You are on page 1of 20

PLANT LAYOUT

ASSIGNMENT-2
ARCHITECTS BRIEF
FACILITY DESIGN AND REQUIREMENTS FOR A PROGRESSIVE-BUNDLE TROUSER
MANUFACTURING UNIT

SUBMITTED TO:

MR. K. RAMMOHAN

SUBMITTED BY:

HARSHDEEP SINGH
SHUBHAM ARYAN
SUBHOJIT DAS
SUPRIYA NANDA
VAISHNAVI SINGH
B.F.TECH (A.P), SEMESTER-VII

INTRODUCTION
An architects brief is an official form of communication from the owner to the architect of a
construction site which entails the facility design, requirements and floor space area
distribution to guide the architect to construct the site as well as fulfil the requirements
specified by the owner. Usually, the architects brief contains the following details Project brief
Topographical survey
Plot details
Manpower requirements
Product development
Nature and type of business
Domain of various departments
Capacity to be met
Approx. sizes of different workspaces required
Compliance and safety requirements
Machine variety and distribution
Nature of machinery used
Process flow
Rough layout
Safety guidelines

PROJECT BRIEF

Mens formal trouser is a garment with a standard process which allows the machinery and
equipment required to be fixed permanently. This type of garment requires very basic
sewing machines as well some sophisticated finishing equipment in order to achieve the
professional look as desired by the garment. The garments construction methods remain
standard with just a few minor changes with different styles. Also, the kind of raw materials
that the production requires are similar amongst all styles. Hence, the site to be designed
can totally eliminate the fact that the machinery needs to be moved at frequent intervals
and can focus on more permanent fixtures.
Here under are the primary details concerned with the industry:
Product category
Product
Nature of business
Rate of production
Daily working hours
Location

Trouser
Mens Formal Trouser
Export
2000 pieces/day
8 hours/day
6 days/week
Apparel Park, Gundlapochampally

TOPOGRAPHICAL SURVEY

The designated plot is situated in the Apparel Expo Park, Gundlapochampally along
with other apparel export industries like Chermas and Pochampally. The park is
designed to provide all the necessities of an apparel industry.

The apparel park is well connected to the NH-7 and just at a distance of 580 kms
from the nearest port.

The park is designed with well-planned roads which facilitate the easy movement of
trucks and other heavy machinery. Also, there is a sufficient allowance between two
consecutive factories.

The park is also equipped with latest security and surveillance systems.

The park is located on medium black soil and contains sufficient green belts around.

The plot is located on the south-west side of the park and faces east.

The distance from the main gate to the plot is around 600m, which is quite feasible
to cover in a short time

PLOT DETAILS

The plot is 25,000 sq. ft in area.

It is L-shaped

FSI is 1.1

Ground coverage should be 40%-60%

Front margin should be 30 feet

Side margin should be 26 feet

FIGURE. ROUGH STRUCTURE AND LAYOUT OF THE PLOT

PRODUCT DEVELOPMENT
The mens formal trouser has the following variations depending upon a little change in the
components:
1. Double-Pleated
2. Single-Pleated
3. Flat-Front
4. With lining
5. Without lining
6. With Bottom Cuff
7. With normal bottom hem
8. With Waistband Extension

NATURE AND TYPE OF BUSINESS


The industry mentioned in the project has high man force requirements and is a worker
oriented industry out of which the 60% of the workers are women. So, the industry needs to
be designed on the basis of high numbers of worker movement and facilities. The industry
is focused towards producing high quality goods for exports and hence, should maintain all
the ISO standards for garment production. The industry is supposed to entail all the safety
provisions and instructions as to guide the workers amongst various departments. Also, the
industry is suggested to be developed to support shorter life cycles and frequent style
adaptations. The industry is supposed to follow the Progressive bundle system i.e. the
production continues in bundles. Hence, there occurs a requirement to store the products
at each stage of production.

DOMAIN OF VARIOUS DEPARTMENTS


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.

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.

