FACTORY LAYOUT

1. GROUND FLOOR
a. Raw material storage department
b. Cutting department
c. Sampling department
d. Warehouse
e. Operator Canteen
f. Maintenance department
g. Boiler room
h. Training department, utility room, medical room, executive
parking, labour parking
2. FIRST FLOOR
a. Director Cabin
b. Administrative department & H.R department
c. Production floor
d. Conference Room
e. I.E. Department
f. Q.A. Department
g. Compliance department
h. Display Room
i. Finishing department
j. Staff Canteen

WORKING IN AN INDUSTRY

BUYER

PRODUCT DEVELOPER

MERCHANT
SAMPLING

FABRIC

TESTING
MARKER PLANNING
SPREADING

CUTTING

BUNDLING & TICKETING

RESEARCH & DEVELOPMENT
PRODUCTION
WASHING
FINISHING & PRESSING
PACKING
& FINISHING
Locational
Analysis

Location

Village Vanj, Taluka Choryasi, District:

Surat

Type of SEZ

Sector Specific SEZ for Apparel. Area: 56 hec.

Status

Notified - Functional

Connectivity:
Road, Rail, Air
and
Port

Road Network: 8 km-National Highway (NH8),

SEZ is on Navsari- Surat State Highway (SH)
Rail Network: 20 km from Surat Railway St.
Nearest Port: 30 km from Hazira port and 18
km from Magdalla port
Nearest Airport: 20 km from Surat Airport

Land availability
& Lease Rates

Plots allotted to
industries @ Rs. 1500
sq. mt.

Available
Infrastructure

Internal roads, Power,

Water, Drainage system
are available in the SEZ

Training Facility

Established by ALT
Training College, an
Apparel Training Centre is
present in the SEZ

Proposed
industries

All kind of apparel

manufacturing industries
are
permitted

CALCULATION FOR PLANT AREA

Given Parameter:

Plant size = 10*100 sq. mt

FSI =1.0

G.C = 40%

Front margin = 5 mt

Side margin = 5 mt
Total space = 100*100 = 10000 sq. mt
FSI = 1.0*10000 = 00 sq. mt (Maximum available floor space)
Ground coverage = .65*3600 = 2340 sq. mt
Available floor space = (60-10) * (60-21)
= 48*39 sq. mt
= 1872 sq.

SPACE ALLOCATION FOR EACH DEPARTMENT IN EACH

FLOOR
GROUND FLOOR :

DEPARTMENTS

AREA (in
sq mts)

TOTAL NO.
OF LIGHTS

TOTAL
NO. OF
FANS

AIR
CONDITIO
N

EXCUTIVE PARKING

353.5 sq
mts.

1 halogen

TIME OFFICE

13.77 sq
mts.

MAIN ENTRY

15 mts.

UNLOADING AREA

91.8 sq
mts.

STORE MANAGER

13.77 sq
mts.

TRIMS AREA

12.39 sq
mts.

REJECTED ROLLS

16.06 sq
mts

TESTING LABS

23.87 sq
mts.

LABOURWASH ROOMS

6.88 sq
mts.

UTILITY ROOM

17.90 sq
mts.

CRECHE

17.9 sq
mts.

LOCKERS

35.8 sq
mts.

SUPERVISOR

3.67 sq
mts.

WASTE ROOM

18.36 sq
mts.

REMENENT

18.36 sq
mts.

CAD

28.4 sq
mts.

CUT PANEL AREA

112.02 sq
mts.

PATTERN MAKING

48.2 sq

mts
MANAGER

28.12 sq
mts.

MEDICAL

28.12 sq
mts.

EXECUTIVE WASH
ROOM

4.59 sq
mts.

EXECUTIVE CANTEEN

22.95 sq
mts.

CONFERENCE

27.54 sq
mts.

RECEPTION

20.66 sq
mts.

PPC

27.54 sq
mts

GM

20.66 sq
mts

MD

21.34 sq
mts

STUDIO

27.54 sq
mts

PURCHASE

20.66 sq
mts

EXPORT

20.66 sq
mts

ACCOUNTS

20.66 sq
mts

MIS

20.66 sq
mts

HR

30.99 sq
mts

LOGISTICS

13.77 sq
mts

MERCHANDISER

27.54 sq

mts
SENIOR
MERCHANDISER

13.77 sq
mts

WORKER PARKING

91.5 sq
mts

FIRST FLOOR:
DEPARTMENTS

AREA (in sq
mts)

TOTAL NO.
OF LIGHTS

TOATAL
NO. OF
FANS

AIR
CONDITION

SAMPLING

530.3 sq
mts.

