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NATIONAL INSTITUTE OF FASHION


TECHNOLOGY, New Delhi


PLANT LAYOUT & FACILITY DESIGN

ARCHITECTURAL BRIEF
OF
TANK TOP MANUFACTURING UNIT





SUBMITTED TO: SUBMITTED BY:
Ms. Bhavna Verma Aadarsh Kadambi
Akhila Menon
Arun Kumar
Rajat Sharma
Somya Tank
M.F.T. (SEM. 2)

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CONTENT

TOPIC PAGE No.
BRIEF 5
DEPARTMENTS LIST 7
SPECIFICATION 9
STORE 10
CUTTING DEPT. 10
SEWING DEPT. 11
FINISHING 11
Q.A.DEPT. 12
WAREHOUSE 13
TRAINING 14
MAINTENANCE 14
SAMPLING 15
CANTEEN 16
MAN POWER 17
COMPLIANCE 20







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Plant layout Architectural Brief

Product category: Tank top
Product: ladies Tank top
Variations:
1- Ruffle collar top
2- Lace top
3- Cotton cull top
4- Crop top
5- V tank top
6- Pull over top
7- Racer tank top
8- Bustier top
9- Kela top
10- Stella top
11- Yoke tank top
Nature of Business: Export
Rate of Production: 7680 pieces/day
No. of lines: 7 lines with 80% efficiency.








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Variation


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BRIEF
Gate :
The main gate should be a sliding metal gate , so it would be easy to open & close it.& also it
should be wider so any truck or heavy vehicle easily can pass through of it.
Security cabin:
An entrance gate should have security check cabin to check the entry of incoming & out coming
transport vehicle and also of visitor . it should have the layed pipe lines to avoid the entrance of
cattles & security personnel will come to know if any vehicle passes through the gate.
A main entrance should have following facilities:
1- CCTV camera
2- Security personnel
3- Biometric /manual enter/ exit record system.
4- Land line phone with Intercom facility.
Reception:
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A reception lounge should have reception desk with sitting facilities like sofa, chairs, table &
feedback book for customers & visitors.
Reception should have daily newspaper, magazine etc.
Parking:
Parking should be available for employees, worker & for visitors or customer. The parking may
be divided by the type of vehicle like two wheelers; four wheelers .parking should have also a
security CCTV camera.
Crche:
A garment industry should have crche because of the most of the employees or workers are
female. so a garment industry should run a crche & should appoint a caretaker.
Medical dispensary: A garment industry should have a small medical dispensary for
providing the first aid treatment to employees & workers .
1- Doctor should be appointed by the organization.
2- Ambulance facility
3- One assistant should be appointed.
Fire extinguisher: for security purpose fire extinguisher should be installed in all the
departments.
Emergency exit: Every dept. should have emergency exit . (10*4feet)




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Various departments in the organization
Marketing: The marketing department plays a key role in getting orders from buyers across the
world. This department usually publicizes its products across the world in Order to get orders.
Merchandising: Once the buyer confirms the order, the job of the merchandising department
starts. Before taking any order the marketing department will also check with merchandising
department for open capacity. The merchandising department checks with PPC for open
capacity. Once an order is finalized, the merchandiser is the Middle man between the buyer and
his factory.
Sampling: The sampling department is responsible for making the above samples as & when
asked for by the merchandiser. These samples have to be carefully stitched & finished by the
sampling department as they are the final samples the buyer will approve for bulk production.
Store: stores are the department where the trims , fabrics, needles , packing materials are kept in
bulk. whenever any departments like sewing , finishing , packing needs the required elements
the stores provide them.

Cutting: This departments objective is to separate fabric parts as replica of pattern pieces in
marker plan.

Sewing: The basic duties of the sewing department is to stitch the cut parts provided by the
cutting department & to provide the required quality of stitching & mend the Reparable
mistakes when pointed out by the QA team .

Finishing: the function of this department is to finish and present the garments as per the buyers
specifications.

