architect's brief

8/10/2019 Architect's Brief

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PLANT LAYOUT

ASSIGNMENT-2

ARCHITECTS BRIEF

FACILITY DESIGN AND REQUIREMENTS FOR A PROGRESSIVE-BUNDLE TROUSER

MANUFACTURING UNIT

SUBMITTED TO:

MR. K. RAMMOHAN

SUBMITTED BY:

HARSHDEEP SINGH

SHUBHAM ARYAN

SUBHOJIT DAS

SUPRIYA NANDA

VAISHNAVI SINGH

B.F.TECH (A.P), SEMESTER-VII


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INTRODUCTION

An architects brief is an official form of communication from the owner to the architect of a

construction site which entails the facility design, requirements and floor space area

distribution to guide the architect to construct the site as well as fulfil the requirementsspecified by the owner. Usually, the architects brief contains the following details-

Project brief

Topographical survey

Plot details

Manpower requirements

Product development

Nature and type of business

Domain of various departments

Capacity to be met

Approx. sizes of different workspaces required

Compliance and safety requirements

Machine variety and distribution

Nature of machinery used

Process flow

Rough layout

Safety guidelines


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PROJECT BRIEF

Mens formal trouser is a garment with a standard process which allows the machinery andequipment required to be fixed permanently. This type of garment requires very basic

sewing machines as well some sophisticated finishing equipment in order to achieve the

professional look as desired by the garment. The garments construction methods remain

standard with just a few minor changes with different styles. Also, the kind of raw materials

that the production requires are similar amongst all styles. Hence, the site to be designed

can totally eliminate the fact that the machinery needs to be moved at frequent intervals

and can focus on more permanent fixtures.

Here under are the primary details concerned with the industry:

Product category Trouser

Product Mens Formal Trouser

Nature of business Export

Rate of production 2000 pieces/day

Daily working hours 8 hours/day

6 days/week

Location Apparel Park, Gundlapochampally

TOPOGRAPHICAL SURVEY

The designated plot is situated in the Apparel Expo Park, Gundlapochampally along

with other apparel export industries like Chermas and Pochampally. The park is

designed to provide all the necessities of an apparel industry.

The apparel park is well connected to the NH-7 and just at a distance of 580 kms

from the nearest port.

The park is designed with well-planned roads which facilitate the easy movement of

trucks and other heavy machinery. Also, there is a sufficient allowance between two

consecutive factories.

The park is also equipped with latest security and surveillance systems.

The park is located on medium black soil and contains sufficient green belts around.

The plot is located on the south-west side of the park and faces east.


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The distance from the main gate to the plot is around 600m, which is quite feasible

to cover in a short time

PLOT DETAILS

The plot is 25,000 sq. ft in area.

It is L-shaped

FSI is 1.1

Ground coverage should be 40%-60%

Front margin should be 30 feet

Side margin should be 26 feet

FIGURE. ROUGH STRUCTURE AND LAYOUT OF THE PLOT


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PRODUCT DEVELOPMENT

The mens formal trouser has the following variations depending upon a little change in the

components:

1. Double-Pleated

2. Single-Pleated

3. Flat-Front

4. With lining

5.

Without lining

6. With Bottom Cuff

7. With normal bottom hem

8. With Waistband Extension

NATURE AND TYPE OF BUSINESS

The industry mentioned in the project has high man force requirements and is a worker

oriented industry out of which the 60% of the workers are women. So, the industry needs to

be designed on the basis of high numbers of worker movement and facilities. The industry

is focused towards producing high quality goods for exports and hence, should maintain all

the ISO standards for garment production. The industry is supposed to entail all the safety

provisions and instructions as to guide the workers amongst various departments. Also, the

industry is suggested to be developed to support shorter life cycles and frequent style

adaptations. The industry is supposed to follow the Progressive bundle system i.e. the

production continues in bundles. Hence, there occurs a requirement to store the products

at each stage of production.


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DOMAIN OF VARIOUS DEPARTMENTS

Marketing:

The marketing department plays a key role in getting orders from buyers across the world.

This department usually publicizes its products across the world in Order to get orders.

Merchandising:

Once the buyer confirms the order, the job of the merchandising department starts. Before

taking any order the marketing department will also check with merchandising department

for open capacity. The merchandising department checks with PPC for open capacity. Once

an order is finalized, the merchandiser is the Middle man between the buyer and his

factory.

Sampling:

The sampling department is responsible for making the above samples as & when asked for

by the merchandiser. These samples have to be carefully stitched & finished by the sampling

department as they are the final samples the buyer will approve for bulk production.

Store: stores are the department where the trims , fabrics, needles , packing materials are

kept in bulk. whenever any departments like sewing , finishing , packing needs the required

elements the stores provide them.

