Professional Documents
Culture Documents
Architectural Brief Of a
Trouser Manufacturing
Unit
PLANT LAYOUT
12/16/2014
EFFORTS BY
FACULTY INCHARGE
Mohammad Umar
DFT
NEETEK KUMAR
PRASHANT TYAGI
PREYANSHU SOLANKI
WATAN CHUGH
DFT
SEM VII
PROJECT DESCRIPTION
Proposed Industry
Apparel Industry
Type of Industry
Manufacturing
Nature of Business
Export
Sl. No.
1.
Products
Formal Trouser
Site Location
(Approx)
SAM
22.5
Daily Production
1000
SITE DETAILS
Gurgaon is a leading financial and industrial city of India, situated in
the National Capital Region near the Indian capital New Delhi in the state
of Haryana.
Located 19.9 miles (32 km) south-west of New Delhi, Gurgaon has a
population of 876,824. Witnessing rapid urbanization, Gurgaon has become
the city with the third highest per capita income in India.
Accessibility
Availability of Airways: 23 Km
Availability of Railways: 9 Km
Reasons for the Selection of the site
Easy availability of laborers
Skilled Labor
Cheap Land
Easy Transportation
Closeness to buying offices
Closeness to raw material resources
LAND COST
Total Area (400 * 100)
Rs. 12500
Total cost
Rs. 50 Crore
: Rs. 10,000/month
: Rs. 7000/month
PLANT LAYOUT
The manufacturing plant is to be spread across an area of 40,000 sq. m. in Sec-37,
Guurgaon, Haryana, India.
Setbacks of width 4.5 m will run on all four sides.
An electrical substation of capacity 11kV of area 500 sq. m, boilers and
pneumatic compressor rooms occupy 250 and 170 sq. m. Respectively.
The plant will open to two opposite gates onto main streets of 12 m
width.
The main front gate will open to Loading and unloading area.
Floor Area Ratio (FAR) = 2.5
THE PRODUCT
Product to be manufactured is Formal Trouser.
Unit Production system (UPS)
Line layout Straight
Production per day 1000 garments
DEPARTMENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
FACILITIES
22.
23.
24.
25.
26.
Main Entrance
Security Room
Parking
Garden
Reception Area
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
DEPARTMENT DETAILS
1. General Manager Cabin
Sl. No.
1.
2.
Manpower Requirement
Designation
General Manager
Assistant General Manager
No. of Manpower
1
1
Area Allocation
Sl.
Particulars
Quantity Dimensions
No.
(Feet)
1.
Chair
2
1.5 X 1.5
2.
Table
2
5x3
3.
Cabinets For Storage
2
3x2
4.
Visitors Chair
2
1.5 X 1.5
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
4.5
30
12
4.5
51
76.5
127.5
No. of Manpower
1
3
Area Allocation
Sl. No. Particulars
Quantity Dimensions
(Feet)
1.
Chair
4
1.5 x 1.5
2.
Table
4
5x3
3.
Cabinets For Storage
4
3x2
4.
Visitors Chair
5 +1
1.5 x 1.5 + 6
(sofa)
x3
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
9
60
18
29.25
116.25
174.37
290.6
Sl. No.
1.
2.
Manpower Requirement
Designation
Factory Manager
Assistant Factory Manager
No. of Manpower
1
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Chair
2
1.5 X 1.5
2.
Table
2
3x5
3.
Visitors Chair
4
1.5 x 1.5
4.
Cabinets For Storage
2
3x2
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
4.5
30
9
12
55.5
83.25
138.75
Sl. No.
1.
2.
Manpower Requirement
Designation
Production Manager
Assistant Production Manager
No. of Manpower
1
2
Area Allocation
Sl. No.
Particulars
Quantit Dimensions
y
(Feet)
1.
Chair
3
1.5 x 1.5
2.
Table
3
3x5
3.
Visitors Chair
6
1.5 x 1.5
4.
Cabinets For Storage
3
3x2
5.
Hanger stand
1
10 x 3
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
6.75
45
13.5
18
30
113.25
169.85
283.12
5. PPC Department
Manpower Requirement
Sl. No.
1.
2.
3.
Designation
PPC Manager
Assistant PPC Manager
Helper
No. of Manpower
1
2
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Chair
4
1.5 x 1.5
2.
