PLANT LAYOUT Assignment 01.

Submitted By:

Romisha Priyadarshini

Shivam kumar

Shivam Sagar

Tushar Tumsarkar
Basic Shirt

Machines
required for
making a shirt

 Plain (lock stitch) sewing machine

 Over lock/edge neatening sewing machine
 Flat lock machine
 Button holing machine
 Button attaching machine
 Feed of the arm m/c
Accessories used for making a shirt

 Fusible interlining
 Sewing thread (40/2 or 40/3 or 50/3): Matching color
 Label: Main label, size label, care label
 Button: Plastic or wooden or horn
 Motif
Trimmings used for making a shirt

 Neck board
 Back board
 Collar insert: Usually plastic
 Hang tang
 Tag ping
 Price tick
 Tissue paper
 Poly bag
 Butter flies, etc.

Individual parts of basic shirt:

 In the first case, yoke and body back part is of one piece of cloth.
 In two pieces and single yoke, a single yoke is attached with the body back part.
 When two pieces of yoke are attached with the body back part then it is put in
the third category, i.e. two pieces and double yoke.
 Process flow for shirt making

The manufacturing process of shirt starts from designing a shirt, sourcing of fabrics and
ends after selling the shirt to retailers.
Order Receiving Checking
Fabric and raw material Fabric and Trim

Stitching Cutting
Pattern making Production planning

Thread Trimming Pressing Dispatch Store Folding Tagging Packing

Quality Checking

Steps by step guide for order processing

Here are the steps to be followed for making shirts (from order receiving to shipment).
 Once receive the shirt sample with the order, analyze the garment and list down
all detailing (construction, workmanship, seam, fabric used, trims attached etc).
Estimate consumption of fabric and trims per garment.
 Make bill of materials (BOM) after receiving the order. Include all items in the
BOM.
 Source Fabrics and trims as per requirement.
 After receiving fabrics and trims, check for quality and quantity of sourced items.
Fabric and trims need to be checked as per specification (quality standards). For
the confirmation for fabric properties it needs to send fabric sample to the testing
labs. Test fabric shrinkage.
 Develop patterns for the style. Pattern grading to be done for different sizes.
Start bulk process
 Lay fabric on the table as per marker length. Cut multiple layers at a time to save
time in cutting.
 Make marker on the top layer. Cut fabric as per pattern. Cut quantity to be as per
size ratio in the in order. cut some extra garment for buffer. Like if some defective
or rejected garment are made in the following processes.
 Check cut panels randomly for fabric defects and cutting is done according to the
pattern.
 Make bundles of cutting (if required). Or feed complete layers to the sewing
operator.
  Set a group of tailors for stitching garments. Define sequence of the operations to
be followed by tailors. Sew garments maintaining stitching quality.
 Check stitching quality during sewing and at the end of sewing. Do correction of
defective garment found in the line. Repair work (alteration and part changing job)
can be done separately or by same tailors.
 Send stitched garment to finishing section. Trim uncut threads.
 Remove stains before pressing garments with steam iron (if stains are found in
garments). If needed wash garments for cleaning and removing stains and getting
wash effect.
Press garments
 Fold garments. Attach hang tags and price tags to garments. Pack garments into
poly bags. Pack garments according to customer requirement.
 Check finished and packed garment randomly for quality assurance.
 Store packed garments for shipping to your buyers.

List of operations involved in making shirt

Shoulder Join: Join the both shoulders using an overlock machine.

Neck rib tuck: Join ends of the rib using a lock stitch machine. Neck rib length should be
cut a per neck circumference. (A different method can be used for neck rib. In the
following, neck piping is done first. After attaching one shoulder, neck is closed. )

Neck rib join to neck: Fold the neck rib and attach to the neck. While attaching neck rib
stretch both neck and rib. Attach neck rib using overlock machine and top stitch using
lock stitch or chain stitch machine. Which machine to choose depends on the shirt
design. (In case of neck piping, it is done using Flat lock machine).

Label make: This process is optional. In case you have source main label/care label in
the roll form, cut it and keep ready for the following process. A single needle lock stitch
machine is used for this operation.

Front neck T/S: Top stitch the front neck using 2 needle flat lock machine

Back Neck T/S: Finish neck binding using a single needle lock stitch machine. While
finishing the back-neck tape/binding, attach the size label.
Sleeve Hem: Hem sleeve opening in the flat lock machine. (sleeve hemming is done after
underarm overlock).
Sleeve attach: Attach both sleeves at the armhole. An overlock machine is used to attach
sleeve.

Side seam with care label: Join side seams and under arm using an overlock machine.
Attach the wash care label, attach it left side of the garment, above 10 cm from bottom
hem.

Sleeve Tacking: Tack sleeve at the overlock stitch to secure the stitch. Use single needle
machine for this job.

Bottom Hem: At last hem the t-shirt bottom using a 2-needle flat lock machine.
Ground Floor

Material Flow
First floor
SECOND FLOOR
Terrace
Ground Floor

Manpower Flow
First Floor
Second Floor
Comment on material flow
Talking about the material flow in the said production unit, the cutting dept. is located on
the ground floor followed by sewing, finishing and packaging departments on all floors.
Even the storage racks for the finished goods are available on all floors. The material flow
seems quite impressive with the availability of storage racks on each floor at the end of
the product processing line. The aim of continuous production flow is being maintained at
every point in the facility. The preparatory processes are being followed by UHS (unit
hanger system) assembly line which goes hand in hand for the continuous and
uninterrupted flow of material and work in progress.
However, the placement of cutting, bundling and ticketing sections at the ground floor
makes the task of cut pieces movement to upper floors a bit difficult to evaluate in terms
of feasibility however numerous lifts are available in the facility which supports the flow of
material and manpower.
The loading and unloading section at the end of ground floor just beside the fabric and
other raw materials storage is again a positive side in terms pf material flow in the setup.
Talking about the whole of the setup, the material flow is U-Shaped with small
customizations. However, it’s a well-organized setup and space allotted for activities are
fair enough. A major fault in the material flow can be sought by looking at the inter floor
material flow as the cutting section end its process in the opposite direction to that of the
lift which will facilitate the material movement on inter floor levels. Also, the preparatory
processes starting at the individual floors start at the opposite end of the facility to that of
the lift facilitating the material movement. So, in this way the materials need to be
transported at multiple times which is of no use in terms of quality and would be a waste
of manpower, and time.