Sourcing : helps in finding out as to where the fabric , trims etc. can be obtained.
Fabric warehouse:
The warehouse has be designed to keep the sourced material that is ready to be cut and fed
into the production system. The section consists of huge racks that are enabled to keep the
bales and rolls of different fabrics separate and segregated.
Fabric inspection:
This section is equipped with checking tables that check the fabric which is supposed to
enter the fabric lines.
Goods Warehouse:
This warehouse keeps the finished goods ready for delivery after packaging
Ticketing/Bundling:
This section divides the cut pieces into bundles that are to be fed in the sewing lines.
Trims and accessories:
These departments keep all the trims and accessories required per order. These may
contain Buttons, Zipper etc.
CAD/ Pattern making:
This department is responsible for making patterns and markers to enable cutting.
Testing Lab:
The testing lab is a very sophisticatedly maintained workspace with temperature, humidity
and lighting maintained. The testing lab is supposed to be designed as per the ASTM
standards for testing.

Boiler:
The boiler is centralized and is responsible for providing steam to all the departments of
production
Maintenance:
This department is responsible for maintaining the physical and electrical issues occurring
with the industry. It also keeps the track for faulty facilities and replacement parts
AHU:
The AHU room is designed to provide central air-conditioning to all the offices as well as the
production floors. The AHU is to be designed to provide proper ventilation within the
industry.
Vacuum Room:
This department is responsible for provide pneumatic vacuum pressure in the pressing
machines in the finishing department
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:
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)

PROCESS FLOW
Hereunder is a rough process flow in order to provide a relationship amongst the
departments as how the departments should be arranged in order to enhance the
continuous movement of products:

GENERAL STRUCTURAL REQUIREMENTS

The building structure required should be a steady permanent construction, using


cement, concrete and iron bars.

The roof of each floor should be strong enough to hold the weight of machinery and
workers designated.

The floor for each unit should be properly levelled.

The walls, the floor and the roof should contain proper plumbing, electrification and
proper insulation in order to prevent fire hazard.

Depending

AREA REQUIREMENTS BASED ON DIFFERENT DEPARTMENTS

Basement
Cutting
Fabric Warehouse
Inspection
Quality
Sourcing
Ticketing / Bundling
Trims/Acc
Toilets
CAD/ Marker /PM
Sampling
Testing
Training Centre

3000 Sq. Ft
800 Sq. Ft
600 Sq. Ft
800 Sq. Ft
400 Sq. Ft
600 Sq. Ft
400 Sq. Ft
300 Sq. Ft
200 Sq. Ft
300 Sq. Ft
500 Sq. Ft
400 Sq. Ft

Ground Floor
Finishing
Packaging
Boiler
Electricity and maintenance
AHU
Vacuum Room
Crche
Clinic
HR/IT/Admin/Fin/Log
Toilets
Conference Room
Meeting Rooms

1500 Sq. Ft
1500 Sq. Ft
600 Sq. Ft
400 Sq. Ft
200 Sq. Ft
200 Sq. Ft
300 Sq. Ft
200 Sq. Ft
200 Sq. Ft
800 Sq. Ft
300 Sq. Ft
240 Sq. Ft

First Floor
Sewing
Mark/Mirch
I.E.
Canteen Executive
Canteen Workers
Toilets

1500 Sq. Ft
540 Sq. Ft
60 Sq. Ft
500 Sq. Ft
400 Sq. Ft
500 Sq. Ft

AREA DISTRIBUTION IN VARIOUS DEPARTMENTS


1. STORES

(2.7 X1.5 X2.7)

2. FABRIC & TRIM WAREHOUSE


Rolls to be stored in palletized form
Inventory of 15 days
FABRIC STORAGE REQUIREMENT

Fabric required for 2000 trousers for 15 days inventory

Fabric required per top =1.4 m

So, total fabric for 15 days sewing=1.4X2000X15mts.+5%wastage (5760)=44100


mtrs.

