NATIONAL INSTITUTE OF FASHION TECHNOLOGY

APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT
Master of Fashion Technology
One Complete Layout in A1 size paper
Statutory Warning:

1
2
3
4
5
6
7
8
9
10
11
12
13

In case of non completion of this format,

The Layout should cover following:
walk in complete darkness during the mo
All Openings from the Compound / Plot
strongly suggested. It is suggested that
Building Details like Column Size, Beam Size.
to have all the required data pre-docume
unorganized style of industrial operation
Road Positions
Directions
The data collected by this format will be of a g
All the departments
subject includes a lot of data collection and co
Machine Positions within the departments
be feasible.
Furniture details
The subject requires input from all the various
layout will require very detailed calculation lik
Material Handling Equipments
fabric store, you need the dimension of fabric
Clearly demarked Ailes Spaces, Window Openings, Doors, Emergency
Exit. etc
your factory)
then you work upwards on that c
Most
of
the
data
would have already been col
Detailed Utility Drawings
departments.
Manpower Movement
Do not be intimidated by the terminologies lik
basic understanding of dimensions, scale, ele
Material Handlimg Movement
studied in school level must be easy!!!).
Documentation of building construction material.
AND... if by chance someone does not get the
company!!!
Go ahead give it your best shot.

Page 1 of 14

Page 2 of 14

Statutory Warning:
In case of non completion of this format, you may find yourself taking a
walk in complete darkness during the module; so completion of same is
strongly suggested. It is suggested that one should not expect a company
to have all the required data pre-documented with them; owing to highly
unorganized style of industrial operation.
The data collected by this format will be of a great help in executing the module since the
subject includes a lot of data collection and collecting this data during the module will not
be feasible.
The subject requires input from all the various subjects studied till now and completing a
layout will require very detailed calculation like if you need to calculate the area of a
fabric store, you need the dimension of fabric roll (depending on the kind of fabric used in
your factory) then you work upwards on that calculation.
Most of the data would have already been collected during the study of individual
departments.
Do not be intimidated by the terminologies like beams, columns etc. Go ahead with the
basic understanding of dimensions, scale, electrical rating etc. (something you have
studied in school level must be easy!!!).
AND... if by chance someone does not get the data. Be ready to run back to the
company!!!
Go ahead give it your best shot.

Page 3 of 14

Page 4 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT AREA
Name of the Company

AREA AVAILABLE FOR EVERY

ACTIVITY.
Activity
Department
Area
Sampling
Pattren making
Sewing
Design section
Embroidery
Data entry
Cutting
Spreading/Cutting
Ticketing
Passage
Printing
Prnting
Block printing

AREA AVAILABLE FOR

EVERY DEPARTMENT.
DEPARTMENT
Store
Sampling
Cutting
Finishing
printing
Sewing
Finishing

TOTAL
CONSTRUCTION
AREA.

TOTAL PLOT
AREA.

PERCENTAGE OF ACTIVITY
AREA / TOTAL AREA OF
EVERY DEPARTMENT.

Area

Activity

PERCENTAGE OF MOVEMENT
AREA / PASSAGES TO TOTAL
AREA IN EVERY
DEPARTMENT.
Movement
while spreading
Sewing (feeding)
While supervising
Cutting
Sewing
Cutting to Sewing
Sewing to finishing

PERCENTAGE OF AREAS IN
EVERY DEPARTMENT TO
TOTAL AREA OF PLANT.
DEPARTMENT

Area

AREA AVAILABLE IN VARIOUS

SECTION LIKE PRODUCTION,
ADMINISTRATION,
ENTERTAINMENT.
DEPARTMENT
Area
Adminstration
Production
Store
Parking
Plantation

STATEMENT OF AREA WRT

PRODUCTION CAPACITY.