Cutting:

This departments objective is to separate fabric parts as replica of pattern pieces in

marker plan.

Sewing:

The basic duties of the sewing department is to stitch the cut parts provided by the cutting

department & to provide the required quality of stitching & mend the Reparable mistakes

when pointed out by the QA team .


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Finishing:

The function of this department is to finish and present the garments as per the buyers

specifications.

Packaging:

the garments are packed either in poly bags , hangers , etc and then these

are in turn packed in cartons as per buyers requirements.

Quality Control:

Ensuring the production of the garment with reference to the

standard specification is known as quality control. Quality of the garment is inspected

in various stages from fabric to finished garment.

Maintenance:

The machineries used in the garment production are to be maintained Periodically for

continuous working.The main objective of it is:

Solving problems in machineries

Preventive measurements

Monitoring at regular intervals

Accounts:

it looks after all the financial aspects of the industry.

Human Resource:

The human resource department deals with following:

1. Factory human resources.

2. Salary as per Grade and Designation

3. Health and Safety Policy


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Training:In this department the new joiners are given training for 30-45 days at Technical

Training Division. The trainees are evaluated for production team during training and are

graded A, B, C and D. If required, training is extended for further 15 days.

Sourcing :helps in finding out as to where the fabric , trims etc. can be obtained.

Fabric warehouse:

The warehouse has be designed to keep the sourced material that is ready to be cut and fed

into the production system. The section consists of huge racks that are enabled to keep the

bales and rolls of different fabrics separate and segregated.

Fabric inspection:

This section is equipped with checking tables that check the fabric which is supposed to

enter the fabric lines.

Goods Warehouse:

This warehouse keeps the finished goods ready for delivery after packaging

Ticketing/Bundling:

This section divides the cut pieces into bundles that are to be fed in the sewing lines.

Trims and accessories:

These departments keep all the trims and accessories required per order. These may

contain Buttons, Zipper etc.

CAD/ Pattern making:

This department is responsible for making patterns and markers to enable cutting.

Testing Lab:

The testing lab is a very sophisticatedly maintained workspace with temperature, humidity

and lighting maintained. The testing lab is supposed to be designed as per the ASTM

standards for testing.


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Boiler:

The boiler is centralized and is responsible for providing steam to all the departments of

production

Maintenance:

This department is responsible for maintaining the physical and electrical issues occurring

with the industry. It also keeps the track for faulty facilities and replacement parts

AHU:

The AHU room is designed to provide central air-conditioning to all the offices as well as the

production floors. The AHU is to be designed to provide proper ventilation within the

industry.

Vacuum Room:

This department is responsible for provide pneumatic vacuum pressure in the pressing

machines in the finishing department

Gate:

The main gate should be a sliding metal gate , so it would be easy to open & close it.& also

it should be wider so any truck or heavy vehicle easily can pass through of it.

Security cabin:

An entrance gate should have security check cabin to check the entry of incoming & out

coming transport vehicle and also of visitor . it should have the layed pipe lines to avoid the

entrance of cattles & security personnel will come to know if any vehicle passes through

the gate.

A main entrance should have following facilities:

1- CCTV camera

2- Security personnel

3- Biometric /manual enter/ exit record system.

4- Land line phone with Intercom facility.


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Reception:

A reception lounge should have reception desk with sitting facilities like sofa, chairs, table

& feedback book for customers & visitors.

Reception should have daily newspaper, magazine etc.

Parking:

Parking should be available for employees, worker & for visitors or customer. The parking

may be divided by the type of vehicle like two wheelers; four wheelers .parking should have

also a security CCTV camera.

Crche:

A garment industry should have crche because of the most of the employees or workers

are female. so a garment industry should run a crche & should appoint a caretaker.

Medical dispensary:

A garment industry should have a small medical dispensary for providing the first aid

treatment to employees & workers .

1- Doctor should be appointed by the organization.

2- Ambulance facility

3- One assistant should be appointed.

Fire extinguisher:

for security purpose fire extinguisher should be installed in all the departments.

Emergency exit:

Every dept. should have emergency exit. (10*4feet)


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PROCESS FLOW

Hereunder is a rough process flow in order to provide a relationship amongst the

departments as how the departments should be arranged in order to enhance the

continuous movement of products:

GENERAL STRUCTURAL REQUIREMENTS

The building structure required should be a steady permanent construction, using

cement, concrete and iron bars.

The roof of each floor should be strong enough to hold the weight of machinery and

workers designated.

The floor for each unit should be properly levelled.

The walls, the floor and the roof should contain proper plumbing, electrification and

proper insulation in order to prevent fire hazard.

