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Plant Layout Trouser Production using UPS

By Apar Singh (03) Geetika Gulyani (06) Sanjit Pandey (16)

Acknowledgement
Plant Layout assignment was an enriching experience. It was an immense learning oppurtunity. It was possible due to kind cooperation and guidanace of my faculty and friends. We would like to thank Mr. Saikat Pramanik and Mr. Ram Mohan, the faculty for Plant Layout for his continued support and guidance without whom the project would not have been possible. By working on the assignment not only did we learn the intricasies of architectural brief but also improved our knowledge of the topic.

Contents


Introduction Organizational Structure Flow Process Chart Departmental Study Operation Breakdown Manufacturing Systems Material Flow Building Structure Space Utilization Area Calculation of Departments

Introduction
 

Nature 100% Exports Location Apparel Park, Gundlapochampally, Hyderabad Product Formal trouser Production Capacity per day 3,000 Manufacturing System Unit Processing System (UPS)

  

In-House Facilities Stores, Sampling, Spreading and Cutting, Sewing, Washing, Packing and Finishing, Quality Assurance. Export Market Europe, USA

Location
Gundlapochampalli is an apparel park. It has many apparel related industries. The apparel park has been set up with all the required infrastructural facilities to setup an apparel industry. It has facilities like uninterrupted power supply from a dedicated plant. Water supply, effluent and sewage control system, roads, telecommunication services, etc.

Organizational Structure

Flow Process Chart

Departmental Study

This dpt looks after the planning of production right from the confirmation of order to till its shipment

Other Facilities
Canteen Creche/Dispensary Washrooms Water Coolers Parking Area

Manufacturing System


The manufacturing system is Unit Production System (UPS). The system is based on a concept of suspended bundles of trouser's parts hung by special clamp that flow on a conveyer situated on the left of the operator. The bundle of trouser's fronts and backs including all the parts, are loaded onto two clamps (one for the front's bundles and another one for the backs).

Both the clamps reach every work station along the line in such a way that the operator is able to perform his operation without detaching the garment components from the clamps. The bundle then returns to a natural position and the clamp keeps moving on the aerial conveyer from one workststion to another.

It is necessary to detach the bundles from the pliers only for the following three operations: Front knee lining attach and back serging;  Outseam and inseam stitch; and  Side seam and Inseam ironing. Always in these specific operations, the workstation must properly be equipped with workaids and stackers. Front and back bundles on separate clamps with all the parts components attached with special strap band help the operator concentate more on the operation and not waste precious time in searching parts and accessories.

Material Flow


There is a top-bottom (downward) flow of materials. We try to use gravity and Washing Department is at bottom due to aheavy machinery. There are lifts across floors of certain capacity. The sewing floor uses Eton.

Third floor

Offices

Second floor

Stores

First floor

Sewing department

Ground floor

Finishing & washing department

Building Structure


The foundation is 9-10 feet deep with load bearing pillars as per the soil of the land. Height of the building is 60 feet (15x4) excluding the basement. Floors are coated epoxy and hard for strength. Pillars (2x2 feet) are at a distance of 20 feet in lengthwise direction & 25 feet in breadth wise direction. There is one staircase for the operators and 2 lifts (for the material flow & other general purpose).

 

Space Utilization
Ground coverage Total Plot Area = 15000 sq ft Area under construction = 50%= 7500 sq ft The dimension of factory = (100*75) ft A clearance of 7500 ft has been provided. Area calculation Required work place areas + Required temporary storage areas + Cold regulation aisle space = Minimum space requirement for the plant layout.

