Plant Layout

Name : Satyam Singh

Shrey Vij
Department : Fashion Technology
Semester : VIIth
Faculty : Mr. Pawan Godiawala
Factory Area : 100 x 100 = 10,000 sq. ft.
Daily production : 3000 (denim + cargo)
(450denims+600 cargos)
 Assumptions
Wastage per piece : 5%
So, wastage for 3000 pieces : 3500
 Stores

Stores Area : =
W.I.P-15 days
Average Fabric consumption per garment 1.3 mtrs

So, fabric consumption for 3000 pcs in 15 days = 3000 * 1.3*15

58,500mtrs

No. of rolls required(100mtrs)- 585

Pocketing Material per garment consumption- 0.2mtrs

So, consumption for 3000 pieces in 15 days will be 9000 mtrs

No. of rolls required(100mtrs)- 90

Capacity required calculations for 2 weeks (15 days)

One roll has total meter age : 100
Fabric Width : 5
Diameter of Fabric rolls with poly packing : 1
Length of the roll with poly packing and allowance : 6
Fabric inventory for 15 days (meters) : 58,500
Pocketing Material Inventory for 15 days(mtrs) : 9000
So, No. of rolls : 585+90
Number of rolls in one rack : 20
Number of racks required : 35
Number of shelves in one rack : 4
Rack for rejected rolls : 1
Racks for cartons : 4
Total racks : 40
Manpower Requirement
Store Incharge : 1
Assistant incharge : 1
Fabric inspector : 1
Sorting personnel : 3
Helpers : 1
Total man power : 7

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
Height of one shelf : 2
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
Dimensions
Height of one rack : 8
Length of a rack
Total Length3 + 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)
Width of rack
Total width = 72 (6 )
Width of the fabric roll : 60(5)
Allowance for free movement : 6 (0.5)
Trims Racks
Length : 2
Width : 2
Height : 2
No of racks : 20
Space of the aisles : 3.5
Office
Area : 15 x 16 : 240 sq. ft.
Machine and Waste
Area : 15 x 17 : 255 sq. ft.
Inspection & Sorting Tables
Number of them : 2
Dimensions
Length : 6
Width : 6
Height :
 Consumption For 3000 For 2 weeks (15
No. Material per GARMENT garments days)

Fabric (meter)
1 Shell Fabric 1.3 3900 58500
Pocketing
2 Material 0.2 600 9000
Trims and Accessories

1 Buttons 1 3000 45000

3 Threads 185 555000 8325000
4 Kimble 1 3000 45000
5 Brand Card 1 3000 45000
Business Price
6 Card 1 3000 45000
12 Studs 10 30000 450000
13 Polybags 1 3000 45000
14 Cartons .125 375 5625
Labels +
15 Washcare labels 2 6000 90000

A carton contains on an avg. 8 denims (6kgs)

So, carton required per denim- .125
 Cutting

Cutting Area : =

Fabric Storage Racks

Cutting capacity : 3000 garments per day

Required fabric inventory : 1 days

So, storage capacity required : 3000 garments

Fabric consumption of 1 garment : 1.3 meters

Fabric for 3000 garments : 3900mtrs

Number of rolls in one rack : 20

Diameter of one roll : 12

Total number of racks required : 2

Total number of rolls required : 39

Fabric width in bundle (approx.) : 1mm

Total cut pieces- 3000

So, total height- 3000*1 3000 mm-3mtrs 9.85 feet

Max length of cut piece : 48

Max width of cut piece : 12

Cut pieces racks required(for large(4 panels)) : 8

Dimension of cut pieces racks(for large(4 panels))-

L 4.5 H- 5

W-1.5
Cut pieces racks required for smaller parts : 15

Dimension of cut pieces racks (smaller pieces)

Length 1.5

Width 1.5

Height 1.5

Dimensions of Fabric racks

Length : 6

Width : 6

Height : 8

Spreading and Cutting Tables(bundeling +ticketing) : 2

Inspection Tables : 2
Fusing Table : 1
Band Knife : 1
Fusing Machine : 1
Main Inspection and Sorting Table : 1

One lay of : 85 plies

1 ply of : 10.4 meters

No. of garments in 1 ply : 8

One lay : 680 garments

We require garments to be cut : 3000

No. of lays would be 3000/680 : 4.5

Time taken to spread one lay : 2 hours

Spreading & cutting table
Length of the table : 40

Width : 5

Height : 3.5

Inspection & Sorting table

Dimensions

Length : 6

Width : 6

Height :

Band Knife Machine table

Dimensions

Length : 7

Width : 5

Height :

Fusing Machine
Dimensions

Length : 15

Width : 5

Height :
For carrying the cut bundles there will be hangers
Manpower No. of
No. Requirement Personnel

