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8/3/2019 Detail Document- Abhijit

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The National Institute of Fashion Technology Gandhinagar

Plant Layout

Assignment IV

Submitted by

AbhijitBiswas

MFTech - II

Batch2010-12

Submitted to

Prof. PavanGodiawala

Department of Fashion

Technology


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Factory Area : 217 x 83 = 18,011 sq. ft.

Daily production : 3000 formal shirts

Departments :

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

Sampling : 23 x 53 = 1219sq. ft.

Cutting : 92 x 28 = 2,576 sq. ft.

Maintenance : 23 x 9 = 207 sq. ft.

Sewing : 116 x 52 = 6,032 sq. ft.

Packaging : 63 x 43 = 2,709 sq. ft.

Administration (offices)

Human Resource : 15 x 8 = 120 sq. ft. Marketing/Merchandizing/Planning :15 x 8 = 120 sq. ft. Cutting & IE : 15 x 8 = 120 sq. ft. Conference Room : 15 x 15 = 225 sq. ft. Quality Room : 15 x 8 = 120 sq. ft. Final Inspection Room : 15 x 8 = 120 sq. ft. Final Dispatch Room : 15 x 8 = 120 sq. ft.

Cafeteria : 30 x 20 = 600 sq. ft.

Restrooms : 10 x 7 = 70 sq. ft.

Security Room : 10 x 7 = 70sq. ft.

Community Center : 12 x 8 = 96 sq. ft.

Locker Rooms : 12 x 8 = 96 sq. ft.

Parking Area : 28 x 20 = 560 sq. ft.

Loading / Unloading Zones/Temporary storage


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Assumptions

Wastage per shirt : 5 %

So, wastage for 3000 shirts : 3150


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Stores

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

Capacity required calculations for 1 month (30 days)

One roll has total meter age : 300

Fabric Width : 5

Diameter of Fabric rolls with poly packing : 1

Length of the roll with poly packing and allowance : 6

Fabric inventory for 30 days (meters) : 139860

So, No. of rolls : 466

Number of rolls in one shelf : 9

So, number of shelves required : 52

Number of shelves in one rack : 4

Number of racks required : 14

Manpower Requirement

Store In-charge : 1

Fabric inspector : 1

Helpers : 1

Total man power : 3


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Additional requirement for stores department

Fabric weighing machine : 1

Accessory weighing machine : 1

Fire extinguishers : 2

Fabric inspection machine : 1

Office working tables : 2

Fabric Racks

Rolls are stacked vertically in the racks

Heightof one shelf : 12+12+4+2.5

= 30.5 (2.54)

12 for the diameter of fabric roll

4 allowance for free movement of the roll

2.5 for thickness of the plank

Number of shelves in one rack : 4

DimensionsHeight of one rack : 122(10.21)

Length of a rack

Total Length 3 + 12+3+12+3+12+3+12+3+12+3 = 78(6.5)

Moving space between two rolls : 3( 0.25)

Diameter of one roll : 12( 1)

Length : 11 meters (considering 4 racks and 2 aisles )

Width of rack

Total width = 64(5.3 )

Width of the fabric roll : 60(5)

Allowance for free movement : 4 (0.33)


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Trims Racks

Length : 5 meter (16.40)

Width : 3 meters (9.84)

Height : 2.3 metres(7.5 feet)

Space of the aisles : 1 meter (3.28)

Office

Area : 15 x 16 : 240 sq. ft.

Machine and Waste

Area : 15 x 17 : 255 sq. ft.

Inspection & Sorting Tables

Number of them : 4

Dimensions

Length : 13

Width : 6.5

Height : 3.48


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Trims required Inventory

No. TRIMS/ ACCRESSORIES

NO OF

PIECES

REQUIERED

FOR

STACKING

NO OF

PCS IN 1

BOX

NO OF BOXES

REQUIRED

DIMENSION

OF THE BOX

VOLUME

OF ONE

BOX

(cubic

inches)

VOLUME

REQUIRE

(cubic

inches)

1 Threads 11340000 24 95 16" x 23" x 6" 2208 208656

2 Button Felts 189000 1000 189 5" X 5" X 5" 12.5 2362.5

3 Kimble 94500 5000 19 8.5" X 7" X 3" 178.5 3391.5

4 Brand Card 94500 100 945 4" X 3" X 2" 24 22680

5 Business Price Card 94500 100 945 4" X 3" X 3" 36 34020

6 Shirt Pins 378000 5000 76 7" X 5" X 1.5" 52.5 3990

7 Butter Paper 94500 200 473 16" X 16" X 1" 256 121088

8 Outer Collar Board 94500 100 945

16" X 1.5" X

3" 72 68040

9 Inner collar PVC 94500 100 945

20" X 1.5" X

2" 60 56700

10 Butterfly 94500 100 945 6" X 3" X 4" 72 68040

11 Back body Cardboad 94500 200 473 14" X 10" X 8" 1120 529760

12 Polybags 94500 100 945 16" X 11" X 2" 352 332640

13 Packing boxes 94500 100 945 23" X 20" X 2" 920 86940014 Labels + Washcare labels 189000 375 504 RADIUS = 1.5 6.285 3167.64