Packaging: the garments are packed either in poly bags , hangers , etc and then these
are in turn packed in cartons as per buyers requirements.


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Quality Control : Ensuring the production of the garment with reference to the
standard specification is known as quality control. Quality of the garment is inspected
in various stages from fabric to finished garment.
Maintenance: The machineries used in the garment production are to be maintained
Periodically for continuous working.
The main objective of it is:
Solving problems in machineries
Preventive measurements
Monitoring at regular intervals

Accounts : it looks after all the financial aspects of the industry.

Human Resource : The human resource department deals with following:
1. Factory human resources.
2. Salary as per Grade and Designation
3. Health and Safety Policy
Training: In this department the new joiners are given training for 30-45 days at Technical
Training Division. The trainees are evaluated for production team during training and are graded
A, B, C and D. If required, training is extended for further 15 days.

Purchase: The purchasing department deals with purchase of every single thing
required in the industry.
Sourcing : helps in finding out as to where the fabric , trims etc can be obtained.





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DEPARTMENTS SIZE( IN FEET)
Reception/ Waiting Room 2010
CEOs Cabin 2010
Conference Room 2030
Buyers Room 3010
PPC Cabin 2010
Staff Canteen 10
HR Cabin 2010
Canteen 2035
Merchandising 2010
Purchase account & finance
Department
2010

Top Tank Plant Layout
Specification:
Plot Area: 310 150 feet = 46500 sqft.
FSI: 1.1
Ground Coverage: 40%
Front Margin: 30feet
Side margin: 26 feet
Daily Production Capacity: 7680 pieces/day
Daily working hours = 8 hrs.
Working days = 6day/week

1. ADMINISTRATION DEPARTMENT




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DEPARTMENTS SIZE( IN MTR)
Trim & Accessories Cabin 1510 feet
Rack size (2.7 X1.5 X2.7)
Number of roll in one rack 36
Roll length 100
Roll dia 0.45
Total no. of racks 27
Total number of roll storage 945

DEPARTMENTS SIZE( IN FEET)
CAD 4025
Spreading & Cutting table 225
Ticketing & bundling 44( for each table)
Managers cabin 1010
Water closet 33
No of pieces cut/day 1440
Average consumption per garment 0.8 meter
Marker 8 way
Expected marker length 8 0.8mtr =6.4 mtr
Total no of layers per cut 90

STORE DEPARTMENT








CUTTING ROOM










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SEWING ROOM
Total sewing m/c = 180
Total Area for 180 m/c =1134 sqft
Total chairs area : 296 sqft
For future expansion: 2lines of 360 sqft
Total no. of inspection table = 7
Area of table: 30sqft/table
Total area = 210 sqft
TOTAL AREA OF SEWING FLOOR = 11625sq.ft.
TOTAL SMV = 9
TOTAL NO. of M/C = 24 / LINE
(Note:- Area of the floor= Total Area + 150% of Total Area)

Finishing
Finishing department being the final process of garment manufacturing endures value addition to
the product, thus providing it with aesthetic and attractiveness for packaging. Each and every
process in garment finishing adds value in which pressing and packaging contributes the most.
Following are the activities.
Ironing
Tags attached
Checking




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Finishing department
No. of work force
Designation Number Area (sq.ft.)
finishing Head 1 100
Finishing executives 4 100
finishing operator 16 -
Pressing 2 73 = 21
Folding & packing 3 74= 28 each
Area required for equipments


Inspection Tables 1 33 =9
Stain removing station 1 88 = 64
Total area 278

Q&A Department: The quality assurance department is meant for setting the quality standards
for the product and then checking their sustainability in the production process. The department
requires one quality manager and quality supervisors.
QA department
No. of work force
Designation Number Area (sq.ft.)
QA Head 1 10 10 = 100
QA executives 4 -
Computer 3 24 = 8
Seam slippage testing m/c 1 -
Tear strength testing 1 -
Wash fastness testing m/c 1 -
Rubbing fastness m/c 1 -
Light fastness 1 -
Pilling testing 1 -
Chair 5 11= 1
Total area 109




