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DESCRIPTION
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Architectural Brief
Plant Layout
Presented by:
Shipra Singhai
Plant layout Architectural Brief
Product category: Jeans
Product: Five pocket Basic Jeans (men’s)
Variations: Slim Fit, Low Waist.
Nature of Business: Domestic
Rate of Production: 5000 pieces/day
Departments
i. Design Department
ii. Marketing and Merchandising Department
iii. Store Department
iv. Pre Production Department
v. CAD Department
vi. Cutting Department
vii. Sewing Department
viii. Finishing Department
ix. Quality assurance Department
x. Industrial Engineering Department
xi. Information Technology Department
xii. Maintenance Department
xiii. Administrative Department
xiv. Human Resource Department
xv. Safety Department
xvi. Security Department
xvii. Warehouse department
Marketing and Merchandising Department
This department caters to the marketing and sourcing of the product and its components. The marketing and merchandising departments also requires a list of workstations and cabins for officers and managers. Following are the list of activities that are carried out in this department.
Material Planning Initial Costing Purchase Orders Sample development Approval/Rejection
Marketing and Merchandising DepartmentPersonnel
Designation Number Description Area (mtrs)Marketing Head 1 Junior Marketing
Executives 4 9*4
Merchandiser 1 Junior
Merchandiser4
MachineMachine Number Description Dimension (ft)
Computer 10 IBM 3*5Furniture
Furniture Number Description Dimension (ft)Chair 10 1.5*1.5
Store Department
This department is required for the storage of trims and raw materials received. The department also keeps a record of trims received and issued to the production. Following are the activities carried out in this department.
Raw Material (fabric and trim receipt) Quality checking Issue material for production Packaging material storage Weighing machines
Spring balance
Store Department
Personnel
Designation Number Description Area (meters)
Store Manager 1
Helpers 4 putting and removing of rolls
40*15.5
Fabric/Shade Inspectors
3
Machine
Machine Number Description Dimension (ft)
Computer 2 IBM 3*5
Trolleys 4 4*3
Fabric Inspection Machine 2 Yash 9*8
Furniture
Furniture Number Description Dimension (ft)
Chair 4 1.5*1.5
Roll dimension Number of rolls in rack
total rolls in one Pigeon
Holerack dimensions
1.5 ft dia and 6ft width 18stack of 3
racks: 8*3= 54 rolls
6*6*4.5
Sampling Department
This department serves the purpose of sample making before the actual production. The department requires a set of machinery to manufacture these samples. Following are the basic activities carried out in this department.
Sampling Patterns, sample approved Machineries required Cutting tables Sewing Machines Iron tables Inspection tables
Sampling DepartmentPersonnel
Designation Number Description Area (meters)Pattern Master 1
Sampling Department
manager1
Supervisor 1 Cutting Master 1
15*10Sewing Operators 16 Ironing Opertors 1
Pattern Store
Fabric/Sample Store
MachineMachine Number Description Dimension (ft)
Computer 1 IBM 3*5SNLS 10 Juki 35
DNLS(FOA) 5 Juki 35Irons 2 30
Pattern Table 1 5*7Furniture
Furniture Number Description Dimension (ft)
Chair 20 1.5*1.5
CAD Department
The purpose of the CAD department is to generate pattern for the garment and thus produce the production marker for the same. The CAD department also requires to produce costing markers for the merchandisers. Following are the activities and assets required in the department.
Plotter Digitizer Marker making Marker Preparation Costing marker Bundle preparation report
CAD DepartmentPersonnel
Designation Number Description Area (sqft)CAD Executive 1
6*6
Pattern Masters 1 Junior Pattern
Masters1
Plotter & Digitizer 1
MachineMachine Number Description Dimension (ft)
Computer 1 IBM 3*5Plotter 1 3*8
Digitizer 1 6*8Furniture
Furniture Number Description Dimension (ft)Pattern making
Tables1 8*6
Marker table 1 9*7Chair 4 1.5*1.5
Cutting Department
The department serves the purpose of spreading of the fabric on long tables and cutting the pattern pieces out of it. The critical factor in deciding the area of the department is the length of the cutting table. The process of numbering and bundling is also carried out in this department. The department requires the storage space for the cut fabric rolls, cut components, bundles etc. Following are the requirements for this department.