Total volume to stack 2323935.6

Storage rack for accessories in Feet

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

Width 4

Height 7.5

Volume that can be stacked 450

Hence numbe of racks required 2.98860036

Taking allowance into consideration we will take 3 racks


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No. Material

Consumption

per shirt

For 3150

shirts

For 1 month

(30 days)

Fabric (meter)

1 Shell Fabric 1.48 4662 1398602 Fusing 0.4 1260 37800

Trims and Accessories

1 Buttons 16 50400 1512000

2 Button Felts 2 6300 189000

3 Threads 120 378000 11340000

4 Kimble 1 3150 94500

5 Brand Card 1 3150 94500

6 Business Price Card 1 3150 94500

7 Shirt Pins 4 12600 378000

8 Butter Paper 1 3150 94500

9 Outer Collar Board 1 3150 9450010 Inner collar PVC 1 3150 94500

11 Butterfly 1 3150 94500

12 Back body Cardboard 1 3150 94500

13 Polybags 1 3150 94500

14 Packing boxes 1 3150 94500

15 Labels + Washcare labels 2 6300 189000


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Cutting

Cutting Area : 92 x 28 = 2,576 sq. ft.

Fabric Storage Racks

Stitching : 3150 shirts per day

Cutting capacity : 3600 shirts per day (20% extra)

Required fabric inventory : 3 days

So, storage capacity required : 10800 shirts

Fabric consumption of 1 shirt : 1.48 meters

Fabric for 10800 shirts : 15984 meters

Number of rolls in one rack : 5

Diameter of one roll : 12

Total number of racks : 8

Total number of rolls required : 52

So, no of shelves required : 14

There will be 4 racks of two shelves

Dimensions of Fabric racks

Length : 6

- 5 one roll placed length wise- 1 allowance for placement

Width : 4 (1.21 m)


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

Height : 2.3

Spreading and Cutting Tables : 3

Inspection Tables : 2

Bundling and Ticketing tables : 3

Fusing Table : 1

Band Knife : 1

Fusing Machine : 1Main Inspection and Sorting Table : 1

One lay of : 100 plies

1 ply of : 7 meters

No. of shirts in 1 ply : 4

One lay : 400 shirts

We require shirts to be cut : 3600 shirts

No. of lays would be 3600/400 : 9

Time taken to spread one lay : 2 hours

Spreading & cutting tableLength of the table (two of them 7.5 meters each put together) : 49

Width : 2 meter (6)

Height : 1.06 meter ( 3.48)


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Inspection& Sorting table

Dimensions

Length : 13

Width : 6

Height : 3.48

Bundling & Ticketing Table

Dimensions

Length : 6.5

Width : 5.6

Height : 3.48

Band Knife Machine table

Dimensions

Length : 7

Width : 5

Height : 3.48

Preparatory Fusing Table

Dimensions

Length : 6.5

Width : 5.6

Height : 3.48


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Fusing Machine Table

Dimensions

Length : 6

Width : 3.8

Height : 3.48

Fusing Inspection table

Dimensions

Length : 8

Width : 5

Height : 3.48

For carrying the cut bundles there will be Trolleys

No.

Manpower

Requirement

No. of

Personnel

1 Cutting master 12 Supervisor 3

3 Spreaders 12

4 Band knife operator 3

Straight Knife operator 4

5 Sorting personnel 6

6 Fusing, laying & cutting 6

7

Teflon placing &

soldering 4

8 Inspection 6

9 Stickering 3

10 Bundling 5

11 Helper for transportation 8

Total 61


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Machine List in the Cutting Department

S. No. Machines Number

1 Straight Knife 3

Specification : Eastman Co. Blade

length 8 inches2 Band Knife 1

3 Fusing machine 1

4 Hot Notcher 1

5 Driller 1

Other Requirements

S.

NO. Requirements No.1 Big Clamps 30

2 Small Clamps 30

3 Fabric weights 30

4 Pair of cutting gloves 1

5 Soldering machine 3

6

Trolleys for moving cut

parts 2

7 Stickering guns 2

8 Scissors 14 inches 89 Scissors 12 inches 6

10

Glass pencil for

marking 4 packets

11 Measuring tape 10

13 Pattern hanging system 1

14

Manual spreading roll

stands 3

15

T-scales, rulers, hip

curves, etc. Lump sum

16 Brown cellophone tape Lump sum


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Sewing

Area of the sewing department : 116 x 52 = 6,032 sq. ft.