Since, 1 roll contains 100 mtrs. Fabric

Total roll=44100/100 = 441rolls

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=441/36= 13 racks

3. DISPENSARY
Equipments
Beds
Checking table
Doctor cabin
Equipment storage

Quantity
3
1

Total area

Area sq. ft.


63= 54
63=18
200

4. SEWING/ FINISHING/CUTTING
Machine

No. of
machines

Weishi fabric
inspection
machine
SpectraLUX Jr
i2 Colour
matching
cabinet
(Paramount)
Morgan FOX
100
Automatic
spreading
machine
Gerber
Automatic
spreader
XLs125
Cnc cutter
gerber GTXL

Power
Standardized(Wa
tt)
1100 watt

Dimensions

Weight

2600*1850*2100

600 kg

1100

Length 406mm
Depth355mm
Height482mm

15 kg

10392

Width available 180 - 230 cm

400 kg

11500

Heavy
machine,wt not
mentioned

9872

Total Height over Table Top with


Full Size Roll 90 cm /35 in
Table Width Machine width + 20
cm
L-4.19 m,breadth-2.74m

Gerber
vaccum table

6600

2.34 x 4.37 m (92 x 172 in)

Veith pin
table
Eastman band
knife ec-900 n
Eastman
straight knife
blue streak 2
Eastman
round knife
Plastic Master
Kannegiessar
Fusing
Machine
MultiStar DXT
1400L

1280

170cm x 404 cm

750

1500* 1800 mm

1100

34 lbs. (15.4kg)

5715

9.52 kg

10392

Working width 1400 mm

Heavy
machine,wt not
mentioned
Heavy
machine,wt not
mentioned
300 kg

1440 kg

WEISHI YTPW20 Stepper


Vacuum Table
Weishi
YTPW28B Up
steam table
Macpi form
finisher
Macpi legger
machine

12

9872

1300*700*870mm

125 kg

12

9872

1400*750*1650mm

125 kg

1700

12

9872

2670mmx1560mmx1680mm

750kg

Macpi 820
Topper
machine
Macoi q58c
Buck flap
turning &
pressing
WeishiQ51F
Buck bottom
press

2450

4100*2100 mm

2000

1200X1150X1400 mm

270 kg

12

1900

1200*650*1650/1400*750*1650
mm

125 kg

30

5.8 amps, 110 VAC


at
60 Hz; single phase

100*70*80cm

38.5 kg

DURKOP ADLER
220-5300 NR
NLS( needle feed)
With UBT

Snls edge
cutter
DURKOPP
ADLER 272-740642
SNLS( drop feed)
With UBT
PFAFF-1483

Sncs

20

39 kg

35

100*70*80cm

10

100*70*80cm

40 kg

100*70*80cm

39 kg

20

100*70*105cm

53 kg

10

100*70*105cm

61 kg

10

100*70*105cm

68 kg

PFAFF-3801

5 thread o/l
JUKI MO-6716S

Bartack
BROTHER BF438D

Button sew
BROTHER BE438C

Button hole
DURKOPP
ADLER 580
PREMIUM

Button
warping

400 VA

600mm x 600 mm x 400 mm

65 kg

590VA

1,800mm (W) 790mm (D)


880mm (H)

LOIVA ST-10

Auto serging
Blind hem
strobel

100*70*890cm

Long-table type
(L): 160kg (with
stacker)
45 kg

SNLS(
differential feed)
With UBT
DURKOPP

50 cm x 35 cm x 25 cm

25 kg

DURKOP ADLER
1465-4

ADLER 275-140342

COMPLIANCE AND SAFETY REQUIREMENTS


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


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
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 month-wise
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)
Security Salary register file (If outsourced)
Security ESI, PF Challan (If Outsourced)

FACILITY REQUIREMENTS
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

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.

WATER CONSUMPTION
Total Man power =600
Total Drinking Water requirement/day= 1550 ltrs
Water requirement required for basic necessities =3840 ltrs(6.4 ltr/man power)

MANPOWER DETAILS