“BFTECH DEPARTMENT”

ASSIGNMENT SUBMITTED TO DEPARTMENT OF FASHION

TECHNOLOGY

PLANT LAYOUT

Guided by:-
Mr. Mohammad Umar

SUBMITTED BY:
Sakshi Chaudhary ,
Varsha Kundi
Yashika
Venya
BFT
 ACKNOWLEGMENT

I am highly indebted to Mr. Mohammad Umar for his guidance and

constant supervision as well as for providing necessary information regarding
different sites and books to study PANT LAYOUT.

I would like to express our special thanks to our parents and friends who gave
us their time and support.

Our thanks and appreciations also go to our colleagues in developing the

project.

THANK YOU
 PRODUCT
VERIFICATION:-

“ JUMP-SUIT “

“BOM –SHEET”

FABRIC POUTE(50% COTTON, 50%

POLYSTER)
BODY ,POCKETS ,STRAOS, (GREY TAN WHITE)
FRONT LINING FACING

THREAD TOP-STITCH POCKET ,HEM (DTH)

INVISIBLE ZIPPER DTH

CARE LABEL WOVEN 100%, ORGANIC

COTTON WITH BLACK WATER –
BASED ECO INK
 OPERATION BULLETIN

Transportation Time (in

Sr. No. Operations O/P Time (in sec.) Sec.)

A. Back Panel Overlock 48 11

B. Front Panel Overlock 48 11

C. Overlock Top Front 36.24 11

D. Overlock Top Back 36.24 11

E. Pocket Folding By Iron 14.22 11

F. Making Strips 30.24 11

G. Top- Stitch Strips 30.6 11

H. S, Front placket Facing Overlock 22.2 11

I. Front placket facing attach 27 11

J. Topstitch Placket bag 36 11

K. Attach Front to Back 40.6 11

L. Attach strips 19.2 11

M. Attach front bottom together 18.27 11

N. Attach back crotch till mid 11.3 11

O. Front Placket Attach 36.2 11

P. Placket top stitch 27 11

Q. Iron 26.42 11

R. Attach Care label 22.54 11

S. Attach Side Seam bottom 74.34 11

T. Attach side Seam Top 56.2 11

U. Attach Top to Bottom 58.3 11

V. Attach pocket 49.2 11

W. Top Stitch Pocket 27.3 11

X. Label Main Size 18.24 11

Y. Label Main Stitch 36 11

Z. Add Facing to top 80.34 11

AA. Top Stitch Neck &Sleeve 42.7 11

AB. Attach Seam 78.25 11

AC. Attach Zipper 144.32 11

AD. Overlock Hem 19.8 11

AE. Topstitch Hem 21.4 11

AF. Iron 178 11

Total 1414.66 352

Total Sum = Operational Time + Transpotation Time

1414.66 352 1766.66

Total Sum/ 60 1766.66/60 29.44

FABRIC CONSUMPTION : 2.5m

TOTAL TARGET OF PRODUCTION: 6000

TECH PACK

BUYER ADDRESS :GENUINE GARMENT EXPORT COMPANY, NEW DELHI

Jumpsuit with single

product ID 01126357 Product name pocket

Order Quantity 1500 Group Plain

Season summer Brand Local

Size M gender FEMALE

50% COTTON 50%

Fabric POLYESTER Date 6/4/20

fabric weave Plain GSM 180

COLOUR DETAILS :-

Base Fabric GRAY, TAN, WHITE

Stitching Thread DTM

ZIP DTM

Different sections of the unit

The new manufacturing unit will consist of following sections / departments:

A. Production Related
• Fabric Stores

• Sewing Trims & Accessories Store

• Spreading and Cutting Section

• Sewing Section

• Finishing Section

• Merchandising Department

• Sampling & Technical Department

• Quality Department

• CAD Section

• IE Department

• Maintenance

• Warehouse

B. Administration and other departments

 • CEO Office

• Accounts Department

• HR Department

• Medical Room

• Training Department

• Conference Room

• Reception

• Generator, Boiler, Compressor and other utilities Room

• Security Room

• Toilets

• Parking

Statement of the study: To prepare a plant layout for a jumpsuit

manufacturing unit with a capacity of 1500 JUMPSUIT per day.

Objective: Preparation of a layout plan for a JUMPSUIT manufacturing unit.

Need of the study: Designing an efficient layout helps a lot in reducing the
time taken by the material to travel in the department.

