (3*2*3)
• In a pallet, number of shirts = 18* 18 = 324
• Aisle space between 2 racks would be 2 m for the movement of fork lifter.
• The main aisle of 3.5 m
• Rail Girdles on all sides = 3 inches
• Ground clearance = 3 inches
• Roof Clearance = 1 feet = 12 inches
Pallet Dimensions:
• Total number of shirts in 12 days = 150000 shirts
Total no of cartons in warehouse at a time = 1, 20,000/18
= 6,666 cartons.
• Total no of pallets to be stored = 6,666/18 = 150 pallets
• Racks dimension:
Length = 14 m Breadth = 0.9 m Height = 1m Total Height = 7m
• Length = 1.8m
• Width = 0.8m
• Height = 1.0m
• Total production per day = 1250 lm
12. Plan the service and auxiliary activities
13. Determine space requirements
DEPARTMENT DESCRIPTION: DEPARTMENTS TOTAL AREA
REQUIRED (sq ft) REQUIREMENT
MANPOWER
HR Department 700 4
General Admin 200 1
Export Import Department 255 2
Financial Department 255 3
Merchandising & Sourcing 820 7
Reception 100 1
Fabric store, Inspection 1440 7
Trim store 247 3
Cad department, Spreading 2250
Cutting department, Cad 23
Sewing department 3000 226
Quality 200 9
Planning 200 2
Meeting 100 -
Finishing 1350 27
Washing 375 7
Maintenance department 300 5
Industrial engineering 400 7
Warehouse 983 5
Crèche 225 1
Dispensary 150 1
Cutting department cabin 100 1
Production department cabin 100 1
Kitchen 80 1
Sampling 720 13
Training 630 3
conference room 620 -
Ground Floor toilet 278 -
First Floor toilet 178 -
Ground Floor Lift &First Floor 182 -
First Floor Aisle 1446 -
Ground Floor Aisle
1460 -
Water cooler Ground & First Floor 36
TOTAL 19380 360
HR DEPARTMENT Area Required: 35*20 =700 Sq Ft
Man Power required
1 HR manager
2 HR Persons
1 Helper
1 Cabin for HR manager of 10*10
Furniture Quantity Dim( Ft) Area Req (Sq Ft)
Table 1 4*3 12
Chair 7 1*1 7
Almirah 4 3.5*3 42
Cube 1 10*10 100
162
Equipment Quantity Dim Area Required( Sq
Ft)
System 3 - -
Printer 1 - -
Scanner + photo
State
1 3*3 9
9
General Admin CEO Cabin of dimension 20*10=200 Sq Ft
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Table 1 4*3 12
Chair 3 1*1 3
System 1 - -
15
Export Import Department
Area Required : 17*15 = 255 Sq Ft
Man Power Required
2 person
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Table 2 4*3 24
Chair 3 1*1 3
System 2 - -
Almirah 1 3.5*3 10.5
35.5
FINANCIAL DEPARTMENT Area Required : 17*15= 255 Sq Ft
Man Power Required
1 Head
2 Account
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Table 4 4*3 48
Chair 4 1*1 4
System 3 - -
Almirah 1 3.5*3 10.5
62.5
MERCHANDISING & SOURCING DEPARTMENT
a) Merchandising
Area Required : 20*10 +20*31=820 Sq Ft
Man power required
1 Head
2 Merchandiser
1 Helper
Cabin for Head of 10*10 Sq Ft
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Table 1 4*4 16
Chair 4 1*1 4
System 4 - -
Almirah 2 3.5*3 21
Cube 1 10*10 100
Hanger Stand 2 10*3 60
201
b) SOURCING DEPARTMENT
Man power required
2 sourcing Persons
1 Helper
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Chair 4 1*1 4
System 3 - -
Almirah 4 3*22 284
Table 2 4*3 24
RECEPTION Area Required: 10*10= 100 Sq Ft
Man Power Required
1 Receptionist
FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required
(Sq Ft)
Chair 1 1*1 4
System 1 - -
Sofa 1 10*5 50
Table 1 3*5 15
71
FABRIC STORE& INSPECTION
Area required = 72 X 20= 1440 sqft
Man power requirement
1 Head
2 Data entry Persons
2 Inspection Persons
2 Helpers
Furniture Quantity Dim (L*B)(in ft) Total area req. (sq ft)
Table 3 4*3 36
Chair 7 1*1 7
Racks 10 6*3.3 198
241
Equipment Quantity Dim(L*B*H) (in Ft) Total area
Req(Sq Ft)
Trolley 2 3*4.5 27
Weighing Machine 1 3.2*1.6 5.12