STATEMENT OF AREA WRT

NUMBER OF WORKERS IN
EVERY DEPARTMENT
Department

Passage
Data entry
Checking
Sewing
Sewing
Checking
Passage
finishing/warehouse
Ironong table
Inspection table
Thread sucker
Washing machine
Inspection machine
Boiler
Stain remover

Total area which is covered by the building of

the factory.
You will have to visualize it by walking aroud
first and then take dimensions of outer
periphery of the construction. Then do the
inward detailing.
Locate the activity listed, observe the
place where it is exucuted and then
calculate the area. No necessarily by
a measuing tape, it can be an
approximation by calculating foot
dimensions. I am sure every one has
a foot with stable dimension!!! USE IT

Observe and calculate the area dedicated for

Production of a department divided by the area
walking and material movement in every
of that department.
department. This is known as aisle area. Divide
the aisle area of a department by total area of
the department and you get the % aisle area
per dept.
Total area of the plot in which the factory is i.e.
The area of various functions. This will have
the area covered within the boundary of the
addition of areas of various departments.
factory.
Divide the area of activity calculated (first one)
by the area of separtment (second one). You
Number of people working in a department
get the % allocation of space for an activity by
divided by the area of that department.
a department.
Divide "dept area"(second one) by "plot area" (fourth
one).

Page 5 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT - INFRASTRUCTURAL
Name of the Company

Number of artificial light points per activity in every department.

(with voltage output if possible)
Dept / Activity
Sampling
Pattren making
Sewing
Design section
Embroidery
Data entry
Cutting
Spreading/Cutting
Ticketing
Passage
Printing
Printing
Block printing
Passage
Data entry
Checking
Sewing
Sewing
Checking
Passage
finishing/warehouse
Ironong table
Inspection table
Thread sucker
Washing machine
Inspection machine
Boiler
Stain remover

No.

Approximate
coverage area of
such points wrt its
height.

Approximate
Presence of other services Location of external
Number of fan points per activity
coverage area of fan and its department wise
connections and its
in every department
point
concentration
impact on plan
Dept / Activity
Sampling
Pattren making
Sewing
Design section
Embroidery
Data entry
Cutting
Spreading/Cutting
Ticketing
Passage
Printing
Printing
Block printing
Passage
Data entry
Checking
Sewing
Sewing
Checking
Passage
finishing/warehouse
Ironong table
Inspection table
Thread sucker
Washing machine
Inspection machine
Boiler
Stain remover

Total number of lights in each department

segregated as types of light and number of
lights for each activity

Dept / Service

Coverage of area, by a unit artificial

fan.

Other infrastructual facility in each department

Coverage of area, which gets lightened by a
unit artificial light source.

Details of light fixtures outside the factory but

within the boundary of factory.

Total number of fans in each department

segregated as per the acitivity

Page 6 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT - MATERIAL HANDLING
Name of the Company Methods and carriage
Area required / reserved as
capacity per hour
passages & percentage to total
when pick
floor area in every department
Method

Capacity

Department
Store
Sampling
Cutting
Finishing
Printing
Sewing
Finishing

Material flow chart

Length maximum /
Inout points and its
indicating frequency, minimum of different
impact on flow layout
intensity and duration
laps

Width / length ratio

Department
Store
Sampling
Cutting
Finishing
Printing
Sewing
Finishing

Ratio

Make a flowchart as to how the

material moves from "fabric
unloading" to "finished goods
dispatch". Give the details of
frequency of travel of material in
each dept. and the duration it takes
to move the material in each dept.
Aisle space %. Already calculated in "Area"
sheet
Total number of entry and exit points, theri
details and your observation as to how they
affect the production process.
The equipment used to carry material in each
department and their respective capacity. (for
ex. sewing>> trolley>> 30 bundles of all cut
patterns of shirt)

Ratio of length and width of a department. This

can be calcualted based on data aquired for
"Area" worksheet.

Maximum and minimum distance travelled by

material in a department, due to hindrance of
present infrastructure. This will be subjective so
just take some readings and infer from there.

Page 7 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT - BUILDING - STRUCTURAL STUDY
Name of the Company

Structural span in both direction

and its relevance

Relationship between structural

span and arrangement of
activities / departments

Structural materials

Finishing Materials :
for Floor / Roof /
Walls / Openings

SMT of windows available for SMT of

floor area in every department
Department

Ratio

Material used for structural support.

(SS, Wood etc)

Why such a support system for the building?

Ratio of window area and department
area

Distance between and dimension of

intermediate supports for astructure, e.g. a
beam

Self explanatory

Observe the areas of various types of windows.

Get individual area and total area of window in
each dept.