It helps in:  Optimum flow of the material through each department

  Efficient operation of the various related processes. Increase in efficiency.
Introduction

 The design of a process plant is a complex activity that will usually involve many
different disciplines over a considerable period of time.

 The design may also go through many stages from the original research and
development phases, through conceptual design, detailed process design and
onto detailed engineering design and equipment selection.

 Many varied and complex factors including safety, health, the environment,
economic and technical issues may have to be considered before the design is
finalized.

 At each stage it is important that the personnel involved have the correct
combination of technical competencies and experience in order to ensure that all
aspects of the design process are being adequately addressed.

 Evidence of the qualifications, experience and training of people involved in

design activities should be presented in the Safety Report to demonstrate that the
complex issues associated with design have been considered and a rigorous
approach has been adopted.

 The process design will often be an iterative process with many different
options being investigated and tested before a process is selected. In many
occasions a number of different options may be available and final selection may
depend upon a range of factors. Factors considered for layout construction

A. Movement This factor includes inter and interdepartmental transport and

handling at various operations, at storage, at inspections, the type of
equipments and methods for material handling. This remains the most
important factor while deciding upon the selection of layout and utilization
of available land. The various support departments are planned such that
they are near to their requisite sections of the plant, so that lesser material
handling takes place as well as time is saved. The material handling
equipments are selected and designed as per department’s requirement
and interdepartmental movement
 . B. Product This factor includes type of product, the range and variety it
covers, the quantity in a shift, the number of shifts, necessary operations
and their sequence. The product to be made is high quality dress jumpsuit
for export. There are various variations of the dress jumpsuit which have
been covered while selecting the type of machinery. The operation
breakdown was done along with the time study and the final sequence of
operations is decided by elimination of unnecessary operations.
C. Machinery This factor includes the process, production equipments /
furniture type, special precautions to be taken, tools - their utilization and
service net-work related to the same. During selection of machinery, the
type, productivity, price and service provided by the supplier was kept in
mind, so that no hassles are met in future. D. Waiting This factor includes
permanent and temporary storage and delays and their locations. The
stores and warehouse are planned such that there is minimum amount of
material handling happening between various departments and the
store/warehouse. Proper amount of inventory storage capacity is planned
so that inventory cost never goes higher.

Steps in facility design

1. Procure the basic data

a) Sales forecast

b) Quantity to be produced

c) Production schedule

d) Inventory policy

e) Production

f) Operations to be performed

g) Production time standards

h) Scrap percentages

2. Analyze the basic data Above data is analyzed by the designer to determine
the desired interrelationships and then preparing for subsequent planning steps.
Assembly charts give a quick and early glimpse of the possible flow of materials.
 3. Design the production process The next is to decide how the raw material
would be converted to final part or product. Herein the production engineer
designs an OPERATION SHEET or PRODUCTION ROUTING, which is the tabulation
of the steps involved in the production of a particular part and necessary details
on related items. Information on routing may include: i. Part names and number
ii. Operation numbers and sequence iii. Operations name and descriptions iv.
Machine names and numbers v. Production standards vi. Number of operators vii.
Space requirements viii. Material With the above information along with the
Assembly chart, an OPERATION PROCESS CHART is constructed, which provides a
better impression of the potential material flow pattern.

4. Plan material flow pattern Overall material flow pattern must be carefully
designed to assure minimum movement and expeditious interrelation of the
several components –part flow paths. Assembly chart and production routing
along with data on quantity and frequency of material movement, a preliminary
material flow pattern should be developed, which is then worked upon keeping in
mind the factors affecting material flow to reach to a finalized pattern of flow of
material in a particular unit. Flexibility for future expansion or any changes 5.
Consider general material handling plan

 The material handling system converts the static flow pattern into a dynamic
flow of material through the plant

.  The ideal system consists of an integrated combination of methods and

effective methods of performing every handling task- from unloading of material
to shipping of the final product. This involves both manual and mechanical
methods.

 Detailed handling methods should only after individual work stations have been
planned. 6. Calculate the equipment requirements

 Any layout is incomplete w/o estimation of how many pieces of each type of
equipment (manufacturing, service and auxiliary) will be required.

 Preliminary requirement has been made while tabulating production routing.

Here final decisions must be made as to the quantity of the equipment as a basis
for planning individual workstations and planning space requirements for each
activity area.
 Also the number of operators must also be determined.

 If final decisions regarding above , have not been made, at least an estimation
should be available.

7. Plan individual work areas

 At this point, each operation , work station , area , process etc. must be planned
in detail.