Inspection Machine 1 7*4.6 32.2
Color matching cabinet
1 13.12*13.12 172.5
236.56
TRIM STORE Area required = 19 x 13 sqft
Total Area = 247 sqft
Man power requirement
1 In-charge
1 inspection person
1 Helper
CAD DEPARTMENT, CUTTING DEPARTMENT& FUSING DEPARTMENT Area required = 75 x30 sqft
Furniture Quantity required
Dim (L*B*H)(in ft) Total area req. (sqft)
Racks 10 5*2*6 100
Table 1 4*4 16
Chair 1 1*1 1
Stools 3 1*1 3
120
Total Area = 2250 sqft
Man power requirement
1 In-charge
2 person
CUTTING DEPARTMENT
Man power requirement
1 In-charge
4 Spreader
3 Cutter
2 Ticketing
2 Bundling
2 Fusing
2 helper
1 person for data entry
MACHINES NO. OF M/CS Dim (L*B*H)(in ft) Total area req.(sqft)
PLOTTER 1 7.36*2.15*3.83 15.82
Digitizer 1 3.91*5.90 23.08
38.9
Furniture Quantity required Dim (L*B*H)(in ft) Total area req .(sqft)
Table 2 4*4 32
Chair 4 1*1 4
Almirah 1 3.5*3*6.5 10.5
System 3 -
46.5
MACHINES No. of m/cs Dim (L*B*H)(in ft) Total are required(sqft)
Straight Knife cutter
3 -
Band Knife Cutter 1 7.49*4.89 36.62
Die Clicker 1 -
Fusing machine 1 7.38*2.78*4.0 20.57
57.19
SEWING DEPARTMENT: Area required = 75 x 40 sqft
Total Area = 3000 sqft
Man power requirement
1 In-charge
4 supervisor
221 workers
Furniture Quantity required
Dim (L*B*H)(in ft) Total are required(sqft)
Spreading/cutting Table
3 10*5*3 150
Table 1 4*4 16
Chair 3 1*1 3
Racks 5 4*2*6 40
Almirah 1 3.5*3*6.5 10.5
219.5
Machines No. of m/cs Dim (L*B*H)(in ft) Total area required(sqft)
SNLS W/UBT 30 6.18 185.4
SNLS WE/C 4 6.18 24.72
FOA 1 6.30 6.30
KANSAI 1 6.30 6.30
222.72
Furniture Quantity Dim (L*B*H)(in ft)
Total area required(sq ft)
Pressing Tables 2 3*5 30
End Line Inspection tables
4 7*3 84
Trolleys 5 5*2 50
164
QUALITY DEPARTMENT: Area required = 20 x 10 sq ft
Total Area = 200 sq ft
Manpower requirement
1 Quality manager
8 checker
INDUSTRIAL ENGINEERING DEPARTMENT:
Area required = 20 x 20 sq ft
Total Area = 400 sq ft
Manpower requirement
1 In-charge
6 persons
MAINTENANCE DEPARTMENT:
Area required = 20 x 25 sq ft
Area required = 300 sq ft
Manpower requirement
1 In- charge
4 person
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 4*4 16
Chair 5 1*1 5
Almirah 1 3.5*3 10.5
31.5
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table (Head) 1 4*4 16
Chair 2 1*1 2
Table (Assistant) 1 4*4 16
Chair 2 1*1 2
36
PRE PRODUCTION:
Area Required = 20 x 10 sqft
Total Area = 200 sqft
Manpower requirement = 2
SAMPLING DEPARTMENT:
Area Required = 40 X 18 sqft
Total Area = 720 sqft
Manpower requirement
1 Sampling Head
1 Pattern master
20 operator
1 cutter
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 4*4 16
Chair 3 1*1 3
Almirah 1 3.5*3 10.5
29.5
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 4*4 16
Chair 3 1*1 3
19
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Pattern Table 1 5*4 20
Cutting Table 1 5*4 20
Stools 15 1*1 15
Almirah 1 3.5*3 10.5
SNLS W/UBT 12 6.18 74.16
SNLS WE/C 4 6.18 6.18
Button hole 1 6.18 6.18
Button Attach 1 6.18 6.18
FOA 1 6.30 6.30
KANSAI 1 6.30 6.30
Mini Boiler Cum pressing
1 5*3 15
204.34
TRAINING ROOM
Area Required = 35 x 18sqft
Total Area = 630 sqft
Man Power Requirement
1 Training head 2 Trainers
CONFERENCE ROOM:
Area Required = 31x20 sqft
Total Area = 620 sqft
Meeting-
Area Required = 10x10 sqft
Total Area = 100 sqft
Furniture Quantity Dim (L*B*H)(in ft) Area req.(sq ft )
Tables 1 4*4 16
Chair 23 1*1 23
Machines No. of m/cs Dim (L*B*H)(in ft) Total area required(sqft)
SNLS W/UBT 15 6.18 92.7
SNLS WE/C 3 6.18 18.54
FOA 1 6.30 6.30
KANSAI 1 6.30 6.30
123.84
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 10*5 50
Chair 16 1*1 16
