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DEPARTMENT OF FASHION TECHNOLOGY

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

Daily working hours

8 hours (single shift)

Total no. of Employee

Sl. No.
1.

Products
Formal Trouser

Site Location

(Approx)
SAM
22.5

Daily Production
1000

Sec 37, Gurgaon, Haryana.

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)

40,000 sq. ft.

Cost per sq. ft.

Rs. 12500

Total cost

Rs. 50 Crore

MINIMUM LABOUR COST


Skilled Labour
Unskilled Labour

: 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

STRUCTURAL DESIGN AND CONSTRUCTION


Boundary wall minimum height of 2.4 m.
Provision for underground water storage of 1,00,000 l capacity.
Paved, bitumen roads of width 2 m circumventing the manufacturing unit.
The dimensions of the main manufacturing unit will be - m X m X 12 m.
Structural Shed to be braced steel framed structure.
Masonry walls.
Cemented Floor for manufacturing unit.
Overhead, Pneumatic-powered conveyors for Unit Production System.
Rain water harvesting pipes affixed outside external walls.
Plant divided into two floors with false roofing.
Manufacturing processes designed in straight line on the ground floor and
non-involving departments demarcated on first floor.
Three staircase of width 1.5m, 15 steps per flight .
Emergency and escape routes 2 m wide.
Wood fuel used for Boilers - Fire load density up to 50kg/m3.
The interior finish materials shall not have a flame spreadability rating
exceeding Class 1.

THE PRODUCT
Product to be manufactured is Formal Trouser.
Unit Production system (UPS)
Line layout Straight
Production per day 1000 garments

Type of fabrics required for production


Shell - Wool, Linen, Viscose, Poly-Wool, Poly-Viscose, Cotton, Lycra,
Canvas, Polyester, Silk, Rayon, Poly-Cotton etc.
Lining - Knee Lining, Piping etc.
Fusing - NR Fusing, Welt Fusing, Belt Fusing etc.
Pocketing - Herringbone, Stripes, Solids etc.

The production flow process for Formal Trousers

DEPARTMENTS

1.
2.
3.
4.
5.
6.
7.
8.

Administrative Block General Manager


Human Resource Department
Factory Manager Cabin
Production Manager Cabin
PPC Department
Marketing & Merchandising Department
Accounts & Finance Department
Conference Room

9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.

Production Block Sampling Department


CAD Department
Fabric Receipt Area
Fabric Store
Trim Store
Spreading & Cutting Room
Sewing
Finishing & Packaging Section
Ware House
Quality Assurance Department
Industrial Engineering Department
Maintenance Department
Training Department

FACILITIES
22.
23.
24.
25.
26.

Main Entrance
Security Room
Parking
Garden
Reception Area

27.
28.
29.
30.
31.

Physical Plant Boiler


Generator
Escalator (Lift)
General Maintenance
Store Room

32.
33.
34.
35.
36.

Personnel Block Creche


Canteen
Water
Safety Department
Toilet

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

2. Human Resource Department


Manpower Requirement
Sl. No. Designation
1.
HR Head
2.
Assistant HR

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

3. Factory Manager Cabin

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

4. Production Manager Cabin

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

6. Marketing & Merchandising Department


This department caters to the marketing and sourcing of the product
and its components. The marketing and merchandising departments
also requires a list of workstations and cabins for officers and
managers. Following are the list of activities that are carried out in
this department.
Material Planning
Initial Costing
Purchase Orders
Sample development
Approval/Rejection

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

7. Accounts & Finance Department


The Accounts & Finance Department caters to documentation
regarding to the following documented activities.
Purchase department
Documentation
Finance
Accounts
Shipment details and documentation
Bank documents
Letter of Credit
Bills
The purchase department is a sub department under the
administration. This department is responsible for issue of purchase
orders to buy fabrics and trims and also other requirement of the
plant. The purchase department also requires space for keeping

records and workstations. Following are the activities that are


carried out in this department.
Placing Purchase Orders
Raw material Procurement
Affirmation of Purchase order by Supplier
Evaluation of Supplier in terms of cost and quality

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

The purpose of the CAD department is to generate pattern for the


garment and thus produce the production marker for the same.
Following are the activities and assets required in the department.
Plotter
Digitizer
Marker making
Marker Preparation

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.

Fabric Receipt Area

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

This department is required for the storage of trims and raw


materials received. This department also keeps a record of trims
received and issued to the production. Following are the activities
carried out in this department: Raw Material (fabric and trim receipt)
Quality checking
Issue material for production
Packaging material storage
Weighing machines
Spring balance

Area calculation for fabric store WIP


Average Fabric Consumption - 1.5 m
Per day requirement - 1000 x 1.5 = 1500m
Per week requirement: 1500 x 7 = 10500m
Now, assuming that 1 roll has 100m fabric. Then,
Total rolls to be stored for 7 days= 105 rolls.
Given, this rack (4 shelves) will accommodate 20 rolls at a time.
Therefore, number of such racks required: 105/20 = 5.25 ~ 6
racks.
The extra three shelves will be used for storage of end bits and
extra fabric after order completion.