 The interrelationships between machines, operators and auxiliary equipment

must be worked out.

 Each workstation must be tied into the overall flow pattern and flow through
each work station must be planned as an integral part of the overall plan. 8. Select
the specific material handling equipment Specific methods of material handling
must be decided upon for each move of material or item. Many factors need to
need to be considered in the selection of handling methods. 9. Coordinate the
group of related operations Once the workplaces have been designed,
interrelationships between the work areas, related group of operations or
activities should also be planned. LAYOUT PLANNING CHART is a useful technique
at this point.

10. Design activity relationships Production activities need to be inter-related with

auxiliary and service activities with respect to the degree of closeness required by
material, personnel and information flow.

11. Determine the storage requirements

 Plans should now be crystallized in terms of storage of raw material, WIP and
finished products.

 Square foot and cubic foot requirements should be calculated , with thought
also given to the location of the storage areas in the layout.

. Randomized storage When an individual SKU can be stored in any available

storage location. The closest available slot is designated as storage location 2.
Dedicated storage When a SKU is assigned to a specific storage location or a set of
locations. Fixed slot is defined.
12. Plan the service and auxiliary activities (Administration, transportation and
storage)

 A look at the plant service area planning sheet shows the complexity of this step

.  Depending on the size of the plant all of the service activities must be carefully
studied, in order to determine which are needed

.  Later, during the space planning and final design aspects of the planning, the
details of many of these service activities must be worked out.

13. Determine space requirements

 At this stage, a preliminary estimate of the total space required for each activity
in the facility can be made and cumulatively, designer can arrive at a first estimate
of the total area.

 Production space needs are estimated with the aid of a production space
requirement sheet.

 Space determinations made at this stage are estimates. So these are on a little
higher side to ensure there is sufficient area. Only the final layout will show
accurately the total space needs.

14. Allocate activity areas to total space

 The total space requirement work sheet provides for an area template for each
activity listed

.  Activity relationship diagram is helpful in determining the relationships b/w the

different area templates.

 Then an Area Allocation Diagram can be made based on the above, which
depicts the inter-relationships between the internal flow of materials and the
external flow-by means of various transportation modes.

 It will also depicts the relationship w/ surrounding facilities e.g. power plant,
parking areas, storage places and adjacent buildings.  A preliminary layout has
now been established.
 15. Consider building types Building type, construction, shape and number of
floors should be considered. Building usually comes after the layout. The layout
should never be squeezed into or altered to fit into a building, if it can be avoided
by designing a layout first. As imp a building might seem to be, it is the layout that
forms the basis for the efficient operation of an enterprise.

16. Construct the master layout This step is the culmination of the detailed work
and planning done in the preceding steps. Final Layout is prepared using
templates, tapes, etc. to a scale e.g. ¼” = 1 ft. Two dimensional or three
dimensional models are prepared.

17. Evaluate, adjust and check the layout with appropriate personnel No matter
how carefully or scientifically previous steps have been carried out, there are
always personal and judgmental factors to be considered. Facility designer and his
associates should check over their work at this stage before submitting it for
approval. Preliminary checks might also be made with others who have
contributed in designing the layout (production, methods, and personnel safety).

18. Obtain approvals In the final stages , the layout must be formally approved by
certain plant officials, depending on plant facilities and procedures

. 19. Install layout A layout designer should carefully supervise the necessary work
involved in the installation of the layout to make sure all work is done according
to the plans in the approved layout. Any changes, if desired, should be carefully
investigated and approved by the concerned authorities.

20. Follow up on implementation of layout Just because layout has been installed
as planned, there is no guarantee that will work as planned. No plant layout is
100% perfect and layout designer must continually take note of how the layout is
affecting the production operations. Scope should be improvement must always
be kept and incorporated if found desirable. 1. Procure basic data 2. Analysis Of
Basic Data a. Product Information b. Tech – Pack c. Factory Information

i. Foundation

ii. Location

iii. Electric Supply

iv. Nearness to Labor Supply v. Proximity to external Economies Of Scale vi.
Reputation Of Area

vii. Transport and Communication Services

viii. Government Support ix. Opportunities For Expansion

x. Development Agencies And Inward Investment

xi. Building Typology xii. Construction Details xiii. Description Of Floors

xiv. Area Of Factory- Department-wise

xv. Government And Industry Compliances

3) Design production process The production process of various sections

involved in the production process is designed using the analyzed data along with
the consultation with concerned experts and consultants The next is to decide
how the raw material would be converted to final part or product. Herein the
production engineer designs an OPERATION SHEET or PRODUCTION ROUTING,
which is the tabulation of the steps involved in the production of a particular part
and necessary details on related items. Information on routing may include

: i. Part names and number

ii. Operation numbers and sequence

iii. Operations name and descriptions

iv. Machine names and numbers

v. Production standards

vi. Number of operators

vii. Space requirements

viii. Material.

