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So from operation bulletin we know total no. of machines to be set up, say
500, so total area required will roughly be equal to 500*175= 87500sqft.
Importance of aisles
Plant space economy: - Whereas a small building 20 ft wide may have one
aisle 3 0r 6 ft wide, taking 25 to 30 percent of the available floor space, a
building 600ft wide may have three main aisles, down centre and sides 300ft
apart, each 10 ft wide, taking only 3 percent of the space, with secondary
aisles raising this to 10 to 12 percent given to aisles in large plant.
There should usually be a main aisle through the centre of the building,
straight if at all possible, starting and ending at outside entrances.
Below are some points that we should consider on macro level before getting into
details of each section:-
1. Whole covered area should have two aisles:
a) Primary – It should be 6ft wide.
b) Secondary – It should be 4ft wide.
13. TOILETS:-
There should be separate toilets for both genders depending
upon the number of employees of each gender.
The toilet requirement to be as follows:
14. All stairways must have proper railings .Though it is good to use
ramp instead of stairs.
c) Main storage area: - After unloading the rolls should move to this
place after keeping aside 10% of total rolls aside for checking in
unloading area racks.
And it should have an arrangement of racks for storing fabric
equal to the inventory planned i.e. for 10 days.
Maximum height of racks should not be more than 8 ft and running
length should not be more than 88 ft. And rack should be slightly
above the floor to avoid excessive bending, but it is advisable to use
vertical space with proper arrangement of unloading it from height.
Now if we use height of racks as 8ft then leaving ground clearance
& space between each roll we can easily place 5 rolls in one column
and in length of 88 ft we can easily place 60 such columns.
That means 300 rolls can be placed in one such arrangement and
we need around 6 such arrangements to accommodate 1600 rolls of
inventory.
d) Stock lot area: - This can be utilized to store any extra/left over
fabric from the current lot. The area for this depends upon the
space available after allocating space to above mention.
2. CUTTING
Pieces to be cut daily = daily production = 8000 + 5% extra = 8500 shirts
From above we are sure that we have to plan a cutting room with capacity
to cut 8500 shirts.
Now the next step should be to decide what marker we are planning to do
which is directly proportional to:-
o The length of table required to lay the fabric e.g. a six way marker
will require to lay fabric up to 12mt on one table.
o Space available in the cutting room i.e. if there is no room to put a
12mt table then we can’t plan a six way marker.
Let’s say we decided to do six way markers, now the calculations are as
follows:-
Total garment to be cut in one lay = 6
No. of plies = 150
Total garments cut in one lay = 900
The important thing to consider is the ratio of solids to check, say it is
50:50,
Spreading of one lay of solids with 150 plies on a six way marker will take
around 2 hrs
Cutting of same lay will take around 1 hr if done with straight knife by two
cutters.
For solids:-
Further calculations of no. of tables required will depend on the cutting
time i.e. if in 1 hr one can cut 900 garments then in 5 hrs the pieces cut with
six way marker will be= 4500.
So for cutting to happen continuously, the cutter should always have the
spread ready for next cutting for this to happen we should have at max 3
spreading tables as it takes 2 hrs to lay 150 plies on a six way marker.
For checks:-
Spreading time for a lay of 150 plies on a six way marker = 2.5hrs
Cutting time for same when doing block cutting = 1 hr (with one cutter)
So here also we require 3 spreading tables.
Total spreading tables = 6
Cutters = 3
Spreaders = 12(two per table)
Straight knife = 4
From here the cut pieces will move to band knife however checks will be
relayed before band knife cutting.
SAM of relaying one whole garment by one operator = 3 minutes
Total time to relay 4250 pieces = 25500 which translates into 27 relay
helpers.
Time to cut relayed pieces on band knife = 18 seconds
So, total no. of band knives required = 6
Relay helpers = 27
Band knife = 6
Relaying tables = 7 of 8ft*6ft
So, area of cutting room depends upon the area required to place all these
tables, plus given below:-
Fusing machine (large bed) = 2 for collar, cuff, flap & collar band.
Roller fusing machine = 2 for front placket.
Dye cutting machine.
Area of these can be acquired from catalogues given by manufacturers.
However the aisles running in cutting room between tables will follow the
specification:-
4ft for man movement space + 3ft for trolley.
Cutting room should also have space for storing cut parts equal to the days of
inventory planned. Calculations for that are already explained in store
section.
3. SEWING
a) For setting sewing room the basic requirement is no. of
machines, helper & checking tables
And the operation bulletin will give these figures. Say for 500 machine
shirt’s factory the figures above mentioned are:-
Machine- 48, helper table- 9, checking tables – 5
I. For over head system – distance between two machines and two
lines will depend upon the specification given by the vendor of such
systems.
II. For centre table –
i. Width of table should be – 15 inches for preparatory & 24
inches for assembly as assembly involves handling of larger
parts.
ii. Distance between two machines in a line should be 22
inches with or without work aids i.e. space for entering the
workstation should be 22 inches.
iii. Distance between two lines should be 4 ft i.e. straight line
distance from the end of maximum width machine in a line
to the start of another machine in another line.
III. For trolley movement –
i. Instead of centre table the space will be used for movements
of trolleys with in the line so this space should be around 8-
10 ft.
ii. Distance between two lines should be 6ft for easier
movement in between lines.
Note: - For any of the system we should avoid long lines usually not more than 88ft
because it results in increased movement from one side to another, so there should
be break after 88ft.
c) The placement of machines should be such that one side of operator
should always be free for movement i.e. when using centre table the
operators either side of table should face each other as this way they
will always be disposing to their right side which has centre table.
d) Two pigeon hole should be placed one at start of line before
preparatory to store cut parts to load to preparatory and one after
preparatory & before assembly to load parts to assembly.
e) Attention should be laid on fact that flow of work should be smooth in
the line with proper demarcation as to how a bundle will move in the
line.
4. FINISHING
The layout of finishing depends upon the product being produced.
Actually the need to have an ETP depend upon the local laws i.e. whether
the factory should have:-
ZERO DISCHARGE.
% DISCHARGE ALLOWED.
The last two steps will be FINAL AUDIT & CARTON PACKING both should
be in finishing room whatever the case may be.
Now if followed above calculation and steps the area required for major
operations in a garment factory can be calculated, however for proper
functioning space should also be allocated to below departments:-
5. Internal Laboratory
6. CAD room
7. Cutting room waste storage
8. AAMT training center
9. Maintenance room
10. Machine storage
11. Provision for Metal disposal
12. Office space for 25-30 people and Sample room
13. Compressor room, Diesel storage, Generator area, Parking area
14. Staff dining room, Medical room, crèche.
15. Worker’s canteen:-
The total area required for setting up canteen hinges on the information
whether the canteen will be having cooking facility or not.
Area required without cooking. – 10/15sqft per person.
Area required with coking. – 25sqft per person