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 Room

The department serves the purpose of spreading of the fabric on long


tables and cutting the pattern pieces out of it. The critical factor in
deciding the area of the department is the length of the cutting table.
The process of numbering and bundling is also carried out in this
department. The department requires the storage space for the cut
fabric rolls, cut components, bundles etc. Following are the
requirements for this department.
Spreading Tables
Cutting tables
Numbering tables
Bundling tables
Checking tables
Cutters required
Area calculation for cutting section and manpower Daily production: 1000 garments
Daily working hours: 8

Let 1 lay consist of 70 plies with 4 way marker


Thus, no. of garments = 70x4 = 280

Spreading

Spreading time of 1 lay for 2 spreaders and 1 helper = 90 min


So, SAM = 90/280
= 0.321
Now, total SAM req. per day= 1000x0.321
= 321 min

Thus, total no. of tables req.= 321/480 = 0.60


=1
Manpower req. per lay (spreading) = 3 (2 operator + 1 helper)

Cutting

Cutting time for 4-way marker, 1 lay for 1 cutter = 120mins


SAM = 90/280
= 0.428
Now, total SAM req. per day= 1000 x 0.4285
= 429 mins

Thus, total no. of tables req.= 429/480 = 0.89


=1
Manpower required per lay (spreading) = 3 (2 spreaders + 1 cutter)
Manpower required per lay (cutting) = 1
Machine requirement = 2 straight knife (1 extra)

Ticketing

Ticketing time per cut component = 1s


Ticketing time per garment = (12 x 1) = 12 sec
Time required per day = 1000x0.2 = 200mins
Machine requirement = 200/480 = 0.416
=1
Manpower requirement = 1
No. of tables required = 1

Part Change
It is found that 1 operator is sufficient for this operation.
Fusing

It is found that 1 machine is capable of handling fusing required per day


Assuming ( 2 operators + 2 helpers ) per m/c.

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

Area calculation and manpower requirement for sewing section


Product Formal Trouser
Daily production - 1000 pcs
Efficiency 64 % (assumed)
SAM: 22.5 mins
Daily working hours - 8
Total SAM needed per day = 1000x22.5 mins
= 22500 mins
Actual minutes req per day = 22500/0.64
= 35156.25 mins
Number of work stations/line= 74

Actual mins/line = 74 x 8 x 60= 35520


Thus, no. of lines required = 35156.25/35520 = 0.989 = 1
PRODUCTION MANAGER OFFICE Variable

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

Finishing & Packaging Section

The finishing department is meant for ironing, folding and packing of


the garment the department will require tables for checking as well
as tables for folding and packaging. Following are the activities: Ironing
Tags attached
Checking
Folding and Packaging
Area calculation for finishing department Daily production= 1000 pcs/day
SAM

No. of sec required for Inspection & Trimming = 40


SAM = 40/60mins=0.66 min
Total time required per day = 1000 x 40/60 = 667 mins
Manpower requirement = 667/480 = 1.3(approx) ~2
Assuming 2 persons per table,
No. of tables required = 1

No. of sec required for Thread sucking = 10

SAM= 10/60 mins=0.166 min


Total time required per day = 1000 x 10/60 = 166 mins
Machine requirement = 166/480 = 0.34 ~ 1(approx)
Manpower requirement =1

No. of sec required for Stain removal = 60


SAM = 60/60 = 1mins
Taking average 1 stain per 10 trousers,
Total time required per day = 100 x 1 = 100 mins
Workstation requirement = 100/480 = 0.2~ 1(approx)
Manpower requirement = 1

No. of sec required for final Ironing = 90


SAM= 90/60 mins
Total time reqd per day = 1000 x 85/60 = 1500 mins
Workstation requirement = 1500/480 = 3.125 ~ 4(approx)
Manpower requirement = 4

No. of sec required for Folding & Tagging = 60


SAM = 60/60 = 1 min
Total time required per day = 1000 x 1 = 1000 mins
Manpower requirement = 1000/480 = 2
Assuming 1 person per table,
No. of tables required = 2

No. of sec required for Final Packaging =60


SAM = 60/60 =1 min
Total time reqd per day = 1000 x 1 = 1000 mins
Manpower requirement = 1000/480 = 2
Assuming 2 persons per table,
No. of tables required = 1

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.

Quality Assurance 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.
Decision of Inspection points
Solving quality problems
Improving quality

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.