Material Flow Pattern

• Receipt of palletized fabric to store: Palletized fabric is received at the unloading
dock and is transferred to the fabric store through the articulated fork lifter
. • Issue of fabric to cutting section: The required amount of fabric is issued to the
cutting section through fork lifter or the power pallet truck as per requirement.

• Transfer of cut parts to parts section: The cut parts are transferred to the parts
section through a vertical trolley system. The cut parts would be lifted by the help
of a trolley to the parts section from where it would be fed to the respective lines.
In the parts section, material is handled via bins, or racks as per requirement

. • Transfer of panels to assembly section: From parts to assembly garments are

transferred through use of various bins, racks or trolleys. And in the assembly
section, garment panels move on a mover system.

• Transfer of garments to finishing section: Garment is transferred to the

finishing section through the stairs using gravity. There would be slider provided
in the stairs for easy movement of the bins on the stairs. In the finishing section
garments will move on mover system and racks

. • Transfer of packed garments to warehouse: The packed and/or palletized

cartons are transferred to the warehouse through the articulated fork lifter or the
power pallet truck.

• Shipment of palletized cartons: Eventually palletized cartons are shipped and

loaded in the container at the dock with the help of fork lifter and the power
pallet truck.
5) Material flow pattern plan Specific methods of material handling
must be decided upon for each move of material or item
. Many factors need to need to be considered in the selection of handling
methods. Material handling equipment is selected based on the requirement with
consideration for various factors like cost, service etc. Progressive bundle system
(PBS)  The progressive bundle system (PBS) gets its name from the bundles of
garment parts that are moved sequentially from operation to operation.
 Bundles consist of garment parts needed to complete a specific operation or
garment component.

 Bundles are assembled in the cutting room where cut parts are matched up with
corresponding parts and bundle tickets.

 The sewing operations are laid out in sequence . Each operator receives a
bundle , does his work , re-ties the bundle and passes it to the next operator .

 There is usually a storage facility such as rack, bin or table for storing the
interprocess work between each operation. The work is routed by means of
tickets

.  Any imbalance in production can be corrected by using utility workers . It is

used in jumpsuit factories, jeans factories , jacket factories, etc Advantages

 Operators perform the same operation on a continuing basis, which allows

them to increase their speed and productivity.

 This system may allow better utilization of specialized machines, as output from
one special purpose automated machine may be able to supply several operators
for the next operation

1. Material Characteristics

2. Move Requirements

3. Method (Equipment)
Capabilities There are various kinds of equipments available for material handling.
Since the type of equipment will materially affect the layout, the layout planner
should be familiar with the characteristics and capabilities of each type. Usually
the best, most economical and most efficient handling is accomplished by an
integration of different types of handling equipments. For the selection of specific
material handling equipments following points should be checked:  Cost of the
equipment delivered and installed complete with power and fuel facilities  Cost
of operation  Cost of maintenance  Ability to do a specific job  Safety aspect of
material and operator  Effect on working conditions  Dependability of
performance A sound approach to the problem of selecting the most suitable
material handling system for a plant layout must take into consideration not only
the engineering aspects of the handling system but also the economic appraisal of
the various material handling systems that lend themselves to the job to be
performed. A) Storage and handling equipment Storage and handling equipment
is a category within the material handling industry. The equipment that falls
under this description is usually non-automated storage equipment. Products
such as Pallet rack, shelving, carts, etc. belong to storage and handling. Selective
pallet rack is an example of storage and handling equipment. B) Engineered
systems Engineered systems are typically custom engineered material handling
systems. Conveyors, Handling Robots, AS/RS, AGV and most other automated
material handling systems fall into this category. Engineered systems are often a
combination of products integrated to one system. Many distribution centers will
optimize storage and picking by utilizing engineered systems such as pick modules
and sortation systems. Equipment and utensils used for processing or otherwise
handling edible product or ingredients must be of such material and construction
to facilitate thorough cleaning and to ensure that their use will not cause the
adulteration of product during processing, handling, or storage. Equipment and
utensils must be maintained in sanitary condition so as not to adulterate product.
C) Industrial trucks Industrial trucks usually refer to operator driven motorized
warehouse vehicles, powered manually, by gasoline, propane or electrically.
Industrial trucks assist the material handling system with versatility; they can go
where engineered systems cannot. Forklift trucks are the most common example
of industrial trucks but certainly aren't the extent of the category. Tow tractors
and stock chasers are additional examples of industrial trucks. D) Bulk material
handling Bulk material handling equipment is used to move and store bulk
materials such as ore, liquids, and cereals. This equipment is often seen on farms,
mines, shipyards and refineries Different types of material handling equipment
can be: Trolleys, Bins, Pallet, Guides, Conveyor, Fork Lifters, Pallet Truck, Order
Pickers, Manual handling system etc.