1 Cutting master 1
2 Supervisor 2
3 Spreaders 8
4 Band knife operator 1
Straight Knife
5 operator 2
6 Sorting personnel 2
7 Inspection 4
8 Stickering 4
9 Bundling 4
Total

Machine List in the Cutting Department

S. No. Machines Number
1 Straight Knife 2
Specification : Eastman Co. Blade
length 8 inches
2 Band Knife 1
3 Fusing machine 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
7 Stickering guns 2
9 Scissors 12 inches 6
10 Glass pencil for marking 4 packets
11 Measuring tape 10
13 Pattern hanging system 1
Manual spreading roll
14 stands 2
15 T-scales, rulers, hip Lump sum
 curves, etc.
16 Brown cellophone tape Lump sum
Sewing
Area of the sewing department : =

Sewing shifts : 1

Timings : 8:00 am 5:00 pm

1 garment takes : 15 mintues (approx.)

Minutes Available : 480

Denims from Line 1 : 450 per day

Cargos from Line 2 : 600 per day

Machines in Line 1 : 35

Machines in Line 2 : 40

Daily production : 1050 denims and cargos

Number of sewing lines : 2

Absenteeism : 10%

There will be a hanger system for the movement of pieces :

Number of
S. No. Manpower requirement Personnels
1 Operators 75
2 Helpers 6
3 In process inspection 6
4 Final Checking 12
5 Helpers 12
6 Line Supervisor 2
7 Production manager 1
Total Manpower requirement for
shop floor 115
Operation Breakdown of denims:

There will be a feeding hanger system for cut parts

Also hangers for carrying sewn garments to the washing department

Preparation tables
Total number of tables : 6

Dimensions : 5 x 5 x 3

Shop Floor requisition

Width of the machine : 20 24 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 1 : 35 machines,

18 machine on one side and 17

on other side of the line

Machines in one line 2 : 40 machines,

20 machine on each side of the

line

There will be the movement of hangers in the middle of both the lines which
will take space around 2 feet.

Inspection Tables
Number of Inspection tables : 3

Dimensions : 4 x 3x 3

End line inspection tables

Total number of tables : 6

Dimensions : 9 x 5 x 3

Chairs
Total number of chairs : 78 ( 36 x 6)

Iron Tables : As per requirement

Other Materials
Scissors : 30
Measuring tapes : 216 ( 36 x 6)

Production blackboard : 6
 Washing
Area of washing department:

No. of garments to be washed 3000

Washing machine of 400 kgs

Dimensions-

Length 20

Width 5.6

Height 5.7

Dry Weight of the machine 240 kgs

Washing cycle 4 hrs (so, one machine can complete 2 cycles in 8 hrs shift)

Weight of 3000 garments- 3000* .750 gms 2250 kgs

So, one machine can wash around (240/.750) 320 garments in one cycle

In 2 cycles 640 garments

No. of washing machines required -3000/640 4.68 (5 machines)

Hydro extractor of 200 kgs

Dimension

Length 8.4

Width 6.4

Height 4.6

Hydroextractor cycle hrs

Weight of 3000 garments- 3000* .750 gms 2250 kgs

No. of machines required - 1

 Dryer of 200 kgs

Dimension

Length 8

Width 5.9

Height 4.2

Dryer cycle hrs

Weight of 3000 garments- 3000* .750 gms 2250 kgs

No. of machines required - 1

 Finishing & Packaging
Area of packaging department :

Capacity of finishing department would be 3000 garments per day

Vacuum table steam press is being used for pressing

Complete packing for the denim as well as cargo takes place in the poly bag and
finally seating in the carton boxes

Thread Trimming Table

Number of them : 3

Dimensions

Length : 10

Width : 5

Height : 3.5

Final Inspection Table

Number of them : 7

Dimensions

Length : 6

Width : 6

Height : 4

Pressing Table
Number of them : 6

Dimensions

Length : 4
 Width : 3

Height : 4

Folding Table
Number of them : 10

Dimensions

Length : 8

Width : 5

Height : 4

Final Packaging Table

Number of them : 3

Dimensions

Length : 15

Width : 5

Height : 4

Storage Racks
Number of them : 9

Dimensions

Length : 6.5

Width : 5.5

Height : 8

Furniture Requirement
* AQL level followed is 2.5
 Operation Time Peopl
No. of Dimensions in minutes per
Furniture Tables (feet) (approx) furnitu
Thread trimming table 3 10x 5 x 3 2.7
Inspection table 6 6x3x3 4
Pressing table 6 4x3x3 2
Folding table 10 8x5x3 3
 Administration / Offices

S. No. Office Requirements Number

1 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
Rubber stamp, ink
16 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