Table
3
3x5
3.
Visitors Chair
6
1.5 x 1.5
4.
Cabinets For Storage
2
3x2
5.
Hanger stand
1
10 x 3
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
9
45
13.5
12
30
109.5
164.25
273.75
Sl. No.
1.
2.
3.
4.
Manpower Requirement
Designation
Marketing Head
Junior Marketing Executives
Merchandiser
Junior Merchandiser
No. of Manpower
1
4
1
4
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Table
6
5x3
2.
Chair
10
1.5 x 1.5
3.
Cabinets for Storage
2
3x2
4.
Visitors Chair
10
1.5 x 1.5
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
90
22.5
12
22.5
147
220.5
367.5
Sl. No.
1.
2.
3.
Manpower Requirement
Designation
Accounts Manager
Assistant Account Manager
Data Entry Operator
No. of Manpower
1
1
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Table
3
5x3
2.
Cabinets for Storage
2
3x2
3.
Chair
3
1.5 x 1.5
4.
Visitors Chair
6
1.5 x 1.5
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
45
12
6.75
13.5
77.25
115.88
193.12
8. Conference Room
All the official meetings within company heads, buyers and
contractors take place here.
Manpower Requirement
Sl. No. Designation
1.
NIL
No. of Manpower
NIL
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Tables
1
28 x 7
2.
Chairs
30
1.5 x 1.5
3.
Cabinets for Storage
2
3x2
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
196
67.5
12
275.5
413.25
688.75
9. Sampling Department
This department serves the purpose of sample making before the
actual production. The department requires a set of machinery to
manufacture these samples. Following are the basic activities carried
out in this department: Sampling
Patterns, sample approved
Machineries required
Cutting tables
Sewing Machines
Iron tables
Inspection tables
Sl. No.
1.
2.
3.
4.
5.
6.
Manpower Requirement
Designation
Pattern Master
Sampling Department Manager
Supervisor
Cutting Master
Sewing Operators
Ironing Operators
No. of Manpower
1
1
1
1
23
1
Area Allocation
Sl. No.
Particulars
Quantit Dimensions
y
(Feet)
1.
Pattern Store
3
2x4
Racks
2.
Fabric/Sample
3
2x4
Racks
3.
Cabinets for
1
3x2
Storage
4.
SNLS
10
3.5 x 2.5
5.
SNLS UBT
5
3.5 x 2.5
SNCS
1
4x3
6.
Auto Serger
1
5x3
7.
Belt Loop Machine
1
3x3
8
Tandem Needle
1
4x3
9
Kaz Machine
1
5x3
10
Button Attach
1
4x3
Machine
Bartack Machine
1
4x3
APW Machine
1
5x5
6.
Iron Tables
1
6x4
7.
Pattern Table
1
5x7
8.
Table
1
3x5
9.
Operator Chair
25
1.5 x 1.5
Total Area
Allowance (150%)
Total Area including Allowance
10.
Area
(sq. ft.)
24
24
6
87.5
43.75
12
15
9
12
5
12
12
25
24
35
15
56.25
417.5
626.25
1043.75
CAD Department
Costing marker
Bundle preparation report
Sl. No.
1.
2.
3.
4.
Manpower Requirement
Designation
CAD Executive
Pattern Masters
Junior Pattern Masters
Plotter & Digitizer
No. of Manpower
1
1
1
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Table
2
3x2
2.
Plotter
1
6x3
3.
Digitizer
1
6x4
4.
CAD Machine
1
8x3
5.
Chair
4
1.5 x 1.5
6.
Cabinets for Storage
1
3x2
Total Area
Allowance (150%)
Total Area including Allowance
11.
Sl. No.
1.
Sl. No.
1.
Area
(sq. ft.)
24
18
24
24
9
6
93
139.5
232.5
Manpower Requirement
Designation
NIL
Area Allocation
Particulars
Quantity
Temporary Fabric
Storage
Total Area
Allowance (150%)
Total Area including Allowance
No. of Manpower
NIL
Dimensions
(Feet)
10 x 5
Area
(sq. ft.)
50
50
75
125
12.
Fabric Store
Sl. No.
1.
2.
3.
4.
Manpower Requirement
Designation
No. of Manpower
Store Manager
1
Assistant Manager
2
Helpers
4
Fabric/Shade Inspectors
3
Sl. No.