Spreading Tables Cutting tables Numbering tables Bundling tables Checking tables Cutters required
Cutting DepartmentPersonnel
Designation Number Description Area (sqft)Cutting
Department Manager
1
Cutting Supervisor 2 Cutting Master 4
Helper(Spreading) 8
Helper(Trolley) 2
Numbering 10
Bundling 3
Helper 1 Machine
Machine Number Description Dimension (sqft)
Computer 1 IBM 3*5
Straight Knife Cutting Machine
4+1
End Cutters 6
Band Knife 1Fusing machine 1
FurnitureFurniture Number Description Dimension (ft)
Cutting Tables 4 60*6Numbering
Bundling Tables3 20*6
Chairs 1 1.5*1.5
Sewing Department
The department serves the purpose of sewing the garment and thus carrying out the production. The department contains 143 sewing machines and operators with proper space for lighting. The department is generally a large single floor the approximate area required for this department is calculated as 6000sq ft. Following are the various activities that go in the sewing room.
Approval of operation breakdown Special machines and attachments approval Sewing department Line balancing No. of machines required Deciding or approval of manufacturing system Sewing Checking Sending the garments for washing. Receiving the washed garments.
M/C TYPE
3T O/L-4
DNCS FLAT BED
DNLS (UBT)-5
SNLS-10
WORKING TABLE-3
3N FOA-3
DNCS FLAT BED
COMP.CYCLE M/C
AUTO.STEAM PKT CREASING
COMP.CYCLE M/C
4T O/L SAFETY STITCH
4N FOLDING & ATTACHING M/C
COMP.CYCLE M/C
LABEL CREASING M/C
COMP.CYCLE M/C
2N BELT LOOP MAKING M/C
SNLS AUTO.BELT LOOP ATTACH
AUTO BOTTOM HEMMER
1N CYLINDER BED LS BARTACK
1N CYLINDER BED LS BARTACK
EYELET B/H M/C
FASTENING M/C
Washing Department
Machine particulars for dry process:
Machine No Area (sqft)
Heat guns 24Flashers 12 5x5=25x12=300Tearing guns 5Tagging guns 8Grinding m/c 4 3x3=9x4=36Horizontal mannequins 34 3x3=9x34=306Vertical mannequins 12 3x3=9x12=108Conveyor booth -PP 1(24 heads) 15x15=225Stationary PP Spray booth 2(6 heads each)
15x15=225
Sand blasting 2(4 heads) 20x20=400Total=1600sqft
Total area (60% extra)=1600+1600x60/100=2560sqft
MACHINE PARTICULARS FOR WET PROCESS:-
MACHINES CAPACITY Nos. Area(sqft)Ramson belly wash 200kgs 1 100Tonello-420 420kgs 1 100Tonello-500 500kgs 1 100Danish-250 250kgs 2 200Smartex-340 340kgs 3 300
smartex-225 225kgs 2 200Tonello-510 510kgs 1 100Tolkar-500 500kgs 2 200Ozone 100kgs 1 100Drier 50 kgs 1 100Drier 150 kgs 9 900
Total =2300(sqft)
Total area (60% extra)=2300+2300x60/100=3680sqft
Finishing Department
The finishing department is meant for ironing, folding and packing of the garment the department will require tables for checking as well as tables for folding and packaging. Following are the activities.
Ironing Tags attached Checking Folding and Packaging
Finishing DepartmentPersonnel
Designation Number Description AreaFinishing
Supervisor1
Checking 16 Ironing/Pressing 10 Tag Attachment 8
Folding 8
Packing 10
Helper 2 Machine
Machine Number Description Dimension (ft)Computer 1 IBM 3*3
Ironing Tables 4 3*5Tag Attachment
Machine2
Form Pressing 2 5*5Snap machine 8
Trolley 2 4*3Furniture
Furniture Number Description Dimension (ft)Inspection Tables 16 3*5
Packing Tables 8 3*5Tag Attachment
Table8 5*3
Folding Table 8 6*6
No. of stools 1 1*1
Quality assurance Department
The quality assurance department is meant for setting the quality standards for the product and then checking their sustainability in the production process. The department requires one quality manager and quality supervisors.
Decision of Inspection points Solving quality problems Improving quality
Quality assurance DepartmentPersonnel
Designation Number Description Area (sqft)QA Department
Manager1
100QA Supervisor 2
MachineMachine Number Description Dimension (ft)
Computer 3 IBM 3*5Chair 3 1.5*1.5
Industrial Engineering and Planning Department
The department is meant for planning the production of a new product in the same product category. The department requires a team of industrial engineers. Following are the list of activities in this department.