Area Distribution
Ground Floor Reception, Creche/Dispensary, Washing, Finishing, Packing, Warehouse


First Floor Sewing, IE, PPC,QA, Maintenance




Second Floor Fabric and Trim Store, Spreading, Cutting,CAD, Sampling,, IT, HR, Finance and Accounts, PPC, R&D


Third Floor Canteen, Owner office, MD office, Conference Room, Showroom,Merchandising Dpt

Space Calculations Floor Wise




Ground Floor
Area (sq ft) 100 100 2700 2250 1050 1050

FirstFloor
Department PPC IE Maintenance QA Sewing Toilet+Lift+Stair+Dri nking Water Total Area Area 150 100 100 150 4875 1050

Department Reception Creche/Dispensary Washing Finishing & Packing Warehouse Toilet+Lift+Stair+Drin king Water,Generator room Total Area

7500

7500

Second Floor
Area 900

Third Floor
Area 800 450 450 450 375 250

Department Stores (Fabric, Trim and General) R&D Spreading & Cutting HR, Finance & Accounts

Department Canteen Owner office

100 2625 120

MD office Conference Room Merchandising Dpt Showroom

Toilet+Lift+Stair+Drink 1050 ing Water Total Area 7500

Toilet+Lift+Stair+Drink 1050 ing Water Total Area 7500

Manpower Requirement
Merchandising Sampling CAD Stores PPC Spreading & Cutting IE Maintenance Sewing Finishing & Packing 6 12 5 10 1 10 2 1 183 67

QA Washing IT HR Reception Canteen Security Sweeper Driver Miscellaneous

1 37 2 2 1 5 3 7 5

Warehouse
Capacity Utilization
Store capacity is kept such to store 7 days fabric + 5 % extra To produce 3000 pcs of formal trouser/day, the fabric required = 3000 x 2.4 meters = 7200 meters Stores must have a capacity of (7 x 7200) +

(0.05 x 50400) = 50400 + 2520 = 52920 meters

So for storing, 52920 meters of fabric; 15 racks are required. Every rack has 5 shelves, each of height 24 , length 72 and width 36 .


Each roll has 100-120 meters of fabric. Each rack can store 30 rolls, 6 rolls in a shelf. Average dimensions of a fabric roll:

Diameter: 12 Width: 60

Area Calculation of Departments




Merchandising Department
375 150-200 Lux 6 6 12 6 1

All Floor Area dimensions are in square feet.

Floor Area Lighting Table Revolving Chair Chair Computer Printer/Scanner/Photocopier

Sampling Department
Floor Area Lighting Spreading Table Table Chair Computer 450 150-200 Lux 2 2 7 1

CAD Department
Floor Area Lighting Inspection Table Table Revolving Chair Chair Computer 180 150-200 Lux 1 5 5 3 5

Stores Department
Floor Area Lighting Table Chair Computer 900 200-900 Lux 10 16 13

PPC
Floor Area Lighting Table Chair Computer 100 150-200 Lux 1 3 1

Spreading and Cutting Department


Floor Area Lighting Spreading & Cutting Table Fusing Table Bundling & Ticketing Table Computer 2625 350-400 Lux 2 4 1 4 1 120 150-200 Lux 2 2 4 2

IE

Floor Area Lighting Table Revolving Chair Chair Computer

Equipments of Cutting Room


Capacity Calculation


Spreading Technique: Two way usually No. of plies in a lay= 80 plies approx. Lay length= 4-6 metres (max) No. of garments in a lay= 240 pieces SAM for spreading + cutting + inspection for 1 lay= 75 For 240 pieces, it takes 90mins, For 1500 pieces, it takes 8 hours No. of pieces per day =3000

minutes


then tables= 3000/1500 = 2 tables

Equipment Requirement
S . No. 1 2 3 4 5 6 Material/Utility Racks Cutting Table Straight Knife Band Knife Bundling & Ticketing Table Fusing Machine 36*60 36*96 36*36 Dimension 72*36*24 90*36 Number 10 3 3 1 2 2

Maintenance Department
Floor Area Lighting Table Chair Computer Almirah Rack 100 250-300 Lux 1 4 1 2 2

Sewing Department
Floor Area Lighting Table Chair 4875 350-400 Lux 4 196

Production Floor Area


Total Area of the Sewing Floor: (300 * 300) sq. ft. = 9000 sq. ft. 1 Square Inch = 0.00694444444 Square Feet Hence, 94.5 square feet Area for Material Handling Eton System : length of system * width : 100 * 3 : 300 square feet Total Production Floor area : (630.25 + 94.5 + 300 ) square feet = (1024.75 + 50 % Free Space) = 1537.13 square feet Area Left for conveyor system : Total Area + 100 % space : (1540 + 1540) : 3080 square feet To double the production in future extra area given to increase production : 8500 square feet