Area Allocation
Particulars
Quantity
1.
2.
3.
Table
Racks
Fabric Inspection
Machine
4.
Inspection tables
5.
Working Table
6.
Chair
7.
Extra Shelves
Total Area
Allowance (150%)
Total Area including Allowance
13.
3
6
3
Dimensions
(Feet)
5x3
9x5
9x8
Area
(sq. ft.)
45
270
216
4
3
6
3
6x3
8x6
1.5 x 1.5
6x3
72
144
13.5
18
535.5
803.25
1338.75
Trim Store
Sl. No.
1.
2.
Sl. No.
Manpower Requirement
Designation
Store Manager
Helpers (Issuers)
No. of Manpower
1
1
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Racks
6
8x6
Working Table
1
5x3
Chair
2
1.5 x 1.5
1.
2.
3.
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
48
15
4.5
64.5
96.75
161.25
14.
Spreading
Cutting
Ticketing
Part Change
It is found that 1 operator is sufficient for this operation.
Fusing
WIP Now, the cutting room should have the capacity to store inventory of three days.
Inventory to be stored= 1000 x 3 = 3000
A rack of (5 x 3) can store 1000 garment pieces.
Hence 3 racks required to keep the inventory.
Sl. No.
1.
3.
4.
5.
6.
7.
8.
Sl. No.
1.
2.
4.
5.
6.
Manpower Requirement
Designation
Cutting Department Manager
Cutting Master
Cutting Operator
Spreaders + Helper
Helper (Trolley)
Numbering
Fusing Manpower
Part Change
Bundling
No. of Manpower
1
1
1
2+1
2
1
4
1
1
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Tables
3
5x3
Straight Knife
3
End Cutters
2
Cutting Tables
1
50 x 6
Numbering &
2
20 x 6
Bundling Tables
Fusing Machine
1
10 x 4
Racks for WIP
3
5x3
Chairs
1
1.5 x 1.5
7.
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
45
300
240
40
45
2.25
672.25
1008.375
1680.625
15.
Sewing
The department serves the purpose of sewing the garment and thus
carrying out the production. Following are the various activities that
go in the sewing room: Approval of operation breakdown
Special machines and attachments approval
Sewing department
Line balancing
No. of machines required
Deciding or approval of manufacturing system
Sewing
Checking
Quantity
Dimensions
Area (sq.ft)
Table
5 x 3
15
Chair
2 x 1.5
12
Sample rack
7 x 2
14
File cabinet
5 x 2
10
Sl. No.
1.
2.
3.
4.
5.
Manpower Requirement
Designation
Sewing Department Manager
Supervisor
Inspectors
Sewing Operators
Helper
Sl. No.
Area Allocation
Particulars
Quantity
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SNLS UBT
SNLS
3TOL
APW
SNCS
Tandem Needle CS
5TOL
Zig - Zag
Bartack Machine
Button Attach
Machine
30
9
10
2
6
1
1
2
4
3
No. of Manpower
1
4
3
71
5
Dimensions
(Feet)
3.5 x 2.5
3.5 x 2.5
4x3
5x5
4x3
4x3
4x3
3.5 x 2.5
4x3
4x3
Area
262.5
78.75
120
50
72
12
12
17.5
48
36
11.
Eyelet Machine
12.
Checker Table
13.
Matching Table
14.
Iron Tables
15.
Seam Burster
16.
Racks
17.
Trim Racks
18.
Side Table
19.
Operators Chair
20.
Office
Total Area
Allowance (150 %)
Total Area including Allowance
16.
1
6
1
9
2
6
2
1
74
1
5x3
5x4
5x3
3x4
5x4
5x4
6x4
67.5 x 1.5
1.5 x 1.5
-
15
120
15
108
40
120
48
101.25
166.5
51
1493.5
2240.25
3733.75
Manpower Requirement
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Designation
Finishing Supervisor
Checking
Ironing/Pressing
Tag Attachment
Folding
Packing
Helper
Trimming
Thread Sucking
Stain Removal
No. of Manpower
1
6
4
2
2
3
2
2
1
1
Area Allocation
Sl. No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Particulars
Quantity
Table
Ironing Tables
Tag Attachment Machine
Pressing
Thread cutting tables
Thread suction machine
Stain removal table
Needle detection machine
Trolley
Inspection Tables
Packing Tables
Tag Attachment Table
Folding Table
1
4
2
4
1
1
1
1
2
6
1
2
2
Total Area
Allowance (150%)
Total Area including Allowance
Dimensions
(Feet)
5x3
3x5
3x5
5x5
3x3
4x3
4x3
5x3
4x3
8x6
3x5
5x3
6x6
Area
(sq. ft.)