We are here discussing the equipments our company uses :- Features and
Benefits of Industrial Trolleys

Powder coated with durable non-slip industrial quality vinyl mats or lipped
metal surfaces

 Fitted quality non-marking wheels and castors

.  All industrial trolleys come standard with castor mounting plates. Castors
are bolted to these castor mounting plates to allow for ease of castor
replacement, or to allow for changes to castor arrangement.

 Available in a large range of models with ability to customise on large orders

Trolleys and Materials Handling Equipment Product Range

:  Custom Made Trolleys

 Platform Trolleys  Imported Trolleys  Hand Trolleys and Dollies

 Hand Trucks

 Panel Carts

 General Cleaning Equipment

 Plastic Containers

 Ladders

 Stackers  Scissor Tables  Guard Rails

 Lifting and Handling Equipment

 Pallet Trucks  Wheels and Castors

 Conveyors Some salient features of storage bins are:  Made from

Polypropylene Copolymer.  Strong rear lip for use with louvered panel. 
Strong heavy duty with reinforced base, sides and stacking rim.  Resistant to
most industrial solvents and withstands high temperatures.

 Clear access to contents.

 All bins with identification card holders.

 Incorporates a safety stop feature at the back for use in shelves

 Features like bin dividers, louvered panels, shop floor trolleys and rotary
stands are also available.

. Determine the storage requirements

 Fabric Storage Area Calculation:

 Rolls to be stored in palletized form


 Inventory of 12 days

ASSUMPTIONS

Aisle space between racks = 1 m

Main aisle = 1 m

Roof Height = 15 m

Average fabric consumption per shirt = 2.5m

Total production per day = 1500 shirts

Total fabric required per day = 1500 * 2.5 = 3750 m

Total consumption of fabric for 12 days inventory = 3750 * 12 = 45,000

Roll Data:

Total yardage = 120 m

Roll diameter = 7 inches

Roll height = 62 inches

Roll weight = 25 Kg

Pallet Data:
Wooden Pallet Weight = 20 Kg

Length = 62 inches

Width = 62 inches
 Height = 5 inches

Total rolls in a pallet = 102 rolls (Rows = 14, Columns = 8)

Final Height of palletized rolls = 56 inches

 Weight of one pallet = 56* 20 + 20 =1140 Kg (It can sometimes go up to

maximum of 1500 Kg)

 Total yardage of fabric in one pallet = 56 * 120 m = 6720 m (It can be maximum
of 7000m)

 One block of the rack will be having: Length = 62 inches + 6 inches (allowance)
= 68 inches Height = 56 inches + 6 inches (allowance) = 62 inches Depth = 62
inches

 Rail Girdles on all sides = 3 inches

 Ground clearance = 3 inches

 Roof Clearance = 1 feet = 12 inches

Conclusions

• Total number of pallets for storing = 25 pallets

• Max rack height = 7 m = 23 feet = 275 inches (But 7.5 m height racks to be made, so

that smaller size pallets can be stored there)

• In the single block of a rack, 1 pallet needs to be stored. Total blocks required
= Number of pallets

• In one column, we will have 4 blocks.

• Total no of columns= 50
• In a row, we will have 10 such columns.