Depending


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AREA REQUIREMENTS BASED ON DIFFERENT DEPARTMENTS

BasementCutting 3000 Sq. Ft

Fabric Warehouse 800 Sq. Ft

Inspection 600 Sq. Ft

Quality 800 Sq. Ft

Sourcing 400 Sq. Ft

Ticketing / Bundling 600 Sq. Ft

Trims/Acc 400 Sq. Ft

Toilets 300 Sq. Ft

CAD/ Marker /PM 200 Sq. Ft

Sampling 300 Sq. Ft

Testing 500 Sq. Ft

Training Centre 400 Sq. Ft

Ground FloorFinishing 1500 Sq. Ft

Packaging 1500 Sq. Ft

Boiler 600 Sq. Ft

Electricity and maintenance 400 Sq. Ft

AHU 200 Sq. Ft

Vacuum Room 200 Sq. FtCrche 300 Sq. Ft

Clinic 200 Sq. Ft

HR/IT/Admin/Fin/Log 200 Sq. Ft

Toilets 800 Sq. Ft

Conference Room 300 Sq. Ft

Meeting Rooms 240 Sq. Ft

First FloorSewing 1500 Sq. Ft

Mark/Mirch 540 Sq. Ft

I.E. 60 Sq. FtCanteen Executive 500 Sq. Ft

Canteen Workers 400 Sq. Ft

Toilets 500 Sq. Ft


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(2.7 X1.5 X2.7)

AREA DISTRIBUTION IN VARIOUS DEPARTMENTS

1. STORES

2. FABRIC & TRIM WAREHOUSE

Rolls to be stored in palletized form

Inventory of 15 days

FABRIC STORAGE REQUIREMENT

Fabric required for 2000 trousers for 15 days inventory

Fabric required per top =1.4 m

So, total fabric for 15 days sewing=1.4X2000X15mts.+5%wastage (5760)=44100

mtrs.

Since, 1 roll contains 100 mtrs. Fabric

Total roll=44100/100 = 441rolls

RACKS requirement:

Now, 1 roll dimension=0.45 (dia)

Racks dimension= (2.7 X1.5 X2.7)

Rolls kept in 1 racks=36 rolls

Racks required=441/36= 13 racks


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3. DISPENSARY

Equipments Quantity Area sq. ft.

Beds 3 63= 54

Checking table 1 63=18

Doctor cabin -Equipment storage -

Total area 200

4. SEWING/ FINISHING/CUTTING

Machine No. of

machines

Power

Standardized(Watt)

Dimensions Weight

Weishi fabric

inspection

machine

4 1100 watt 2600*1850*2100 600 kg

SpectraLUX Jr

i2 Colour

matching

cabinet

(Paramount)

1 1100 Length 406mm

Depth355mm

Height482mm

15 kg

Morgan FOX

100

Automatic

spreadingmachine

1 10392 Width available 180 - 230 cm 400 kg

Gerber

Automatic

spreader

XLs125

2

11500 Total Height over Table Top with

Full Size Roll 90 cm /35 in

Table Width Machine width + 20

cm

Heavy

machine,wt not

mentioned

Cnc cutter

gerber GTXL

2 9872 L-4.19 m,breadth-2.74m Heavy

machine,wt not

mentioned

Gerber

vaccum table

3 6600 2.34 x 4.37 m (92 x 172 in) Heavy

machine,wt not

mentioned

Veith pintable

2 1280 170cm x 404 cm

Eastman band

knife ec-900 n

2 750 1500* 1800 mm 300 kg

Eastman

straight knife

blue streak 2

2 1100 34 lbs. (15.4kg)

Eastman

round knife

Plastic Master

2 5715 9.52 kg

Kannegiessar

Fusing

Machine

MultiStar DXT1400L

2 10392 Working width 1400 mm 1440 kg


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WEISHI YTP-

W20 Stepper

Vacuum Table

12 9872 1300*700*870mm 125 kg

Weishi

YTPW28B Up

steam table

12 9872 1400*750*1650mm 125 kg

Macpi formfinisher

8 1700

Macpi legger

machine

12 9872 2670mmx1560mmx1680mm 750kg

Macpi 820

Topper

machine

8 2450 4100*2100 mm

Macoi q58c

Buck flap

turning &

pressing

8 2000 1200X1150X1400 mm 270 kg

WeishiQ51F

Buck bottom

press

12 1900 1200*650*1650/1400*750*1650

mm

125 kg

DURKOP ADLER

220-5300 NRNLS( needle feed)

With UBT

30 5.8 amps, 110 VAC

at

60 Hz; single phase

100*70*80cm 38.5 kg

Snls edge

cutterDURKOPP

ADLER 272-740-

642

20 39 kg

SNLS( drop feed)