Sewing shifts : 2

1 shirt takes : 27 minutes

Minutes Available : 480

(Total available time * no of machines) / ( processing time)

(480 * 36 )/ 27 = 640 garments from one line in 1 shift

From 6 lines no. of garments : 3840

Daily production : 3150 shirts

Number of sewing lines : 6

Each sewing line produces : 640 garments

Absenteeism : 10%

There will be a progressive bundling system

S. No. Manpower requirementNumber ofPersonnel

1 Operators 240

2 helpers 6

3 Collar Creasing 6

4 Pocket creasing 6

5 In process inspection 6

6 Final Checking 12

7 Helpers 12

8 Production manager 3

Total Manpower requirement 291


15/22

Operation flow for the stitching department

S. No. Operation details

M/c

Specification

Observe the

time (sec)

No. of

machines

1 Collar band / cuff hemming SNLS 80 2

2 Collar band and run stitch SNLS 120 23 Collar turning and creasing Nagaishing 30 1

4 Cuff blocking Nagaishing 25 1

5 Collar and cuff top stitch SNLS needle feed 100 2

6 Band attach to collar SNLS 100 2

7 Front kaj placket Kansai spcl 95 2

8 Button placket making SNLS 45 1

9 Button placket marking Manual

10 Pocket Creasing Iron table

11 Sleeve placket making SNLS 195 312 Pocket attaching SNLS ubt 90 2

13 Pocket and front checking Manual

14 Main label attachment SNLS ubt 60 1

15 Yoke and back attachment SNLS 60 1

16

Shoulder and front

attachment SNLS 90 2

17 Top stitch on back shoulder SNLS 60 1

18 Attach sleeves SNLS 180 3

19 Side seam FOA 110 2

20 Attach collar and top stitch SNLS 180 3

21 Attach cuff SNLS 180 3

22 Bottom hem SNLS 120 2

Total no. of machines in one line 36

There will be a feeding trolley system for cut parts

Also trolleys for carrying sewn garments to the packaging department

Preparation tables

Total number of tables : 6

Dimensions : 7 x 5 x 3


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Shop Floor requisition

Width of the machine : 21 inches

Length of the machine : 42 inches

Gap between two machines : 30 inches

So one machine will be taking space with allowance around 50 inches

: 50/12 = 4.16

Machines in one line : 36 machines,

18 machine on either side of the line

Inspection Tables

Number of Inspection tables : 18

Dimensions : 4 x 3x 3

End line inspection tables



Button Placket Marking Tables



Creasing Tables

Number of creasing tables : 6

Dimensions : 6 x1.5x 3

Other Materials

Scissors : 30


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Handling system for inline processing : 9 x 2 x 6 = 108

Plastic Baskets (one line 10) : 30

Feeding trolleys : 12


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Packaging

Area of packaging department : 63 x 43 : 2,709 sq. ft.

Capacity of finishing department would be 3000 shirts per day

Button holing and button attaching is done in the finishing room

Vacuum table steam press is being used for pressing

One boiler per two pressing table is being used

Shirt folding is done manually

Complete packing for the shirt takes place (viz. pinning, putting collar stand,

butterfly, putting cardboard) and then putting in the boxes and finally seating in thecarton boxes

Machinery

Button making : 3

Button holing : 3

Thread sucking machine : 2

Thread Trimming Table

Number of table : 3

Dimensions

Length : 10

Width : 5

Height : 3.48

Thread SuckingMachine

Number ofthem : 2

Dimensions


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Length : 3

Width : 3

Height : 3.48

Final Inspection Table

Number of table : 7

Dimensions

Length : 6

Width : 3

Height : 3.48

Pressing Table

Number of table : 12

Dimensions

Length : 4

Width : 3

Height : 3.48

Folding Table

Number of table : 10

Dimensions

Length : 8

Width : 5

Height : 3.48


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Final Packaging Table

Number of table : 3

Dimensions

Length : 15

Width : 5

Height : 3.48

Storage Racks

Number of racks : 9

Dimensions

Length : 6.5

Width : 5.5

Height : 7.5


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Furniture Requirement

* AQL level followed is 2.5

Furniture

No. of

Tables

Dimensions

(feet)

Operation Time in

minutes (approx)

People

per

furniture Total people

Button and button hole marking

table 3 8 x 6 x 3 1.7 4 12

Thread trimming table 3 10x 5 x 3 2.7 6 18Inspection table 6 6x3x3 4 2 12

Pressing table 12 4 x 3 x 3 2 1 13

Folding table 10 8 x 5 x 3 3 2 20


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Administration / Offices

S. No. Office Requirements Number1 Working Tables 2

2 Chairs 6

3 Almirah 2

4 File Folders rack 1

5 Swatch Folder Rack 1

6 Calculators 2

7 Clip boards 4

8 Paper weight 6

9 Cellophane tape 2

10 Stationary lump sum

11 Pinking Shears 2

12 Punch Hole machine 2

13 Clips and Pins lump sum

14 File holder 2

15 Gum/fevicol lump sum

16 Rubber stamp, ink pad lump sum

17 Stapler 3

18 Pedestal fan 3

19 Phone 8

20 Trash cans 15

21 Measuring Tape 6

22 Emergency light 5

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