14

MAINTAINENCE

123.9 sq
mts.

IE

19.2 sq
mts.

QUALITY
ASSURANCE

1.83 sq mts

SEWING AREA

2107.2 sq
mts

1065

59

COMPLIANCE

36.7 sq
mts.

TRAINING

31.22 sq
mts.

MANAGER ROOM

13.77 sq
mts.

STORE

31.22 sq
mts.

BOILER

18.36 sq

mts.
EXECUTIVE WASH
ROOMS

11.01 sq
mts

--

EXECUTIVE
CANTEEN

22.9 sq mts

WASTE ROOM

18.36 sq
mts

DRINKING WATER

4.59 sq
mts.

WASH ROOMS

4.59 sq
mts.

RACKS

27.5 sq
mts.

SECOND FLOOR :
DEPARTMENTS

AREA
(in sq mts.)

TOTAL
NO. OF
LIGHTS

TOTAL NO.
OF FANS

AIR
CONDITI
ON

WASH ROOMS

9.18 sq mts.

EXECUTIVE
CANTEEN

34.4 sq mts.

LABOUR CANTEEN

385.6 sq
mts.

11

MEASUREMENT &
INSPECTION

128.5 sq
mts.

65

AUDIT AREA

80.34 sq
mts.

40

PACKAGING

144.6 sq
mts.

50

DISPATCH AND
LOADING

96.4 sq mts.

CARTON STORAGE

18.36 sq
mts.

WASHING AREA

146.9 sq
mts.

10

WASHROOMS

4.59 sq mts.

DRINKING WATER

4.59 sq mts.

SUPERVISOR

2.52 sq mts.

WASHING
MANAGER

27.5 sq mts.

FINISHING
MANAGER

27.5 sq mts.

FINISHING ZONE

156.1 sq
mts.

78

WORKFORCE IN DIFFERENT DEPARTMENT

ADMINISTRATION DEPARTMENT:DEPARTMENT

NO. OF EMPLOYEES

Executive

Accounts and finance

Human resources

Purchase

Export and import

MIS

Logistics

Merchandising

PPC

IE

CAD

Maintenance

TOTAL

42

SAMPLING DEPARTMENT:

Cutting master

Sampling manager

Sampling in charge

Pattern master

Supervisor

Tailors

35

Helpers

Ironer

checker

TOTAL

51

STORE DEPARTMENT:Fabric store

Store manager

Assistant manager

Checker

Workers/helpers

20

TOTAL

26

Trim store
Store manager

Assistant manager

Workers/helpers

10

TOTAL

14

CUTTING DEPARTMENT:

Production manager

Pattern master

Assistant pattern master

Cutting master

Workers/helpers

50

TOTAL

58

SEWING DEPARTMENT:
Production manager

Supervisor

Quality checker

Workers/helpers

268

Male:female(ratio)

70:30

TOTAL

277

QUALITY ASSURANCE DEPARTMENT:

Quality manager

Workers/helpers

TOTAL

FINISHING DEPARTMENT:

OPERATION

WORKER

HELPER

Button holing

Button attaching

Thread cutting

25

Pressing

20

Initial checking

15

Final checking

Re final checking

Spot removal

PACKAGING DEPARTMENT

Assistant manager

Quality checker

Workers/helpers

1. Ease of future expansion or changeFacilities should be

designed so that they can be easily expanded or adjusted
to meet changing production needs.
There must be space for the following machine:
A proper space for sampling,store , operational
activities,finishing and packaging. There must also a proper
space in the industry if the industry plan for expansion.
2. Flow of movement. U-shaped patterns that ends up with
the finished product back at the shipping and receiving
bays can be functional. However, backtracking is to be
avoided . When parts and materials move against or across
the overall flow, personnel and paperwork become
confused, parts become lost, and the attainment of
coordination becomes complicated.
There are bundles of 100 pieces from one operation to another

