Contents

Manufacturing Process................................................................................................................................2
CUTTING (2 Stations)............................................................................................................................3
Yakan Fabric.......................................................................................................................................3
PP-Polypropylene................................................................................................................................3
SHAPING (2 Stations)............................................................................................................................3
Yakan Fabric.......................................................................................................................................3
PP-Polypropylene................................................................................................................................3
PINNING (1 Station)...............................................................................................................................3
SEWING (1 Station)................................................................................................................................3
FINISHING (1 Station)...........................................................................................................................3
QUALITY CONTROL............................................................................................................................3
STERILIZATION...................................................................................................................................3
PACKING...............................................................................................................................................4
Manpower Requirement..............................................................................................................................4
Workers for Each Station............................................................................................................................4
Administration Personnel............................................................................................................................4
PRODUCTION MACHINERY AND EQUIPMENT.................................................................................5
Cutting Stations.......................................................................................................................................5
Shaping Stations......................................................................................................................................5
Sewing Stations.......................................................................................................................................5
Manufacturing Process

Approximate amount of
Approximate amount of PP-Polypropylene (34
Yakan Fabric (50 Meters) Meters)

CUTTING CUTTING

SHAPING SHAPING

PINNING
Approximate amount of thread Approximate amount of elastic ear
(19 kg/spools) bands (144 meters of 5mm)

SEWING
432 Filter Valves

FINISHING

QUALITY
CONTROL

STERILIZATION

PACKING

YIELD: 500 facemasks per day.

 Direct Materials Yield
Yakan Fabric 1-meter yields 10 masks
PP-Polypropylene 1-meter yields 15 masks
Fabric Threads 1 kg/spool yields 27 masks
.
Elastic Ear Bands 1-meter yields 3 masks
Filter Valves 1 valve per mask

CUTTING (2 Stations)
Yakan Fabric
The Yakan fabrics are stacked together and then cut into rectangular shapes using a band
knife cutting machine.
PP-Polypropylene
Rolls of PP-Polypropylene fabric are unrolled and cut by into rectangular shapes by a
sheet fabric cutting machine.
SHAPING (2 Stations)
Yakan Fabric
The rectangular cuts of Yakan fabric are further cut into a different shape using a
standard mask shape template, this is done with the use of straight knife cutting machine.
PP-Polypropylene
The rectangular cuts of PP-Polupropylene are shaped into the standard mask shape
template using a straight knife cutting machine.
PINNING (1 Station)
In this station, the shaped Yakan fabric and PP-Polypropylene are pinned together. The
pins are pierced in the edges to facilitate easier and faster sewing.
SEWING (1 Station)
The pinned masks are delivered to this station using bulk boxes. In this station, the
pinned masks are sewed together and elastic ear bands are attached to the sides.
FINISHING (1 Station)
In this station, the filter valves are attached to each mask.
QUALITY CONTROL
In this station, the masks are examined by Quality Control Officers for defects. Once it
was assessed to pass standards, it is delivered for sterilization.
STERILIZATION
The masks are put through UV Mask Sterilization Machine.
PACKING
The masks are sorted into two types of packaging: individual packaging and by three’s
packaging. It is then loaded into boxes, there are boxes meant for individually packaged masks
and another type of boxes where by the grouped masks are loaded. After this, the boxes are then
delivered into the storage drawers.
Manpower Requirement
Workers for Each Station
Cutting Station 1 2 Shifting Workers
Shaping Station 1 3 Workers
Cutting Station 2 2 Shifting Workers
Shaping Station 2 3 Workers
Pinning Station 15 Workers
Sewing Station 9 Workers
Finishing Station 5 Workers
Quality Control Station 3 Workers
Sterilization Station 2 Operators
Packing Station 5 Workers

Administration Personnel
Operating Manager 2
Roaming Supervisor 3
Runners 23
Human Resource 2
Production Planning Scheduler 2
Accountant 1
Maintenance 3
Utility 15
Dispatch Department 4
Warehouse Personnel 3
Legal Department (Lawyer) 1

Total Number of Employees = 108 Employees

PRODUCTION MACHINERY AND EQUIPMENT
Cutting Stations
The Cutting Station 1 will have one band knife cutting machine. These machines are stationary
cutting machines, that possess fine blades that rotate through a slot in the cutting table while cutting. The
operator positions, controls, and guides the fabric block around the knife. The machine specification is
2340x1500x1620 mm.
The Cutting Station 2 will have one sheet fabric cutting machine. This machine is also stationary,
it unrolls non-woven fabric before it cuts it into sheets. The machine specification is 3000x1800x1500
mm.
Shaping Stations
Every shaping station will have 3 straight knife cutting machines, high speed machines. In the
case of straight knife cutter, machine is moveable but fabric is fixed. The machine specification is 8” x
12” x 20.5”.

Sewing Stations
In the Sewing Station, there will be 9 sewing machines in this station. The specification is
1192x487x763 mm for each machine.

Sterilization Station
A UV Sterilization Machine will be used to facilitate the sterilization process, the specification of
this machine is 2000x500x750 mm.