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Warehouse
Fabric & Trim warehouse
Rolls to be stored in palletized form
Inventory of 15 days
FABRIC STORAGE REQUIREMENT
Fabric required for 7680 top tank for 15 days inventory
Fabric required per top =0.8-1mt
So, total fabric for 15 days sewing=1X7680X15=115200 mts.+5%wastage
(5760)=120960 mtrs.
Since, 1 roll contains 100 mtrs. Fabric
Total roll=120960/100=1209.6 rolls = 1210rolls (rounded off)
RACKS requirement:
Now, 1 roll dimension=0.45 (dia)
Racks dimension= (2.7 X1.5 X2.7)
Rolls kept in 1 racks=36 rolls
Racks required=1210 /36= 34 racks







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Training Dept.:
This department carries the responsibilities of training the newly recruited workers for
production activities. This department consists of all m/c in the sewing department .
Training Department
No. of work force
Designation Number Description Area (sqft)
Training head 1
Supervisor 2
Machine
Machine Number Description Dimension (ft)
Computer 3 24
Chair 5 11
Sewing m/c 15 23 =6

Maintenance dept. :
The department is responsible for the maintenance of the machines. It also requires space for the
maintenance job. Following are the activities of the department.
Maintenance of sewing and finishing machines
Tools and machinery storage for special machines
Spare parts storage
Air conditioning maintenance
Electric supply & power backups






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Product development Cycle (PDC) Dept.
Sampling Room
In sampling room one line of product development is there thus designated machine is required
which are there in sewing room.
Design development
Number of Employees = 1 designer
Helper = 2
Area is around is 800 sq. ft.
Utility
Boiler Room = 2000 Sq ft
Air compressor = 300 sq. ft
Power house = 1000 sq ft
Security
Main security room: 1010=100 sq.feet
Workers entry security room : 10*10= 100 sq. ft.
(Note:- Area of the floor= Total Area + 150% of Toatal Area)
Crche: 20 20 = 400 sq. feet
Dispensary:
Equipments Quantity Area sq. ft.
Beds 3 63= 54
Checking table 1 63=18
Doctor cabin -
Equipment storage -

Total area 100


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CANTEEN
Man power for 1 line =10
Table sizes = 103
No. Of table = 10
Canteen Area= 60 35 = 2100sqft.
Executive canteen area = 35 20 = 700 sqft.

Artificial Lighting for diff. dept.
SEWING:
For checking lux level-900-1000,twin tube light of 24 watt each
For pressing lux level-500-600,single tube light of 30 watt each
For loading lux level-500-600,single tube light of 30 watt each
For loading lux level-500-600,single tube light of 30 watt each
For normal sewing Lux level- 500-600, single tube light of 30 watt each
For trimming lux level-500-600,single tube light of 30 watt each.
CUTTING:
For panel check and re-cutting lux level-1000-1200,twin tube light of 24 watt each
For spreading and cutting lux level-700-800,single tube light of 36 watt each
For fusing and ticketing Lux level- 400-500, single tube light of 30 watt each





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FABRIC STORE AND TRIM STORE:
For trims storage lux level-500,single tube light of 36 watt each
For checking trims lux level-700-800,twin tube light of 30 watt each
Storage of fabric Lux level- 200-250, single tube light of 30 watt each

FINISHING:
For pressing and finishing Lux level- 400-500, single tube light of 30 watt each.