• Total no of racks = 5

• Total minimum height consumed = 266 inches

• Length of racks = 18m

Other equipments in a store are: Fabric inspection m/c = 2 (7 feet x 6 feet x 2)

• Fabric inspection table = 1 (10 feet x 6 feet)

• Fabric inspection machines = 1 (5 feet x 7 feet)

• Lab = 1 (125 sq feet) Office = 1 (125 sq feet)

• Articulated Fork Lifter = 1

Warehouse Area Calculation (Palletized Cartons

ASSUMPTIONS

• Dimension of a carton = 60 cm x 40 cm x 30

18 JUMPSUITs per carton

• Peak Total Inventory = days

Roof Height = 8 m

• In a single pallet 18 cartons would be there (3*2*3)

• In a pallet, number of JUMPSUITS = 18* 18 = 324

• Aisle space between 2 racks would be 2 m for the movement of fork lifter.

• The main aisle of 3.5 m

• Rail Girdles on all sides = 3 inches

• Ground clearance = 3 inches

• Roof Clearance = 1 feet = 12 inches

Pallet Dimensions:

• Total number of shirts in 12 days = 450000 JUMPSUITS

Total no of cartons in warehouse at a time = 1,
45,000/18 = 2500 cartons.

• Total no of pallets to be stored = 2500/18 = 140 pallets

• Racks dimension:

Length = 14 m Breadth = 0.9 m Height = 1m Total Height = 7m

• Length = 1.8m

• Width = 0.8m

• Height = 1.0m

• Total production per day = 1500 lm

12. Plan the service and auxiliary activities

 13. Determine space requirements

DEPARTMENT DESCRIPTION:

DEPARTMENTS TOTAL AREA REQUIREMENT

REQUIRED (sq ft) MANPOWER

HR Department 700 4

General Admin 200 1

Export Import Department 255 2

Financial Department 255 3

Merchandising & Sourcing 820 7

Reception 100 1

Fabric store, Inspection 1440 7

Trim store 247 3

Cad department, Spreading 2250

Cutting department, Cad 23

Sewing department 3000 226

Quality 200 9

Planning 200 2

Meeting 100 -

Finishing 1350 27

Washing 375 7

Maintenance department 300 5

Industrial engineering 400 7

Warehouse 983 5

Crèche 225 1

Dispensary 150 1

Cutting department cabin 100 1

Production department cabin 100 1

Kitchen 80 1
 Sampling 720 13

Training 630 3

conference room 620 -

Ground Floor toilet 278 -

First Floor toilet 178 -

Ground Floor Lift &First Floor 182 -

First Floor Aisle 1446 -

Ground Floor Aisle 1460 -

HR DEPARTMENT

  Area Required: 35*20 =700 Sq Ft

 Man Power required

 
 1 HR manager

 
 2 HR Persons

 
 1 Helper

 1 Cabin for HR manager of 10*10

Furniture Quantity Dim( Ft) Area Req (Sq Ft)

Table 1 4*3 12

Chair 7 1*1 7

Almirah 4 3.5*3 42

Cube 1 10*10 100

162

Equipment Quantity Dim Area Required( Sq

Ft)

System 3 - -

Printer 1 - -

Scanner + photo 1 3*3 9

State

9
General Admin
 CEO Cabin of dimension 20*10=200 Sq Ft

FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Table 1 4*3 12

Chair 3 1*1 3

System 1 - -

15
 Export Import Department

  Area Required : 17*15 = 255 Sq Ft

 Man Power Required

 
2 person

FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Table 2 4*3 24

Chair 3 1*1 3

System 2 - -

Almirah 1 3.5*3 10.5

35.5

FINANCIAL DEPARTMENT

  Area Required : 17*15= 255 Sq Ft

 Man Power Required

 
 1 Head

 
2 Account







 FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Table 4 4*3 48

Chair 4 1*1 4

System 3 - -

Almirah 1 3.5*3 10.5

62.5

MERCHANDISING & SOURCING DEPARTMENT

a) Merchandising

  Area Required : 20*10 +20*31=820 Sq Ft

 Man power required

 
 1 Head

 
 2 Merchandiser

 
 1 Helper

 Cabin for Head of 10*10 Sq Ft

 FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Table 1 4*4 16

Chair 4 1*1 4

System 4 - -

Almirah 2 3.5*3 21

Cube 1 10*10 100

Hanger Stand 2 10*3 60

201

b) SOURCING DEPARTMENT

 Man power required

 
 2 sourcing Persons

 
1 Helper

FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Chair 4 1*1 4

System 3 - -
 Almirah 4 3*22 284

Table 2 4*3 24

RECEPTION

  Area Required: 10*10= 100 Sq Ft

 Man Power Required

 
1 Receptionist

FURNITURE/EQUIPMENT Quantity Dim (ft) Area Required

(Sq Ft)