Operation breakdown of ladies top

SL NO

COLLAR
1
2
3
4
5
6
7
8
FRONT
11
12
13
14
15
13
BACK
20
20
21
22
ASSEMBLY
23
24
25
26

Operation Description

Freq

Machine

SMV

Collar run with trim

SNEC

0.50

Collar turn

CTM

0.24

Collar top

SNUBT

0.45

Band hem

SNUBT

0.50

Band se t

SNUBT

1.05

Band top

SNUBT

0.25

Collar notch &trim

SNEC

0.20

Collar content lbl

SNUBT

0.40

Front plkt

KANSAI

0.60

Btn plkt sew

SNUBT

0.45

Pkt iron
PKT hem
PKT att
Front insp & pair

Pressing Table

0.55

Yoke lbl att

SNUBT

0.55

Sew pleat at back

SNUBT

0.60

SNUBT

0.50

Sew w/c lbl

SNUBT

0.25

Shoulder joint

SNUBT

0.50

Collar attach

SNUBT

0.60

Collar finish

SNUBT

0.75

Slv match (helper)

Helper
table

0.75

Yoke set

SNUBT

0.400

SNUBT

0.650

Helper table

0.350

27
28
29
30
31
B/H & B/S
32
34

Slv set

SNUBT

0.85

Slv top

SNUBT

0.70

Side seam

0.70

sleeve hem

FOA
SNUBT

Bottom Hem

SNUBT

0.55

Frnt btn hole

Btn hole m/c

0.58

frnt btn marking

Helper
table

0.45

35

Front butn sew-7

37

Trimming n checking

Btn att m/c

Checking
table

0.85

0.62
2.00

3. Materials handlingSmall business owners should make

certain that the facility layout makes it possible to handle
materials (products, equipment, containers, etc.) in an
orderly, efficientand preferably simplemanner.
4. Output needsThe facility should be laid out in a way that
is conducive to helping the business meet its production
needs.
1. Space utilizationThis aspect of facility design includes
everything from making sure that traffic lanes are wide
enough to making certain that inventory storage
warehouses or rooms utilize as much vertical space as
possible.
2. Shipping and receivingThe J. K. Lasser Institute counseled
small business owners to leave ample room for this aspect
of operations. "While space does tend to fill itself up,
receiving and shipping rarely get enough space for the work
to be done effectively," it said in How to Run a Small
Business.
3. Ease of communication and supportFacilities should be
laid out so that communication within various areas of the
business and interactions with vendors and customers can
be done in an easy and effective manner. Similarly, support
areas should be stationed in areas that help them to serve
operating areas.

4. Impact on employee morale and job satisfactionSince

countless studies have indicated that employee morale has
a major impact on productivity, Weiss and Gershon counsel
owners and managers to heed this factor when pondering
facility design alternatives: "Some ways layout design can
increase morale are obvious, such as providing for lightcolored walls, windows, space. Other ways are less obvious
and not directly related to the production process. Some
examples are including a cafeteria or even a gymnasium in
the facility design. Again, though, there are costs to be
traded off. That is, does the increase in morale due to a
cafeteria increase productivity to the extent that the
increased productivity covers the cost of building and
staffing the cafeteria."
5. Promotional valueIf the business commonly receives
visitors in the form of customers, vendors, investors, etc.,
the small business owner may want to make sure that the
facility layout is an attractive one that further burnishes the
company's reputation. Design factors that can influence the
degree of attractiveness of a facility include not only the
design of the production area itself, but the impact that it
has on, for instance, ease of fulfilling maintenance/cleaning
tasks.
6. SafetyThe facility layout should enable the business to
effectively operate in accordance with Occupational Safety
and Health Administration guidelines and other legal
restrictions.

SUSTAINABLE RAW MATERIAL FOR CONSTRUCTION

Windows use imported plate glass and aluminium frames.
Floor finishes include polished concrete tile, rendered and cut
concrete, tile, and wood.
Bamboo is used for window blinds and various forms of sunscreen.

 Nonhazardous finishes and materials are used throughout the

building, ensuring good indoor air quality, which is enhanced by
high air-exchange rates.
Stabilizing plants, silt traps, and stormwater-collection ponds were
used to prevent soil erosion during construction.
Special mechanisms to recycle construction waste, which reduced
the amount of waste that went into landfills.
SUSTAINABLE RAW MATERIAL FOR CONSTRUCTION
To reduce the non-renewable energy (energy expended to process
and transport materials) in the building, the main walls are made of
compressed stabilized-earth block manufactured forty kilometres
from the site.
The machine moulded blocks are made of local soil, sand, and
locally manufactured cement. The large size of the blocks minimizes
mortar joints.
The walls require no plaster finish; they are simply sealed with
varnish on the interior and exterior.
Polycarbonate sheets on roof.
Glass strips, running continuously across the breadth of the roof at
regular intervals.