Machine Requirement
Allocated Machine Description SINGLE NEEDLE LOCK STITCH 3 THREAD OVER LOCK MACHINE DOUBLE NEEDLE CHAIN STITCH BAR TACKER SINGLE NEEDLE CHAIN STITCH 133 Dimensions of work area (ft *ft) 1.5 * 1.5 Total Area

299.25 ft2

10 10 17 4

1 * 1.5 2*2 2.5 * 2 2*2

15 ft2 40 ft2 51 ft2 16 ft2

3 BLIND STITCH MACHINE DART MAKING MACHINE Total 2 174

1.5 *2

9 ft2

10 * 10

200 ft2 630.25 ft2

Area for Working Tables/machines

Allocated Machine Table Feeding Table In-Line Pressing Table Inspection Work Stations Thread Trimming Table Label Creasing Machine Pocket Creasing machine Total 3 15 3 4 3 3 21

Dimensions of work area (inch * inch) 36*36 60*60 96*36 96*36 30*30 30*30

Total Area

1296 3600 3456 3456 900 900 13608

Finishing and Packing Department


Floor Area Lighting Tables Ironing Table Chair Computer Floor Area 350 Lux 24 10 4 1

QA Department Lighting
Table Revolving Chair Chair Computer

150-200 Lux 2 1 3 1

Washing Department
Floor Area Lighting Table Chair Computer Inspection Table Washing Machine Tumble Dryer Hydroextractor 2700 350-400 Lux 12 16 1 4 3 2 2

IT Department
Floor Area Lighting Table Chair Computer 100 150-200 Lux 1 4 1

HR Department
Floor Area Lighting Table Chair Computer 120 150-200 Lux 1 3 1

Reception
Floor Area Lighting Table Revolving Chair Sofa 100

150-200 Lux
1 1 1 (seating capacity 10)

Owner's Office
Floor Area Lighting Table Chair Sofa Computer 450 150-200 Lux 2 9 2 (each of capacity 5) 1

Conference Room
Floor Area Lighting Conference Table Revolving Chair Chair Mannequins 450 150-200 Lux 1 2 18 8

Creche/Dispensary
Floor Area Lighting Table Chair Computer 100 150-200 Lux 1 3 1

Canteen
Floor Area Lighting Table Chair 800 150-200 Lux 70 280

Managing Directors Cabin


Floor Area Lighting Table Chair Computer 450 150-200 Lux 1 3 1

Washroom
Floor Area Lighting Exhaust Fan 80 150-200 Lux 4

Generator Room
Floor Area Lighting 225 150-200 Lux

Boiler Room
Floor Area Lighting 100 150-200 Lux

Future Plans


The average floor height is taken as 15 feet, in case the storage needs to be increased the height of racks can be increased. 4500 sq. Feet area left on the third floor for

expansion purpose.

Lighting
 

Office area: 200 lux (Fluorescent tube lights). Fabric store: 200 lux (normal) - 900 lux (inspection). Spreading & Cutting area: 300 lux (0.6 lights/sq. ft.) Each sewing workstation has an attached lamp. Sewing floor: 500-700 lux (0.6 lights/sq. ft.) Washing area: 350-400 lux Finishing and packaging area: 350 lux

   

Few normal lighting fixtures are connected from the emergency lighting distribution board.


Walls and ceilings are painted with light, pale, matt colors to avoid reflection of light and glare.


Ventilation
 

Local exhaust ventilation systems. Ventilation systems like suction and Fans, standing fans and windows in the Production department. Special ventilation system in Washing area. Air conditioners in the office area.

hoods, ducts, tubes.




 

Bibliography
 

http://www.hitex.co.in/ap_biz_textiles.pd Facility Layout and Location, 2nd edition,by Francis McGinnis and White

hank You