Industrial Engineering Department

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

The department stores basic tools for the maintenance of the


machines. It also requires space for the maintenance job. Following
are the activities of the department.
Tools and machinery storage for maintenance of sewing and
finishing machines
Tools and machinery storage for special machines
Spare parts storage
Building maintenance parts storage
Machine maintenance
UPS or power backup maintenance
Air conditioning maintenance
Record Keeping
Electric supply decisions

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

This department comes under administration. Following are the


various requirements: Security cabins
Parking
Here all the vehicles of both operators and officials will be parked.
Also parking is the place where the trucks and other vehicles for
transport will be received. This will also be taken care by security
department who will see to it from the entrance gate that rules are
abided by people. Operators will be allowed to park cycles only.
Sl. No.
1.
2.

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

Reception is where all the people, buyers, contractors etc. will be


received when they visit.
Sl. No.
1.

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

As 1 person require 40 litres water/day for drinking and others


(toilets). So, employees require 34000 litres of water/ day.

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

The department caters to the maintenance of safety assets of the


Organization.
Installation and maintenance of fire extinguishers
First aid Kit installation and Maintenance
Manpower Requirement
Designation
Nurse
Supervisor

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

As per standard 50 Female = 1 Toilet


As per standard 40 Males = 1 Toilet

Manpower Requirement
Sl. No. Designation
1.

NIL

No. of Manpower
NIL

Sl. No.
1.

Area Allocation
Particulars
Quantity

Ladies Washroom (For 4


Floors)
2.
Gents Washroom (For 4
Floors)
Total Area
Allowance (150%)
Total Area including Allowance

Dimens
ions
(Feet)
23 x
11.5
15 x
11.5

Area
(sq.
ft.)
264.5
172.5
437
437

VENTILATION & TEMPERATURE CONTROL

Horizontal cooling tower power by terrace pump of pressure 900 l/min,


fed by rainwater pond of capacity 20000 l
Exhaust ventilation system in storage and finishing departments
200 roof vents (1/100th of total area) having light weight metal frames
and housing with hinged dampers, of 4x7 feet at every 20 inch distance.
Depth from roof -- 3 m
Machine rooms shall be ventilated. They shall be such that the motors and
equipment as well as electric cables etc, are protected as far as possible
from dust, harmful dusts and humidity. The ambient temperature in the
machine room shall be maintained between 5C and 40C.
Roof made of insulated sheet in U-shape with an opening in middle for hot
air to pass by in the environment.

WATER SUPPLY, DRAINAGE & SANITATION

An underground water storage of capacity 1,00,000 l for fire safety and


cooling system.
Rainwater harvesting pond of capacity 20000 l attached with terrace
pump of pumping power 900 l/min
Reservoirs and tanks for the reception and storage of water shall be
constructed of reinforced concrete brick masonry, ferrocement precast,
mild steel, stainless steel or plastic.
Lead-based paint shall not be used in the tank. Lead-lined tanks shall not
be used.
Tank/water reservoir higher than 900 mm deep shall be provided with
corrosion resistant catch rings, steps or ladders according to the depth to
enable a person to reach the bottom of the tank.
Tank/water reservoir shall be provided with an overflow pipe
terminating above the ground/terrace level to act as a Warning Pipe to
indicate overflow conditions. The size of the overflow pipe shall be
adequate to accept the flow. Normally the overflow pipe size shall be one
size higher than the inlet pipe.
Tank/water reservoir larger than 5000 l capacity shall be provided with
vent pipes to prevent development pressure in the tank which might
result in NO FLOW condition or inward collapse of the tank.
Adequate number of manholes for access and repair. The manholes shall
be made of corrosion resistant material (for example, cast iron, reinforced
cement concrete, steel fibre reinforced concrete, galvanized steel, high
density polyethylene, fibre glass reinforced plastic or such other materials
acceptable to the Authority). Manholes shall be provided with locking
arrangement to avoid misuse and tampering.

FIRE & LIFE SAFETY

Water and Foam Fire extinguishers for fires in ordinary combustibles


such as wood, paper, cloth, trash, and plastics.
Carbon Dioxide Fire extinguishers for fires in flammable liquids such as
gasoline, petroleum oil and paint or fires involving energized electrical
equipment .

OTHER FACILITIES

All departments are to be connected via Inter communication lines.


Wiring to be done in a concealed manner through conduits.
Parking space of area 750 sq. m. for operators and employees
Crche for welfare of children of operators and employees
Canteen spread over an area of 1000 sq. m., providing hygienic and
healthy food thrice a day.
Medical room for accidents and unforeseen emergencies.
Training centre for new operators and workers.

OUTDOOR SIGNS & LANDSCAPING

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.

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