Page 8 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT - PRODUCTION PROCESS
Name of the Company

Schematic Production method

and its relevance with PL
relevance of such PL with
building type

Detailed process and its

relevance with area / location
allocation for every activity /
department

Covered in previous column

Type of Furniture / Machines

used with their actual dimensions Nature of activities and their strength
and dimensions required for its
in every department
usage
Dept/activity
Sampling
Pattren making
Sewing
Design section
Embroidery
Data entry
Cutting
Spreading/Cutting
Ticketing
Passage
Printing
Prnting
Block printing
Passage
Data entry
Checking
Sewing
Sewing
Checking
Passage
finishing/warehouse
Ironing table
Inspection table
Thread sucker
Washing machine
Inspection machine
Boiler
Stain remover

Online Storage
Practices
Department
Store
Sampling
Cutting
Finishing
Printing
Sewing
Finishing

Synchronization of PL
+ MH + Building Plan

Method

Covered in previous column

Flowchart of production process on a

schematic layout of the factory, depicting the
machines and infrastructure

Online access to storage systems in individual

depts.
Number of personnel in each dept and their job
description

Page 9 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

POWER
Total Electricity Bill of Factory for Last 3 months
Power Factors

Month 1

Master of Fashion Technology

APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT
REQUIREMENT STUDY ON PLANT LAYOUT

Month 2

Month 3

Unit Cost of Electricity KWHr.

Sr.
Department
No.

Departmental Break up
Based on Activity

Area

SMT.
Window
Opening

in Sq.
Meter

in Sq. Meter

Furniture

Equipement

LxWxH

Nos

KW

Light
Nos

KW

Fan
Lux

Nos

Exhaust
KW

Nos

KW

Factory
Souronding

SMT = Sq. Meter (a

unit to measure
area!!!)

Fabric Store Unloading

Fabric Checking
Storage
2

Ailes

Cutting

Ticketing

Observe the areas of

various types of
windows.
Get individual area and
total area of window in
each dept.

Bundling
3

Ailes

Sewing

Ailes

4
Page 10 of 14

Observe and record the numbers and

dimension of each (light, furniture
etc.) in the departments/ areas listed
vertically on left hand side of format.
For reference of how many
equipments are placed in unit area, do
calculate the area (in smt) of the
referred department also.

Cooling
System
Nos

KW

Sewing

Sr.
Department
No.

Departmental Break up
Based on Activity

Quality
Assurance

Ailes

Area

SMT.
Window
Opening

in Sq.
Meter

in Sq. Meter

Furniture
LxWxH

Observe and record the numbers and

dimension of each (light, furniture
Equipement etc.) in the
Light
Exhaust
departments/Fan
areas listed
vertically on left hand side of format.
For reference
of how many KW Nos KW
Nos
KW
Nos KW Lux Nos
equipments are placed in unit area, do
calculate the area (in smt) of the
referred department also.

SMT = Sq. Meter (a

unit to measure
area!!!)

Finishing

Thread Cutting
Ironing
Folding
Tagging

Poly Packing
Ailes

Carton
Packing
7
Ailes
8

Utility Area

Wash Room
Canteen
Boiler Room
Electric Room

Other

Page 11 of 14

Cooling
System
Nos

KW

You need to
contact the
maintenance or
electrical dept to
get electricity bill
of your factory for
last three months

Page 12 of 14

of your factory for

last three months

Page 13 of 14

NATIONAL INSTITUTE OF FASHION TECHNOLOGY

Master of Fashion Technology
APPAREL INTERNSHIP
PLANT LAYOUT ASSIGNMENT - FEEDBACK OBSERVATIONS
Name of the Company

Relevance of pl with production

process and also with building
types.

Short falls if any of pl and

how to overcome the same

Degree of effective
use of spaces

Judgmental comfort level

department wise and over all
Departmnet

Quality of Internal
Environment

Limitations / Strength of Plant

Any uggestion to increase

Efficiency / Production

Observations on Building /
Structure / Materials

comments
Store

Sampling

Cutting

Finishing

Printing

Sewing

Finishing

Please feel free to criticize and praise the company in

terms of their layout and its effectiveness w.r.t. their
operation.
You can talk to the personnel working there and use
their reviews for the same.

Page 14 of 14

Special Features