15
60
30
100
9
12
12
15
24
288
15
30
72
682
1023
1705
17.
Ware House
This department stores all the finished orders. Here the orders are
stored till they are shipped. Also the finished goods of a consignment
whose production is in process is also stored here. Following are the
various processes:
Cartons are brought in from finishing department
Cartons are stored
Cartons are moved to parking be shipped
Sl. No.
1.
2.
Manpower Requirement
Designation
Warehouse Manager
Helpers
No. of Manpower
1
2
Area Allocation
Sl. No.
Particulars
Quantity Dimension
s
(Feet)
1.
Working Table
2
4x3
2.
Trolley
2
4x3
3.
Table
1
3x5
4.
Chairs
3
1.5 x 1.5
5.
Cabinet for Storage
1
3x2
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
24
24
15
6.75
6
75.75
113.62
189.37
18.
Sl. No.
1.
2.
Manpower Requirement
Designation
QA Manager
QA Supervisor
No. of Manpower
1
2
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Table
3
3x5
2.
Chair
6
1.5 x 1.5
3.
Inspection Table
1
3x8
4.
Cabinets For Storage
2
3x2
5.
Hanger Stand
1
10 x 3
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
45
13.5
24
12
30
124.5
186.75
311.25
19.
Sl. No.
1.
2.
3.
Manpower Requirement
Designation
IE Manager
Assistant IE Manager
Helper
No. of Manpower
1
2
2
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Chair
5
1.5 x 1.5
2.
Table
3
3x5
3.
Cabinets For Storage
2
3x2
4.
Visitors Chair
3
1.5 x 1.5
5.
Hanger stand
1
10 x 3
Total Area
Allowance (150%)
Total Area including Allowance
20.
Area
(sq. ft.)
11.25
45
12
6.75
30
105
157.5
262.5
Maintenance Department
Sl. No.
1.
2.
3.
4.
5.
Manpower Requirement
Designation
Maintenance Manager
Assistant Maintenance Manager
Helper
Mechanic
Issuer
No. of Manpower
1
1
1
5
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Chair
5
1.5 x 1.5
2.
Work Table
3
3x4
3.
Cabinets For Storage
4
4x2
4.
Shelves for Storage
2
2x5
Total Area
Allowance (150%)
Total Area including Allowance
21.
Area
(sq. ft.)
11.25
36
32
20
99.25
148.87
248.12
Training Department
Sl. No.
1.
Manpower Requirement
Designation
Training Incharge
No. of Manpower
1
Area Allocation
Sl. No.
Particulars
Quantit Dimensions
y
(Feet)
1.
Sewing Machines
20
4x3
2.
Operator Chair
20
1.5 x 1.5
3.
Table
1
5x3
4.
Chair
1
1.5 x 1.5
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
240
45
15
2.25
302.25
453.37
755.62
Facility Details
22.
Main Entrance
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
NIL
Area Allocation
Particulars
Quantit Dimensions
y
(Feet)
NIL
NIL
NIL
1.
Total Area
Allowance (150%)
Total Area including Allowance
23.
No. of Manpower
NIL
Area
(sq. ft.)
NIL
NIL
NIL
NIL
Security Department
Manpower Requirement
Designation
Security Head
Security Guards
No. of Manpower
1
8
Sl. No.
1.
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Table
2
5x3
2.
Stool
3.
Punching Machine
4.
Parking Area
Total Area
Allowance (150%)
Total Area including Allowance
24.
Area
(sq. ft.)
30
1x1
5
1
1 x 0.5
83 x 10
2.5
830
871.5
1307.25
2178.75
Garden
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
Gardener
No. of Manpower
1
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Garden
35 x 10
1.
Total Area
Allowance
Total Area including Allowance
Area
(sq. ft.)
350
350
350
25.
