Sampling Floor

.
• Purpose of Sampling:
o Making samples of the design the buyer
wants to offer to their customers in a
season
Sampling o To provide a means for making revisions in
the bulk production process.
o To let the manufacturer estimate the
thread and fabric consumption, and
develop cost quotations.
 The floor is divided into 3 sections –
Stitching
Inspection
Area CAD and Pattern Master’s Room
Description Total area available = 3,601.2 sq. ft.
[Stitching(1,676.73 sq. ft.) + QC(978 sq. ft.) + CAD(654.29 sq.
ft.) + Pattern Master’s Room (292.2 sq. ft.)]
LAYOUT OF SAMPLING FLOOR
 Furniture Quantity Dimension Area

Cutting Tables 4 8ft x 4ft x 3.5ft 32 sq. ft.

Pressing Tables 5 4.67ft x 1.33ft x 3.5ft 6.21 sq. ft.

Sewing Machines
Stitching SNLS 38 + 2 (for 3.5ft x 2ft x 3ft 7sq. Ft

Section Overlock Machines

embroidery)
6

• Length = 54.67 ft. Almirah 1 5.3ft x 2ft x 6.5ft 10.6 sq. ft.
• Width = 30.67 ft.
Cabinets (for 3 9.33ft x 1.67ft x 3.5ft 15.58 sq. ft.
• Area = 1,676.73 sq. ft.
material storage)
EXISTING SEWING WORKSTATION
• • Area consumed by each 1.5 ft
workstation = 1.8 sq meters
• • Area consumed by each
workstation = 3.5 sq meters
• • 2.5 feet space is being
provided for operator’s sitting
and movement.
• Table of 1.5 feet is being
provided between two lines
which is insufficient
Insufficient table space for WIP
PROPOSED SEWING WORKSTATION DESIGN 1
• • Area consumed by each
workstation = 1.8 sq meters
• • Area consumed by each
workstation = 3.5 sq meters
• • 2.5 feet space is being
provided for operator’s sitting
and movement.
• • Tableof 3 feet is being
provided between two lines.
SEWING WORKSTATION DESIGN 2

• Area consumed by each

workstation = 2 sq meters.
• feet space is being provided for
operator’s sitting and
movement.
• On right hand side of
workstation table of 2feet is
being provided
Finishing
Section

• Area consumed by each

workstation = 3.9 sq meters.
• 1.5 feet space is being
provided for operator’s sitting
and movement.
• Distance between two
workstations is 1 feet.
PRESSING
WORKSTATION

• Area consumed by each workstation

= 2.3 sq meters.
• o 2 feet space is being provided for
operator’s sitting and movement.
• o Main aisle of 3 feet is being
provided.
 • Garments after being pressed are placed on the
ironing table itself
Pressing • This reduces the area on the ironing table for
section pressing of garments
Proposed Pressing Workstation

PRESENT PROPOSED
Solution
• Provision of hangers near the
ironing table for hanging
garments after pressing.
• These hangers would be
portable for easy movement
of samples from pressing
area to QC
Finishing
Section

• Area consumed by each

workstation = 3.9 sq meters.
• 1.5 feet space is being
provided for operator’s sitting
and movement.
• Distance between two
workstations is 1 feet.
 Furniture Quantity Dimension (1 unit) Area
Tables (for Pattern 3+3 9.3ft x 4ft x 3ft 111.6 sq. ft. + 111.6 sq.
making and ft.
Inspection)
QC Section Pattern Master’s 1 9.3ft x 4ft x 3ft 37.2 sq. ft.
Table
• Length = 36.67 ft.
Chairs 4 2ft x 2ft 12 sq. ft.
• Width = 26.67 ft.
• Area = 978 sq. ft. Cabinets (for 1 9.33ft x 1.33ft x 12.44 sq. ft.
storage) 3.5ft
Checking
Workstation
(Supervisor and QC)
• Checking Workstation
(Supervisor and QC)
• 1.5 feet is being provided
supervisor or checkers sitting
and movement.
• Area consumed by each
workstation = 1.7 sq meters.
• On right hand side of
workstation main aisle of 3
feet is being provided
 Furniture Quantity Dimension (1 unit) Area

Chairs 4 2ft x 2ft 16 sq. ft.

Computer Tables 4 4.67ft x 2 ft. 37.36 sq. ft.

Cabinet for storage 1

CAD Section Plotter 1 4.7ft x 2.7ft 12.69 sq. ft.

• Length = 30.67 ft. Digitizer 1

• Width = 21.33 ft.
Pattern Making Machine 1
• Area = 654.29 sq. ft.

Other than this, there is a Pattern master’s room whose

dimensions are 21.25ft x 13.75ft
Area Available = 292.2 sq. ft.
 • CAD room has 4 computers, a digitisation board,
Layout of CAD a pattern making machine, a plotter and a shelf.
Room • The window for ventilation is been covered by a
curtain.
CAD Room
CAD
ROOM
LAYOUT
Proposed
Layout
Proposed computer table & overhead shelves
 • Removal of stale air and movement of fresh air in a
room.
• The three basic elements of building ventilation
include:
Ventilation o ventilation rate
o airflow direction
and Air o air distribution or airflow pattern
Circulation • The main problem of ventilation on the sampling
floor is associated with the air distribution or airflow
pattern.
• Problem area – Inspection and pattern making area.
o Lack of windows or exhaust fans.
 • There is no cooling system installed, which
throws out the hot air and circulates cool fresh
air.
Ventilation • 3 Exhaust fans are installed above the
windows.
and Air • 7 ceiling fans &
Circulation • The industry is pollution free, thus, there is no
smoke or harmful gas emission from the
machines. So, no special care has to be taken
for pollution control.
Ventilation
and Air
Circulation
Solution
• HVLS fans(high volume low
velocity)
• An HVLS fan is a large ceiling
fan that moves a High
Volume of air at a Low Speed.
• The low speed delivers gentle
air movement rather than
disruptive wind, and
circulating a high volume of
air effectively distributes
airflow over a large area
• Suggested- 8 feet ( diameter)
HVLS fans
Increasing number of exhaust fans
 • Maintaining proper illumination in the
inspection area is very crucial in a garment
factory, as the workers are responsible for the
final quality of the production.
Lighting • The tasks involved in this area require high
levels of worker focus and accurate lighting
ensures lower errors and defects passing on to
the next stage.
 Poor lighting for hand embroidery
Good lighting on sewing machines
Solution
• Increase the number of lights
for embroidery
• This could be done by using
ceiling fixtures along with the
presently available overhead
fixtures.
TEMPORARY STORAGE
WIP FROM LINE WAITING FOR FINISHING
Solution
• Providing with racks on the
sampling floor beside cutting
tables.
• There is a lot space between
cutting tables & pressing
tables so these racks can be
easily accomodated
• Then further be supplied to
Finishing table which is right
in the proximity
Pattern
Storage
 • The number of patterns hung on walls .
Pattern • Patterns hung are of all the styles that have
Storage been made in the sampling room – whether
approved by the buyer or not
AFTER QC INSPECTION STORAGE
SLIDING DOOR CABINETS

•Sliding door takes less space

•Patterns can be be hung easily
•Finished garment afters qc inspection can be kept in these cabinets
•Also other R&D and design samples can also be stored
MATERIAL MOVEMENT & BINS
Solutions for Material movement
Other Problem Identified
Cracks on the walls