PLANT LAYOUT

JURY ASSIGNMENT

EDREA HIMANSHU SNEHITHA YAMINI

PROPOSED LOCATION FOR THE FACTORY

City Selected- Bangalore(Mahadevapura). The city is fast emerging as the

techno-savvy structured garment manufacturing center with the tag of
IT hub. City with sound base of latest technology and IT Systems for high
productivity. Besides technology city has advantage of skilled labor and
technical know how that this region has acquired over time.

Government Support: Recently government has offered support from the

Union Finance Ministry in the form agreement to provide an additional
Rs. 1,000 crore for the textile sector under the Technology Upgradation
Fund Scheme (TUFS) during the current financial year.
OUR LOCATION

Situated on the North-Eastern outskirts of

Bangalore City.

15 Kms from Bangalore City Railway

System.
73% literacy rate. (No problem in getting
Skilled Labor)
Major IT Hub.

MAHADEVAPURA, BANGALORE
OVERVIEW OF FACTORY

TYPE OF FACTORY MANUFACTURING UNIT

PRODUCTS MANUFACTURED DENIM JEANS

TYPE OF LAYOUT PRE FABRICATED

BUILDING TYPE SINGLE FLOOR

HEIGHT 15 FEET

Img-1 (Pre - fabricated structures)

AREA ALLOCATION

NAME DIMENSIONS

TOTAL AREA 422 feet x 305 feet = 2.9 Acres

FLOOR AREA 300 feet x 224 feet = 1.5 Acres

LIGHTENING SYSTEM

DEPARTMENT MINIMUM LUX

FABRIC & TRIMS STORE 300-500

CUTTING ROOM 500-1000

SEWING 750-1000

IRONING & PRESSING 300-500

Img2- Reference Image Sewing

FABRIC INSPECTION 1000-2000
DEPARTMENTS -
PRODUCTION RELATED ADMINISTRATION OTHER FACILITIES

Fabric Store HR Department Lavatory

Trims & Accessories store IT Department Store Room
Spreading & Cutting Room Finance Department Multipurpose Hall
Sewing Section Training Department Child Care Area
Washing Department Accounts Department Canteen
Merchandising Department Security Medical Rooms
Sampling Department General Manager Cabin
IE Department Deputy Manager Cabin
Warehouse
Quality Department
CAD Department
Maintenance
Finishing Department
Packing Section
TYPE OF FACTORY DENIM PANTS UNIT
FABRIC STORAGE
AMAZON DENIM

TOTAL QUATITY = 10,000

RATIO - 1: 1.5: 1.5: 1

SIZE REQUIRED QUANTITY

28 2000

30 3000

32 3000

34 2000
CALCULATION STYLE 1
Daily working hours = 8 hrs

SAM = 20.19

Daily Capacity. = 480* 52 / 20.19

= 1236.25
= 1236 Approx.

No.number of days = 10,000/1236

= 8.09 days
 Total fabric required
SIZE REQUIRED FABRIC( in mts)
FABRIC STORAGE
= 1.2 (2000) + 1.3(3000) + 1.4(3000) + 1.5(2000)

28 1.2 =2200+3900+4500+3400

=13,500meters
30 1.3

32 1.4 Adding 10% wastage = 13500 +1350

= 14850 meters
34 1.5
FABRIC ROLLS

Fabric width = 53 inches

length of each roll in Meters = 100

No. of rolls required. = 14850 / 100

= 148.5 rolls
= 150 rolls
LEVIS DENIM
TOTAL QUATITY = 15,000

RATIO - 1: 1.5: 1.5: 1

SIZE REQUIRED QUANTITY

28 3000

30 4500

32 4500

34 3000
CALCULATION - STYLE 2
Daily working hours = 8 hrs

SAM = 23.85

Daily Capacity. = 480* 58/ 23.85

= 1166.8
= 1167 Approx.