MAN POWER REQUIREMENT
Administration:
Reception =1
CEO = 1
Canteen = 4
Marketing merchandising = 4
Production merchandising = 4
Compliance = 2+4
Purchase department = 6
HR department = 8
Fire and Security department = 15
Office boy =3
Medical room = 2
Store room:
Store manager = 1
Loading/unloading boy = 5
Inspection = 4
Issuing in-charge (fabric and trims) = 2
Data operator = 1
Sweeper = 2
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Warehouse:
In-charge = 1
Data operator =1
Helper = 4
CAD Room:
Marker planner = 2
Drawing master/designer = 1

Pattern making Room:
Pattern master =1
Asst. Pattern master =1
Sampling Room:
In-charge = 1
Operator = 4
Helper = 1
Cutting Room:
Cutting in-charge =1
Supervisor = 1
Spreading operator = 3
Cutting operator = 3
Data operator = 1
Helper = 3
Ticketing/bundling = 4
Straight knife operator = 2
Sweeper = 1
Sewing Room:
Production manager = 1
Line in-charge = 1
Supervisor = 2
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Operator = 24 7lines
Helper = 20
Data operator = 1
Sweeper = 2
Finishing Room:
In-charge = 1
Supervisor = 1
Ironing operator = 10
Spot cleaner operator = 2
Thread sucker operator = 2
Hang tag operator = 4
Inspection operator = 6
Helper = 2
Data operator = 1
Sweeper = 2
Maintenance Room:
In-charge = 1
Technician = 4
Electrician = 3
Quality department:
Head = 1
Supervisor = 2
Cutting quality checker = 4
Sewing quality checker = 4
IE department:
Head = 1
Staff = 2
Data operator = 1
Total Man power =350
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Total Drinking Water requirement/day= 1550 ltrs

Water requirement required for basic necessities = 2200 ltrs(6.4 ltr/man power)
COMPLIANCE REQUIREMENT:
Building
Name Sign to All Rooms / Area
Indicators / Direction from Security Gate onwards
Storage above Storage limit Carton Box etc.
Aisle marking
Aisle width minimum 3 feet.
Indicators Arrows in the passage
Aisle without block.
Health
Drinking Water
At least4.5 Litres water provided per day per employee
Water Testing Certificate
Drinking water not in plastic pot
Drinking Water, Cup availability
Drinking Water centre (one place to every 150 employees upto 500)
Drinking Water centre (one place to every 500 employees above 500)
Water Cooler / Heater available at every canteen, dining hall, rest room etc.

Toilets
Toilet Seat to Every 20 Women
Toilet Seat to Every 20 men upto 100
Toilet Seat to Every 50 men beyond 100
All toilet seat with proper privacy and lock facility
Urinal Accommodation Min. 61 cm for every 50 employees upto first 500
Urinal Accommodation Min. 61 cm for every 100 employees for above 500
Effective water Sewage system
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Soap/ Towel
Bathroom Lock
Water tap
Tiles/Mosaic floors washed with Detergent or disinfectant once in four month
Daily Cleaning Log sheet provided
Adequate Water Tabs
No smoking Sign in Gents Toilet
Awareness Quotes in Toilets
Ladies / Gents Toilet Name Sign in Dual Language and Picture
Others
500 Cubic feet for every employees
Disposal of Wastes and effluents
Room Temperature
Lighting facility
Trees on factory campus
Safety Guards
Metal Glows on good Condition
Rubber Mat to ironers
Rubber Glows to ironers
Ironers wearing slipper
Motar Guard
Needle Guard
Eye Guard
Scissors and trimmers are tied
Broken Needle Register

Manpower
Manpower Department wise Male/Female Strength Report
Attendance Report
Late Report
Absenteeism Report
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Daily Staff In-Out Register
Is there Under Age
Contract Employees
Punch report
Leave card to each employee
MIR (Material Issue Register)
Salary
Salary date before 7 every month
Bank Salary Account to all
Salary Registers with employees signature monthwise
Minimum Wages
Basic
D.A.
Pay Cover Availability

Security
Adequate Securities
Lady Guards
Staff Movement Register
Visitors Note
Others In-Out Register
Material Inward Register
Material Outward Register
Vehicle Movement Register
Visitor Pass
Visitor Slip
Guards Knowledge about their Roles & Responsibilities
Securities Personnel File
Securities Uniform/Cap/Shoe/Belt etc.
Securities Knowledge about Fire Evacuation & Fire Safety
Security Agreement file (If outsourced)
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Security Salary register file (If outsourced)
Security ESI, PF Challan (If Outsourced)

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