Line planning Production per day calculation and follow up Operation Breakdown Calculation of Standard average minute (SAM) of garment Cost of machine per hour Efficiency calculation Ergonomics
Industrial Engineering DepartmentPersonnel
Designation Number Description Area (sqft)Industrial
Engineering Manager
1 80
Senior IE 4 150Junior IE 4 150
MachineMachine Number Description Dimension (ft)
Computer 5 IBM 3*5
Printer 2 1.5*1.5
Stopwatch 4
FurnitureChair 9 1.5*1.5
MIS Department
This department serves the purpose of IT specialists that solve the software’s problems in the organization. The department also requires a server room for storing important data and managing the internet connection. The department also caters to troubleshoot the software related problems as and when they arrive. Following are the activities:
Computer Room/IT room Conference halls Software and Hardware Storage Maintenance Server
Information Technology DepartmentPersonnel
Designation Number Description Area (meter)IT Department
Head1
IT Executives 2
MachineMachine Number Description Dimension (ft)
Computer 3 IBM 3*5Server 1
Air Conditioner 3 Split AC 4*1
Chair 3 1.5*1.5Furniture
Chair 3 1.5*1.5
Maintenance Department
The department stores basic tools for the maintenance of the machines. It also requires space for the maintenance job. Following are the activities of the department.
Tools and machinery storage for maintenance of sewing and finishing machines Tools and machinery storage for special machines Spare parts storage Building maintenance parts storage Machine maintenance UPS or power backup maintenance Air conditioning maintenance Record Keeping Electric supply decisions
Maintenance DepartmentPersonnel
Designation Number Description Area (sqft)Maintenance Head 1 100
Helpers 2 100Furniture
Chair 3 1.5*1.5
Administrative Department
The administrative department caters to documentation regarding to the following documented activities.
Purchase department Documentation Finance Accounts Shipment details and documentation Bank documents Letter of Credit Bills
The purchase department is a sub department under the administration. This department is responsible for issue of purchase orders to buy fabrics and trims and also other requirement of the plant. The purchase department also requires space for keeping records and workstations. Following are the activities that are carried out in this department.
Placing Purchase Orders Raw material Procurement Affirmation of Purchase order by Supplier
Evaluation of Supplier in terms of cost and quality
Administrative DepartmentPersonnel
Designation Number Description Area (sqft)Plant Manager 1 100
Production Manager
1 100
Documentation & Compliance
3 150
Purchase Manager 1 60Purchase
Executives3 150
Accounts 5 300Machine
Machine Number Description Dimension (ft)Computer 12 3*3
FurnitureChair 12 1.5*1.5
Human Resource Department
This department requires a team of HR executives leaded by a HR manager. The department need not have very big area. Following are the activities.
Employee Benefits Recruitment Training and development Employee guidance Personnel documents
Human Resource DepartmentPersonnel
Designation Number Description Area (sqft)HR Head 1 60
HR Executives 3 120Machine
Machine Number Description Dimension (ft)Computer 4 IBM 3*5
FurnitureChair 4 1.5*1.5
Safety Department
The department caters to the maintenance of safety assets of the organization.
Installation and maintenance of fire extinguishers First aid Kit installation and Maintenance
Safety DepartmentPersonnel
Designation Number Description Area (sqft)Nurse 1 200
Furniture Number Description Dimension (ft)Bed 1 5*6
Stretcher 1 3*7
FurnitureChair 1 1.5*1.5
Security Department
This department comes under administration. Following are the various requirements.
Security cabins Parking Maintenance
Security DepartmentPersonnel
Designation Number Description Area (sqft)Security Head 1
100(at gate)Security Guards 6
MachineMachine Number Description Dimension (ft)
Computer 1 IBM 3*5Furniture
Stool 7 1*1
Warehouse Department
This department stores all the finished orders. Here the orders are stored till they are shipped. Also the finished goods of a consignment whose production is in process is also stored here. Following are the various processes:
Cartons are brought in from finishing department Cartons are stored Cartons are moved to parking be shipped
WarehousePersonnel
Designation Number Description Area (sqft)Warehouse
Manager1
100(at gate)Helpers 2
MachineMachine Number Description Dimension (ft)
Computer 1 IBM 3*5Trolley 2 4*3
FurnitureStool
Warehouse Area Calculation
Average Carton dimensions (ft)
3.5*4*3.4
number of pieces in Carton
Use of cube: No of cartons can be
stacked in column
Number of Cartons required
Floor space
required
rejected storage area:
16 5 765 15 * 25 METER
Net Area
Other Structures or Areas required:
I. CanteenII. Reception
III. ParkingIV. Conference room