No.number of days = 15,000/ 1167

= 12.853 days = 13 days

FABRIC STORAGE
Total fabric required
SIZE REQUIRED FABRIC( in mts)
=1.2 (3000) + 1.3(4500) + 1.4(4500) + 1.5(3000)
28 1.2
=3600+5850+6300+4500

30 1.3 =20250 meters

32 1.4

Adding 10% wastage = 20250+2025

34 1.5
= 22275 meters
FABRIC ROLLS

Fabric width = 53 inches

length of each roll in Meters = 100

No. of rolls required. = 22275 / 100

= 222.75 rolls
= 225 rollS
RACKS CALCULATION
Assuming, there is 100 mtrs in 1 denim roll( diameter = 1 feet and roll length = 5 ft)

Rack size = 6*6 ft 4 Shelves per rack

Roll size - 1 ft* 5ft

5 rolls per shelf 5*4 = 20 rolls per rack

Total rolls required = 375 rolls

375/20 = 18.75 racks approx.

Total = 20 racks
COMPONENTS IN THE RAW MATERIAL WAREHOUSE

Dimensions - 139.7 feet x 60 feet

Racks to store the fabric = 20 Racks (6 feet x6 feet )

1 Fabric Inspection Machine ( 11 feet x 14.8 feet )

1 Fabric Relaxation Machine ( 11 feet x 14.8 feet )

Trolley for movement of Fabric ( 5.8 feet x 3.1 feet)

2 Trims Racks ( 30 feet x 6 feet )

SPREADING AND CUTTING
 FOR STYLE 1
SPREADING AND CUTTING
Fabric width = 53 inches

Since size 28 and size 34 has the same number of garments that has to be produced, they can be cut in a
single lay,

Each ply has 6 garments - 6 way marker

3 of size 28, 3 of size 34
Lay length = 3(1.2)+ 3(1.5) = 8.1 metres

Therefore number of garments per lay = 50*6=300

Therefore total number of lays required = 4000/300

= 10.1 = 13.3

= 14 approx.
Similarly , for size 30 and size 32 have the same number of garments that has to be produced, they can be cut in a
single lay,

Lay length = 3(1.3)+ 3(1.4) = 8.1 metres

Therefore number of garments per lay = 50*6 = 300 garments

Therefore total number of lays required = 6000/300

= 20 lays

Total number of lays to complete this order = 14+20 = 34 lays

Time available in one shift = 480 mins
Planned efficiency = 80%
Number of garments produced per day = 1236

Adding 5% garments = 1236 *0.05 +1236 =1297.8 garments

Average consumption = 1.35

Marker length = 8.1m
Marker way = 6
No of ply per lay = 50
No. of garments per lay = 300
No. of meters of fabric per lay = 405 meters.

Spreading and cutting sam per ply = 2.02

Total SAM to spread and cut one lay = 2.02 * 50 = 101 mins

No. of lays required per day = 1236/300 = 4.326

No. of lays possible per day = 0.08/101 = 3.801
Therefor no. of tables required = 4.326/3.801 = 1.1378 tables
 FOR STYLE 2

Fabric width = 53 inches

Since size 28 and size 34 has the same number of garments that has to be produced, they can be cut in a single
lay,

Each ply has 6 garments - 6 way marker

3 of size 28, 3 of size 34
Lay length = 3(1.2)+ 3(1.5) = 8.1 metres

Therefore number of garments per lay = 50*6=300 garments

Therefore total number of lays = 6000/300

= 20 lays
Similarly , for size 30 and size 32 have the same number of garments that has to be produced, they can be cut in a
single lay,

Lay length = 3(1.3)+ 3(1.4) = 8.1 metres

Therefore number of garments per lay = 50*6 = 300 garments

Therefore total number of rolls required = 9000 / 300

= 30 rolls

Total number of lays to complete this order = 20+30 = 50 lays

Time available in one shift = 480 mins

Planned efficiency = 80%
Number of garments produced per day = 1167

Adding 5% garments = 1167 *0.05 +1167 =1225.35 garments

Average consumption = 1.35
Marker length = 8.1m
Marker way = 6
No of ply per lay = 50
No. of garments per lay = 300
No. of meters of fabric per lay = 405 meters.