With UBTPFAFF-1483

35 100*70*80cm

SncsPFAFF-3801

10 100*70*80cm 40 kg

5 thread o/lJUKI MO-6716S

5 100*70*80cm 39 kg

BartackBROTHER BF-

438D

20 100*70*105cm 53 kg

Button sewBROTHER BE-

438C

10 100*70*105cm 61 kg

Button holeDURKOPP

ADLER 580

PREMIUM

10 100*70*105cm 68 kg

Button

warpingLOIVA ST-10

5 400 VA 600mm x 600 mm x 400 mm 65 kg

Auto sergingDURKOP ADLER

1465-4

5 590VA 1,800mm (W) 790mm (D)

880mm (H)

Long-table type

(L): 160kg (with

stacker)

Blind hem

strobel

5 100*70*890cm 45 kg

SNLS(

differential feed)With UBTDURKOPP

5 50 cm x 35 cm x 25 cm 25 kg


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ADLER 275-140-

342

COMPLIANCE AND SAFETY REQUIREMENTS

Building

Name Sign to All Rooms / Area

Indicators / Direction from Security Gate onwards

Storage above Storage limit Carton Box etc.

Aisle marking

Aisle width minimum 3 feet.

Indicators Arrows in the passage

Aisle without block.

Health

Drinking Water

At least4.5 Litres water provided per day per employee

Water Testing Certificate

Drinking water not in plastic pot

Drinking Water, Cup availability

Drinking Water centre (one place to every 150 employees upto 500)

Drinking Water centre (one place to every 500 employees above 500)

Water Cooler / Heater available at every canteen, dining hall, rest room etc.Toilets

Toilet Seat to Every 20 Women

Toilet Seat to Every 20 men upto 100

Toilet Seat to Every 50 men beyond 100

All toilet seat with proper privacy and lock facility

Urinal Accommodation Min. 61 cm for every 50 employees upto first 500

Urinal Accommodation Min. 61 cm for every 100 employees for above 500


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Effective water Sewage system

Soap/ Towel

Bathroom Lock

Water tap

Tiles/Mosaic floors washed with Detergent or disinfectant once in four month

Daily Cleaning Log sheet provided

Adequate Water Tabs

No smoking Sign in Gents Toilet

Awareness Quotes in Toilets

Ladies / Gents Toilet Name Sign in Dual Language and Picture

Others

500 Cubic feet for every employees

Disposal of Wastes and effluents

Room Temperature

Lighting facility

Trees on factory campus

Safety Guards

Metal Glows on good Condition

Rubber Mat to ironers

Rubber Glows to ironers

Ironers wearing slipper

Motar Guard

Needle Guard

Eye Guard

Scissors and trimmers are tied

Broken Needle Register

Manpower

Manpower Department wise Male/Female Strength Report


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Attendance Report

Late Report

Absenteeism Report

Daily Staff In-Out Register

Is there Under Age

Contract Employees

Punch report

Leave card to each employee

MIR (Material Issue Register)

Salary

Salary date before 7 every month

Bank Salary Account to all

Salary Registers with employees signature month-wise

Minimum Wages

Basic

D.A.

Pay Cover Availability

Security

Adequate Securities

Lady Guards

Staff Movement Register

Visitors Note

Others In-Out Register

Material Inward Register

Material Outward Register

Vehicle Movement Register

Visitor Pass

Visitor Slip

Guards Knowledge about their Roles & Responsibilities

Securities Personnel File


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Securities Uniform/Cap/Shoe/Belt etc.

Securities Knowledge about Fire Evacuation & Fire Safety

Security Agreement file (If outsourced)

Security Salary register file (If outsourced)

Security ESI, PF Challan (If Outsourced)

FACILITY REQUIREMENTS

ARTIFICIAL LIGHTING FOR DIFF. DEPT.

SEWING:

For checking lux level-900-1000,twin tube light of 24 watt each

For pressing lux level-500-600,single tube light of 30 watt each

For loading lux level-500-600,single tube light of 30 watt each

For loading lux level-500-600,single tube light of 30 watt each

For normal sewing Lux level- 500-600, single tube light of 30 watt each

For trimming lux level-500-600,single tube light of 30 watt each.

CUTTING:

For panel check and re-cutting lux level-1000-1200,twin tube light of 24 watt each

For spreading and cutting lux level-700-800,single tube light of 36 watt each

For fusing and ticketing Lux level- 400-500, single tube light of 30 watt each

FABRIC STORE AND TRIM STORE:

For trims storage lux level-500,single tube light of 36 watt each

For checking trims lux level-700-800,twin tube light of 30 watt each

Storage of fabric Lux level- 200-250, single tube light of 30 watt each

FINISHING:

For pressing and finishing Lux level- 400-500, single tube light of 30 watt each.


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WATER CONSUMPTION

Total Man power =600

Total Drinking Water requirement/day= 1550 ltrs

Water requirement required for basic necessities =3840 ltrs(6.4 ltr/man power)

MANPOWER DETAILS

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