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
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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
Total number of tables : 3
Dimensions : 9 x 5 x 3
Button Placket Marking Tables
Total number of tables : 3
Dimensions : 8 x 6 x 3
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