Spreading and cutting sam per ply = 2.02

Total SAM to spread and cut one lay = 2.02 * 50 = 101 mins

No. of lays required per day = 1225.35/300 = 4.0845

No. of lays possible per day = 0.08/101 = 3.801

Therefor no. of tables required = 4.0845/3.801 = 1.07 tables

Total tables required = 1.07 + 1.138 =2.208 = 3 tables approx

COMPONENTS IN THE SPREADING AND CUTTING -

Dimensions - 121 feet x 70 feet

3 Spreading and Cutting Tables - 100 ft x 8 ft

3 Spreaders and Cutters Respectively - Spreader ( 9 ft x 7 ft ) - Cutter (12.5 ft x 6.5 ft)

2 Fusing Machines - 20 ft x 7.2 ft

4 Racks to hold cut panels - 12 ft x 9 ft

3 Ticketing and Bundling Tables - 6 ft x 4 ft each

SEWING
SEWING ROOM

No: of operations in the sewing process in 1 line for style 1 ( Amazon denim) = 52 operations

SAM for the 52 operations in a line = 20.19

No: of machines required for 52 operations is taken as 52 machines approximately.

No. of working hours in a day = 8 hrs

Therefore the no: of garments produced per line= 8 X 60 X 52/20.19 = 1236

Target production at efficiency 75% = pieces/day = 927 Approx

Therefore, the no: of lines required = 1236/927 = 1.33 lines

For 2 lines,

No. of garments produced at 75% = 927*2/1.33 =1394

SEWING ROOM

No. of operations in the sewing process in 1 line for style 2 ( Levis denim) = 58 operations

SAM for the 52 operations in a line = 23.85

No. of working hours in a day = 8 hrs

Therefore the no: of garments produced per day= 8 X 60 X 58/23.85 = 1167

Target production at efficiency 75% = 1167 * 75% = 875 Approx

Therefore, the no: of lines required = 1167/875= 1.33 lines

For 2 lines,

No. of garments produced at 75% = 875*2/1.33 =1316

COMPONENETS IN SEWING DEPARTMENT
Single Needle Lock Stitch 36.00

Double Needle Lock Stitch 7.00

3 Thread Overlock with Thread Trimmer 10.00

Dimensions - 135 feet x 66 feet 5 Thread Overlock with Thread Trimmer 5.00

4 Sewing Lines
Bartack 4.00
4 End Line Check tables - 8 ft x 5 ft
Total Machines = 85 FOA 4.00

Total Tables 25 Single Needle Chain Stitch 6.00

Double Needle Chain Stitch 6.00

Single Needle Edge Cutter 3.00

Flatlock 4.00

TOTAL 85.00
WASHING
 NO: OF GARMENTS WASHED BY 1 MACHINE = 200 GARMENTS

200 GARMENTS HAS TO BE WASHED 3 TIMES

1. Desizing wash
2. Enzyme wash
3. Post wash

Each wash takes 40 mins , therefore for 3 washes = 120 mins

One batch takes 2 hours to wash which has a capacity to wash 200 garments

Therefore in a day no. of garments washed per machine = 200*4 =800 garments

Total no. of garments sewn in both styles = 2710

Therefore no of machines required to complete 2710 garments in a day = 2710/800 = 3.3875 = 4 machines
approx
WASHING DEPARTMENT
COMPONENTS -

Dimensions - 38 feet x 33 feet

4 Washing Machines - 8 ft x 5 ft each
1 Garment storing rack - 12 ft x 9 ft
Washing Officer Cabin - 12 ft x 10 ft
FINISHING
 OPERATION
BULLETEIN FOR
FINISHING
FINISHING CALCULATION
BUTTON ATTACHMENT
SAM = 0.20
Total time taken to attach button for 553 garments = 0.20* 533 = 110.6= 139 mins = 2.31h
so, no of table required = 1

RIVET ATTACHING
SAM = 0.52
Total time taken to attach button for 553 garments = 0.52* 697 = 362.44 = 362 mins = 6.04 h
so, no of table required = 1

LEATHER PATCH ATTACH

SAM = 0.50
Total time taken to attach button for 533 garments = 0.50* 697 = 348.5 = 349 mins = 5.80 h
so, no of table required = 1
FINISHING
LOOP CUTTING
SAM = 0.32
Total time taken to attach button for 697 garments = 0.32* 697 = 223.04 = 223 mins = 3.71 h
so, no of table required = 1