Synchronization with external transport

Talking about the synchronization of the setup with external means of transport, both the
loading and unloading sections are located besides the fabric store on the ground floor.
This goes well with the inward material flow. However, the same is not so with the loading
section for finished goods as, it is also located beside the raw fabric store and it is a bit
far away from the finished goods racks, be it on any floors. Also, the finished goods need
to be transported down the facility for outward movement of materials. The lifts facilitate
the action but some manpower is required and hence it would be an unwanted but
necessary activity. It would be a necessary non value adding activity. However, two
different roads connectivity won’t be a feasible option hence this will have to go through.

Manpower movement
The manpower movement within the facility seems quite feasible as the layout has been
described in such a way that the inter department interactions can take place and the
more interrelated departments are related close to each other. Even the maintenance
department is available on each floor to lower the manpower movement and washroom
placement on each floor of the facility will lower the inter floor movement.
There is no extra movement for manpower and space allotted for activities makes it easier
for people to participate as per needs.
Fire exits and other related things are pretty good and well planned.
Overall, there is no extra manpower movement and it is all as desired

Strength and weakness of the layout

Strengths

 I shaped on floors and u shaped in total

 Process based layout leads to effective utilization of machinery and manpower
 Proper ventilation for kitchen in mess on terrace
 Effective use of terrace space with sunlight harvesting and mess facility
 Singular directional movement in tomes of breaks and emergency
 3 emergency exits in terms of staircase
 The creche facility and the medical rooms are available in the unit
 Washrooms on all floors and in multiple locations
 Lifts for manpower movement

Weakness

 Material movement for cut pieces from one end to other end for transportation
 Boiler room at ground level is hazardous in extraordinary situations as building is
above that and any mistake would be deadly.

Area calculation:
Ground floor:
Total floor area of ground floor: 3798.00 sq meters

Total area used on ground floor: 2800 sq meters

Finishing Dept. 195 sq meters

Laying and Cutting: 934 sq meters

Trims storage: 92 sq meters

Packing and ironing 91 sq meters

Inspection and checking: 46 sq meters

Finishing storage and other activities: 180 sq meters

Quality lab: 18 sq meters

Maintenance Room: 30 sq meters

Compressor: 24 sq meters

Main panel Room: 24 sq meters

Boiler Room: 34 sq meters
DG room: 60 sq meters
UPS room: 5.5 sq meters
Warehouse: 668.16 sq meters
Loading/unloading area: 210 sq meters
Washroom: 17 sq meters
Medical: 27 sq meters
Creche: 88 sq meters

First floor:
Total floor area: 2691.30 sq meters
Total floor area used: 1666.3 sq meters
Pantry: 116 sq meters
Quality Cabin: 133 sq meters
Parts preparation: 696 sq meters
Assembly Line: 301.04 sq meters
Trim Check: 9.68 sq meters
Finishing: 120 sq meters
Packaging:70.74 sq meters
Finishing Storage: 48.18 sq meters
Trims store: 1.88 sq meters
Audit table: 24 sq meters
Trims Store: 32 sq meters
Toilet: 56.55 sq meters

Second Floor:
Total floor area: 2691.3 sq meters
Total floor area used: 1683.4 sq meters
Pantry: 116 sq meters
Training Centre: 130.77 sq meters
Preparatory process: 696 sq meters
Assembly line: 301.04 sq meters
Trims check: 9.68 sq meters
Finishing and folding: 120 sq meters
Packaging: 70.74 sq meters
Carton racks: 48.18 sq meters
Trims storage: 32 sq meters
Audit table: 24 sq meters
Toilets: 56.55 sq meters

Terrace:
Total area: available: 1339.5 sq meters
Sunlight harvesting: 838.71 sq meters
Canteen and mess: 955.36 sq meters

Total area calculation:

Total floor area of unit: 11871.00 sq meters
Storage facilities: 922.4 sq meters
Cutting section: 934.00 sq meters
Packing section: 232.48 sq meters
Sewing preparatory: 1392 sq meters
Sewing assembly: 602.08 sq meters
Finishing Dept.: 663 sq meters
Quality: 216.36 sq meters
Maintenance: 67.42 sq meters
Canteen and mess: 955 sq meters
Solar harvesting: 838.71 sq meters
Personal space including creche, medical, washroom training etc.: 607.87 sq meters

Area calculation for departments: (in %age)

Storage: 922.4 sq meters (7.77%)

Cutting:934.00 sq meters (7.86)

Sewing: 1994.08 sq meters (16.79%)

Quality: 216.36 sq meters (1.82%)

Finishing and packaging: 895.48 sq meters (7.54%)

Canteen and mess facilities: 955 sq meters (8.04%)

Solar harvesting: 838.71 sq meters (7.06%)

Personal space: 607.87 sq meters (5.12%)

Sampling Department :472.1840 sq metres (3.977%)

Stairs Area: 119.91 sq metres (1.01%)

Lift Area:40.16 sq metres (0.33%)

Free Space: 7992.54 sq metres (32.68%)