Reception Area
Sl. No.
Manpower Requirement
Designation
Receptionist
No. of Manpower
1
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Table
1
5x3
Sofa
3
4x6
Chairs
1
1.5 x 1.5
1.
2.
3.
Total Area
Allowance (150%)
Total Area including Allowance
26.
Area
(sq. ft.)
15
72
2.25
89.25
133.87
223.12
Boiler
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
NIL
No. of Manpower
NIL
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Boiler
40 x 10
1.
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
400
400
400
27.
Generator
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
NIL
No. of Manpower
NIL
Area Allocation
Particulars
Quantit Dimensions
y
(Feet)
Generator
2
15 x 5
1.
Total Area
Allowance (150%)
Total Area including Allowance
28.
Area
(sq. ft.)
150
150
150
Escalator (Lift)
Sl. No.
1.
Manpower Requirement
Designation
NIL
No. of Manpower
NIL
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Lift (For 4 Floors)
1
13 x 8
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
416
416
416
29.
General Maintenance
Sl. No.
1.
2.
Manpower Requirement
Designation
Housekeeping Incharge
Housekeeping Staffs
No. of Manpower
1
12
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Housekeeping Stuffs
2
2x4
2.
Racks
4
1.5 x 5
Total Area
Allowance (150%)
Total Area including Allowance
30.
Area
(sq. ft.)
16
30
46
69
115
Store Room
Sl. No.
1.
Manpower Requirement
Designation
Store Room Incharge
No. of Manpower
1
Area Allocation
Sl. No.
Particulars
Quantity Dimensions
(Feet)
1.
Racks
2
2x8
2.
Idle Machine Area
25
2.5 x 3.5
3.
Other Stuffs
8x5
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
32
218.75
40
290.75
436.12
726.87
31.
Creche
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
Creche Incharge
Area Allocation
Particulars
Quantity
1.
Washroom
2.
Sleeping Area
3.
Playing Area
4.
Kitchen
5.
Racks/ Almirah
Total Area
Allowance (150%)
Total Area including Allowance
32.
1
1
1
1
2
No. of Manpower
1
Dimensions Area
(Feet)
(sq. ft.)
5x4
20
20 x 11
220
20 x 15
300
6x4
24
1.5 x 3
9
573
859.5
1432.5
Canteen
Canteen is common for all but there will be different timings for
operators and officials. Meals will only be offered to officials.
Operators will be offered lunch, snacks and tea at subsidized cost.
Sl. No.
1.
2.
3.
Manpower Requirement
Designation
Canteen Supervisor
Cooks
Helpers
No. of Manpower
1
4
10
Sl. No.
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Tables
25
10 x 4
Chairs
250
1.5 x 1.5
Cooking Room
1
15 x 12
1.
2.
3.
Total Area
Allowance (150%)
Total Area including Allowance
33.
Area
(sq. ft.)
1000
562.5
180
1742.5
2613.75
4356.25
Water
Sl. No.
1.
Sl. No.
Manpower Requirement
Designation
NIL
No. of Manpower
NIL
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Water Purifier
2
3x3
Taps
15
1 x 16
1.
2.
Total Area
Allowance (150%)
Total Area including Allowance
Area
(sq. ft.)
18
240
258
387
645
34.
Safety Department
Sl. No.
1.
2.
Sl. No.
Area Allocation
Particulars
Quantity Dimensions
(Feet)
Bed
2
5x6
Stretcher
1
3x7
Chair
1
1.5 x 1.5
1.
2.
3.
Total Area
Allowance (150%)
Total Area including Allowance
35.
No. of Manpower
1
2
A60rea
(sq. ft.)
60
21
2.25
83.25
124.87
208.12
Toilet
Manpower Requirement
Sl. No. Designation
1.
NIL
No. of Manpower
NIL
Sl. No.
1.
Area Allocation
Particulars
Quantity
Dimens
ions
(Feet)
23 x
11.5
15 x
11.5
Area
(sq.
ft.)
264.5
172.5
437
437
OTHER FACILITIES
Open space to be planted with trees and flowering plants and rainwater fed
pond.
A board of dimensions 6 x 8 feet, displaying the companys name shall be
fixed on the boundary wall facing the street.
The logo of the company is to be fixed under the canopy of the roof,
overlooking the front gate.