Light Source Upgrade Alternatives

Lamp Type

Rated Life Hours

Full-size fluorescent
(T5,
high-performance
T8)

20,000 to 30,000 Lumen maintenance

% - 92 to 93

General area
lighting of all
kinds, including
open and
closed offices,
training classrooms,
and high-bay areas.
Sewing, Finishing,

Washing Section
Compact fluorescent

6,000 to 12,000
Lumen Maintenance
- 86 (%)

Incandescent
replacements in
table and
floor lamps, cans,
wall washers, and
sconces

Quartz pulse-start
metal halide

20,000
Lumen Maintenance
65 to 75 (%)

Outdoor lighting,
high-bay
lighting, and
remote-source
Lighting - Landscape

Ceramic pulse-start
metal halide

20,000
Lumen Maintenance
- 80 (%)

Where color is
critical- example
cutting section

Induction

100,000 hours
Lumen Maintenance
70 at 60,000 hours;
55 at
100,000 hours

LED

50,000
Lumen Maintenance
- 70 (%)

Where maintenance
costs
are high like
parking, roadways
and ware house.
In color-based
applications such as
exit signs, niche
applications such as
outdoor
signage, task lamps.

Use of Day Light and Automatic Control

Light

 A mix of top- and side-lighting, light shelves, high-reflectance

ceilings.
Automatically Control Lighting
Over time, all lighting systems become gradually less efficient.
Other efficiency losses include improperly functioning controls, dirt
accumulation on fixture lenses and lumen depreciation.
Follow a strategic lighting maintenance plan of scheduled group re
lamping and fixture cleaning.

Indoor thermal comfort

Cross- ventilation .
Cooling is achieved at the plant primarily by passive design and
secondarily by active systems.
Passive design measures include the orientation and massing of
building volumes, controlled fenestration and ventilation, shading of
the building and its surroundings, and thermal mass and solar
reflectivity of the facades and roofs.
The massing of the building volumes and the positioning and sizing
of windows permit daylight to enter as natural illumination without
causing substantial heat gain
Thermal roof load, the largest contributor to heat gain and indoor
discomfort in the tropics, is controlled by a combination of
photovoltaic roofs, and cool roofs.

IAQ(Indoor Air Quality)

Production spaces and offices are ventilated and cooled by
evaporative cooling units. These units draw in fresh air, filter it, and
add moisture to lower the dry-bulb temperature.
Indoor air is not recirculated, but extracted by suitably sized exhaust
fans to ensure effective moisture and heat removal.
Humidistat in each cooling unit keep the indoor relative humidity at
or below 80 percentv

Window Heat Flow

 Infiltration
Air leaks around the frame, around the sash, and through gaps
in movable window parts. Infiltration is foiled by careful design and
installation.
Convection
Pockets of high-temperature, low-density gas rise, setting up a
circular movement pattern. Convection occurs within multiple-layer
windows and on either side of the window.
Radiation
Radiation is energy that passes directly through air from a
warmer surface to a cooler one. Radiation is controlled with lowemissivity films or coatings.
Conduction
Conduction occurs as adjacent molecules of gases or solids
pass thermal energy between them. Conduction is minimized by
adding layers to trap air spaces, and putting low-conductivity gases
in those spaces.

Window Films
Window films reduce heat gain due to solar radiation and provide
low cost cooling load reduction.
Buildings in sunny areas can benefit from a variety of shading
techniques.
Bamboo sheet shade screens reduce heat gain up to 80 %
compared to normal glass.

Fan System
Centrifugal fans (A) are the most common fans used.
They are often cheaper but usually less efficient than axial fans (B).

COOLING
The heat-island effect around the building is controlled by shading,
by covering parking areas, by using lighter, reflective paving around
the building instead of dark, heat absorbent paving, and by shading
the courtyards between the building volumes.
The combination of the many passive cooling measures reduces the
thermal load to a level that can be handled by environmentally
efficient cooling systems instead of power hungry conventional
systems