Chair 1 1*1 4

System 1 - -

Sofa 1 10*5 50

Table 1 3*5 15

71

FABRIC STORE& INSPECTION

  Area required = 72 X 20= 1440 sqft

 Man power requirement

  
1 Head

 
 2 Data entry Persons

 
 2 Inspection Persons

 
2 Helpers

Furniture Quantity Dim (L*B)(in ft) Total area req. (sq

ft)

Table 3 4*3 36

Chair 7 1*1 7

Racks 10 6*3.3 198

241

Equipment Quantity Dim(L*B*H) (in Ft) Total area

Req(Sq Ft)

Trolley 2 3*4.5 27

Weighing Machine 1 3.2*1.6 5.12

Inspection Machine 1 7*4.6 32.2

Color matching 1 13.12*13.12 172.5

cabinet

236.56

TRIM STORE

  Area required = 19 x 13 sqft

  Total Area = 247 sqft

 Man power requirement

  
1 In-charge

 
 1 inspection person

 
1 Helper
 Furniture Quantity Dim (L*B*H)(in ft) Total area req. (sqft)

required

Racks 10 5*2*6 100

Table 1 4*4 16

Chair 1 1*1 1

Stools 3 1*1 3

120

CAD DEPARTMENT, CUTTING DEPARTMENT& FUSING DEPARTMENT

 Area required = 75 x30 sqft
  Total Area = 2250 sqft

 Man power requirement

  
1 In-charge

 
2 person

MACHINES NO. OF M/CS Dim (L*B*H)(in ft) Total area req.(sqft)

PLOTTER 1 7.36*2.15*3.83 15.82

Digitizer 1 3.91*5.90 23.08

38.9

Furniture Quantity required Dim (L*B*H)(in ft) Total area req .(sqft)

Table 2 4*4 32

Chair 4 1*1 4

Almirah 1 3.5*3*6.5 10.5

System 3 -

46.5

CUTTING DEPARTMENT

  Man power requirement

  
1 In-charge

 
 4 Spreader

 
 3 Cutter

 
 2 Ticketing

 
 2 Bundling
  
 2 Fusing

 
 2 helper

 
1 person for data entry

MACHINES No. of m/cs Dim (L*B*H)(in ft) Total are

required(sqft)

Straight Knife 3 -

cutter

Band Knife Cutter 1 7.49*4.89 36.62

Die Clicker 1 -

Fusing machine 1 7.38*2.78*4.0 20.57

57.19

Furniture Quantity Dim (L*B*H)(in ft) Total are

required required(sqft)

Spreading/cutting 3 10*5*3 150

Table

Table 1 4*4 16

Chair 3 1*1 3

Racks 5 4*2*6 40

Almirah 1 3.5*3*6.5 10.5

219.5
 SEWING DEPARTMENT:

  Area required = 75 x 40 sqft

  Total Area = 3000 sqft

 Man power requirement

  
1 In-charge

 
 4 supervisor

 
221 workers

Machines No. of m/cs Dim (L*B*H)(in ft) Total area

required(sqft)

SNLS W/UBT 30 6.18 185.4

SNLS WE/C 4 6.18 24.72

FOA 1 6.30 6.30

KANSAI 1 6.30 6.30

222.72

Furniture Quantity Dim (L*B*H)(in Total area

ft) required(sq ft)

Pressing Tables 2 3*5 30

End Line Inspection 4 7*3 84

tables

Trolleys 5 5*2 50

164
 QUALITY DEPARTMENT:

  Area required = 20 x 10 sq ft

  Total Area = 200 sq ft

 Manpower requirement
  
1 Quality manager

 
8 checker

Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 1 4*4 16

Chair 5 1*1 5

Almirah 1 3.5*3 10.5

31.5

INDUSTRIAL ENGINEERING DEPARTMENT:

  Area required = 20 x 20 sq ft

  Total Area = 400 sq ft

 Manpower requirement
  
1 In-charge

 
6 persons
 Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table (Head) 1 4*4 16

Chair 2 1*1 2

Table (Assistant) 1 4*4 16

Chair 2 1*1 2

36

MAINTENANCE DEPARTMENT:

  Area required = 20 x 25 sq ft

  Area required = 300 sq ft

  Manpower requirement

  1 In- charge

 4 person
 Furniture uantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 1 4*4 16

Chair 3 1*1 3

Almirah 1 3.5*3 10.5

29.5

PRE PRODUCTION:

  Area Required = 20 x 10 sqft

  Total Area = 200 sqft

 Manpower requirement = 2

Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 1 4*4 16

Chair 3 1*1 3

19

SAMPLING DEPARTMENT:

  Area Required = 40 X 18 sqft

  Total Area = 720 sqft

 Manpower requirement
  
1 Sampling Head

 
 1 Pattern master

 
 20 operator

 
1 cutter
 Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Pattern Table 1 5*4 20

Cutting Table 1 5*4 20

Stools 15 1*1 15

Almirah 1 3.5*3 10.5

SNLS W/UBT 12 6.18 74.16

SNLS WE/C 4 6.18 6.18

Button hole 1 6.18 6.18

Button Attach 1 6.18 6.18

FOA 1 6.30 6.30

KANSAI 1 6.30 6.30

Mini Boiler Cum 1 5*3 15

pressing

204.34
 TRAINING ROOM

  Area Required = 35 x 18sqft

  Total Area = 630 sqft

 Man Power Requirement

  
1 Training head
 
2 Trainers

Furniture Quantity Dim (L*B*H)(in ft) Area req.(sq ft )

Tables 1 4*4 16

Chair 23 1*1 23

Machines No. of m/cs Dim (L*B*H)(in ft) Total area required(sqft)

SNLS W/UBT 15 6.18 92.7

SNLS WE/C 3 6.18 18.54

FOA 1 6.30 6.30

KANSAI 1 6.30 6.30

123.84
 CONFERENCE ROOM:

  Area Required = 31x20 sqft

 Total Area = 620 sqft

Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 1 10*5 50

Chair 16 1*1 16

Maniquences 2

Meeting-

  Area Required = 10x10 sqft

 Total Area = 100 sqft

Finishing:-

  Area Required = 75x18 sqft

  Total Area = 1350 sqft

 Man power required:

  
1 In charge

 
 2 Spotter

 
 8 Thread cutter

 
 8 Pressing

 
 3 Checker

 
5 Packer
 Furniture/ Machine Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 4 8*4 128

Stool 8 1*1 8

Iron table 8 7*3 168

Thread Sucking 1 4*5 20

machine

Button hole 4 6.18 24,72

Button Attach 4 6.18 24.72

Stain Removing 1 8*8 64

Station

Needle Detector 1 3*2 6

Carton Packing 1 3*2 6

machine

Total 449.44

Washing:-

  Area Required = 25x15 sqft

  Total Area =375 sqft

 Man Power Required

  
1 In Charge

 
 4 Washer

 
2 Finisher

 Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Table 1 8*4 32

Washing machine 3 8*12 288

Dryer 1 5*7 35

Total 355

Kitchen

Area Required: 20*4 = 80 Sq Ft

Man Power Required: 1

CANTEEN

  Area Required = 50 x 30 sqft

  Total Area = 1500 sqft

 Man Power Requirement

 
5 person

Furniture Quantity Dim (L*B*H)(in ft) Area req. (sq ft )

Tables 10 10*3’*3 30

Stools 100 1*1*2 100

Serving Table 1 10*2*4 20

150

LAVENTRY:

Area required = 390 sqft

SECURITY DEPARTMENT:

  Area Required 10 * 10 = 100 Sq Ft

 Man Power Requirement

 
2 Security guard
 Furniture Quantity Dim (L*B*H)(in ft) Area req.(sq ft )

Tables 1 4*4 16

Chair 2 1*1 2

Almirah 1 3.5*3 10.5

28.5

BOILER ROOM:

 Total required Area = 200 sqft

GENERATOR:

 Total required Area = 300 sqft

Total Area Outside The main building occupied = 600 sq ft

 SUSTAINABLE PRACTICES

As part of an energy efficient optimization of factories, it is necessary to

extend the focus of planning and to consider the location, the design, the

integration into the environment and the potential of modern energy

efficiency.

The factories provides additional high saving potentials for the company.

Low emission production methods or resource efficient building practices

offer opportunities for integrated environmental factory design.

By examining the entire lifecycle of the manufactured product -- from the

conceptual design of the product through to its end-of-life -- rather than

simply the manufacturing process itself, enterprises will find ways to

compete successfully in his new operating environment.

Conceptual Design: When scoping a product design project based on

customer needs assessments, one should be able to consider the

environmental lifecycle costs associated with different conceptual design

options.

Detailed Engineering: This portion of the workflow happens once the

design team decides on form and function, and involves the sourcing of
motors and circuitry, general material selection, and internal structural

support of a form.