Maniquences 2
Finishing:-
Area Required = 75x18 sqft
Total Area = 1350 sqft
Man power required:
1 In charge
2 Spotter
8 Thread cutter
8 Pressing
3 Checker
5 Packer
Washing:-
Area Required = 25x15 sqft
Total Area =375 sqft
Man Power Required
1 In Charge
4 Washer
2 Finisher
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 10*7 70
Chair 8 1*1 8
78
Furniture/ Machine Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 4 8*4 128
Stool 8 1*1 8
Iron table 8 7*3 168
Thread Sucking machine
1 4*5 20
Button hole 4 6.18 24,72
Button Attach 4 6.18 24.72
Stain Removing Station
1 8*8 64
Needle Detector 1 3*2 6
Carton Packing machine
1 3*2 6
Total 449.44
Kitchen Area Required: 20*4 = 80 Sq Ft Man Power Required: 1
CANTEEN Area Required = 50 x 30 sqft
Total Area = 1500 sqft
Man Power Requirement
5 person
LAVENTRY:
Area required = 390 sqft SECURITY DEPARTMENT:
Area Required 10 * 10 = 100 Sq Ft
Man Power Requirement
2 Security guard
BOILER ROOM: Total required Area = 200 sqft
GENERATOR:
Total required Area = 300 sqft
Total Area Outside The main building occupied = 600 sq ft
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Table 1 8*4 32
Washing machine 3 8*12 288
Dryer 1 5*7 35
Total 355
Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )
Tables 10 10*3’*3 30
Stools 100 1*1*2 100
Serving Table 1 10*2*4 20
150
Furniture Quantity Dim (L*B*H)(in ft) Area req.(sq ft )
Tables 1 4*4 16
Chair 2 1*1 2
Almirah 1 3.5*3 10.5
28.5
14. Allocate activity areas to total space
GROUND FLOOR
FIRST FLOOR
15. Consider building types Building Typology:
Height of One Floor = 15 sq. ft.
Construction Details:
Types of Construction: Concrete
Height of the Building: 30 ft
Roof: Tapered Roof
Description of floors:
Ground Floor
Reception
Finance
Export Import
Merchandising
Training
Sampling
Finishing
Washing
Trim store
First Floor
Sewing,
Cutting +spreading +Fusing +CAD
Fabric store + inspection
Maintenance
IE
Quality
16. Construct the master layout Master layout is drawn in the graph sheet.
17. Evaluating, adjusting the layout.
18. Installation and implementation of layout.
Check list INDUSTRIAL ENGINEERING Not
applic.
OK Remark
Machinery and equipment arranged to make full use of
capacity?
Ok
Machinery and equipment accessible for material supply and
removal?
Ok
Machinery and equipment located for maximum operator
efficiency?
Ok
Line production used where practical? No
Proper use made of mechanical handling? No
Minimum walking required of operators? Ok
Processing combined with transportation? Ok
Finished work of one operator easily accessible to next? Ok
Machinery and equipment “block in” any operators? Ok
Machine over travel extend into aisles or interfere with
operator?
No
Adequate storage space at work stations? Ok
Efficient work place layouts? Ok
Service area conveniently located tool room, tool crib,
maintenance, etc)
Ok
Easy to supervisor to oversee his area? Ok
Machine arrangements permit maximum flexibility in case of
product change?
Ok
Space allocation for foremen and production control records? Ok
Related activity located near each other? Ok
All required equipment included in layout? Ok
Floor area fully utilized? Ok
Provisions made for expansion? Ok
Provision for scrap removal? Ok
Crowded condition anywhere? No
Conclusion:-
The Layout is very Easy to use and departments are planned according to the material
flow and such that no crowded condition will occur.
The Layout is personnel friendly.
Hence whole study is done in a planned manner step by step with keeping all the given
parameters in the mind and with the knowledge of architectural planning.