OUTSIDE TRIMMING
SAM = 0.85
Total time taken to attach button for 697 garments = 0.85 * 697 / 2 = 296.225 = 296 mins = 4.93 h
so, no of table required = 1

OUTSIDE CHECKING
SAM = 0.56
Total time taken to attach button for 697 garments = 0.56* 697 = 390.32 = 390 mins = 6.50 h
so, no of table required = 1
FINISHING
RAW EDGE
SAM = 0.
Total time taken to attach button for 697 garments = 0.32* 697 = 223.04 = 223 mins = 3.71 h
so, no of table required = 1

DUSTING
SAM = 0.85
Total time taken to attach button for 697 garments = 0.85 * 697 / 2 = 296.225 = 296 mins = 4.93 h
so, no of table required = 1

INSIDE TRIMMING
SAM = 1.09
Total time taken to attach button for 697 garments = 1.09 * 533= 580.97 = 581 mins = 9.68
so, no of table required = 9.68/8 =1.21 = 2 Approx.
FINISHING DEPARTMENT COMPONENTS
Dimensions - 66 ft x 34 ft
Stain removing m/c - 1 no. (48" X 24"')
2. Checking tables - 1 no. (60" X 48")
3. Thread sucking machines - 1 no. (4 X 4')
4. Rivet attaching machine - 1 no. (2X3')
5. Button attaching machine - 1 no. (2X3')
6. Ironing tables - 3 nos. (52" X 32")
7. Folding tables - 2 nos. Dimensions - 60" X 48"
8. Packing tables - 2 nos. Dimensions - 60" X 48".
9. Packaging material storage - One rack adjacent to each folding/packing table. (2' X 2' X 3')
PACKING
 OPERATION
BULLETEIN FOR
PACKAGING
PACKING CALCULATIONS -

Daily capacity = 12*480/1.2 = 4800

Target production at efficiency 75% = 3600

No of lines = 4800 / 3600 =1.33

for 1 line , 3600 / 1.33 = 2706.76 = 2707 garments

To pack 2710 garments as per finished per day

2710/2707 = 1.001 = 1 line

PACKING DEPARTMENT COMPONENTS
LAYOUT OF OTHER DEPARTMENTS

CANTEEN
Dimensions - 110 ft x 20 ft
LAYOUT OF OTHER DEPARTMENTS

LAVATORY
2 Lavatory - 51 ft x 17 ft each
LAYOUT OF OTHER DEPARTMENTS

HR & ACCOUNTS

Dimension - 24.7 ft x 16 ft
LAYOUT OF OTHER DEPARTMENTS

RECEPTION

Dimension - 21.5 ft x 18 ft
LAYOUT OF OTHER DEPARTMENTS

Dimension - 25 ft x 15.7 ft
LAYOUT OF OTHER DEPARTMENTS

GM CABIN
Dimension - 25 ft x 15.7 ft
ELECTRICAL CALCULATION -
 OUR GOAL FOR A SUSTAINABLE PLANT

FERROCK- Ferrock is made from waste steel dust and silica from ground up
glass, which when combined and reacted with carbon dioxide produces iron
carbonate, which binds carbon dioxide from the atmosphere into the Ferrock.
Ferrock is made up of approximately 95% recycled materials. Ferrock is both
stronger and more flexible than standard Portland cement, allowing it to be
used in highly active environments where seismic activity is a concern. It is
cheaper because it is sourced from waste materials

HEMP CRETE- It is a bio-composed material that can be use as an alternative

to concrete. It is made up of wood-like core of sativa plant. Hemp Crete bricks
are lightweight, fireproof and work as an excellent insulators. They even lock
up carbon dioxide.
OUR GOAL FOR A SUSTAINABLE PLANT

LOCATION WISE-
Mahadevapura is not an environmentally sensitive area, and has good
public transport network.

EFFICIENT USES OF RESOURCES-

Rainwater harvesting can help in efficient use of water. A great way to
prevent floods in the city. Also, we will be incorporating recycling
system in our plant.

INDOOR POLLUTION CHECK-

Installations of supply diffusers and exhaust fans for proper air
ventilation in the factory.