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NIFT, NEW DELHI

PLANT LAYOUT
Formal Mens Shirt Manufacturing Unit
BY:
BHINI YADAV
KUNAL NAKRA
MAMSHI OSHIN
SAMIRAN HAZARIKA
VASUNDHRA SHARMA

Objective: To propose a plant layout for formal mens shirt manufacturing unit with a capacity
of producing 1500 shirts per day.

Factors considered for layout construction


A. Movement: This factor includes external and internal transport and handling at various
operations including storage and inspections, as well as the type of equipments and methods for
material handling. This remains the most important factor while deciding upon the selection of
layout and utilization of available land. The various support departments are planned such that
they are near to their requisite sections of the plant, so that lesser material handling takes place
as well as time is saved. The material handling equipments are selected and designed as
per departments requirement and interdepartmental movement.
B. Product: This factor includes type of product, the range and variety it covers, the quantity in
a shift, the number of shifts, necessary operations and their sequence. The product to be made is
high quality dress shirt for export. There are various variations of the dress shirt which have
been covered while selecting the type of machinery. The operation breakdown was done
along with the time study and the final sequence of operations is decided by elimination of
unnecessary operations.
C. Machinery: This factor includes the process, production equipments / furniture type,
special precautions to be taken, tools - their utilization and service net-work related to the same.
During selection of machinery, the type, productivity, price and service provided by the supplier
was kept in mind, so that no hassles are met in future.
D. Waiting: This factor includes permanent and temporary storage and delays and their
locations. The stores and warehouse are planned such that there is minimum amount of material
handling happening between various departments and the store/warehouse. Proper amount of
inventory storage capacity is planned so that inventory cost never goes higher.
E. Man: This factor includes direct workers, supervision and service help personals, working
hours, safety and manpower utilization method. Standard aisle space for movement is provided,
so that there is no problem in movement or supervision. Proper amount of area for each
workstation is provided so that the direct workers have no problem while doing the operations or
during movement. All the safety precautions are undertaken while designing the layout like exits,
emergency exits, fire extinguishers.
F. Service: This factor includes service relating to employee facilities such as parking, lockers,
rooms, toilets, waiting rooms etc, service related to materials in terms of quality, production
controls, scheduling, dispatching, waste control etc and service related to maintenance and
repair, its schedule, frequency and intensity.
G. Building: This factor includes outside, inside building features, utility distribution, nature of
service integration. The various blocks are planned as per their requirement like of height, inside
features, type of shedding, flooring etc. The final building is to be done in two floors with Kirby
sheds while the administration, canteen and other utilities block would be an RCC structure.

Steps Involved in facility design


1. Procure the basic data: like Sales forecast, Quantity to be produced, Production
2.
3.

4.

5.

6.

7.

8.

schedule, Inventory policy, Production routing, Operations to be performed, Production


time standards and Scrap percentages.
Analyze the basic data: Above data is analyzed by the designer to determine the
desired interrelationships and then preparing for subsequent planning steps. Assembly
charts give a quick and early glimpse of the possible flow of materials.
Design the production process: The next is to decide how the raw material would be
converted to final part or product. Herein the production engineer designs an OPERATION
SHEET or PRODUCTION ROUTING, which is the tabulation of the steps involved in the
production of a particular part and necessary details on related items. Information on
routing may include: Part names and number, Operation numbers and sequence,
Operations name and descriptions, Machine names and numbers, Production standards,
Number of operators, Space requirements and Material flow. With this information along
with the Assembly chart, an OPERATION PROCESS CHART is constructed, which provides a
better impression of the potential material flow pattern.
Plan material flow pattern: Overall material flow pattern must be carefully designed to
assure minimum movement and expeditious interrelation of the several components -part
flow paths. Assembly chart and production routing along with data on quantity and
frequency of material movement, a preliminary material flow pattern should be developed,
which is then worked upon keeping in mind the factors affecting material flow to reach to a
finalized pattern of flow of material in a particular unit. Flexibility for future expansion or
any changes.
Consider general material handling plan: The material handling system converts the
static flow pattern into a dynamic flow of material through the plant. The ideal system
consists of an integrated combination of methods and effective methods of performing
every handling task- from unloading of material to shipping of the final product. This
involves both manual and mechanical methods. Detailed handling methods should only
after individual work stations have been planned.
Calculate the equipment requirements: Any layout is incomplete w/o estimation of
how many pieces of each type of equipment (manufacturing, service and auxiliary) will be
required. Preliminary requirement has been made while tabulating production routing.
Here final decisions must be made as to the quantity of the equipment as a basis for
planning individual workstations and planning space requirements for each activity area.
Also the number of operators must also be determined. If final decisions regarding above,
have not been made, at least estimation should be available.
Plan individual work areas: At this point, each operation, work station, area, process
etc. must be planned in detail. The interrelationships between machines, operators and
auxiliary equipment must be worked out. Each workstation must be tied into the overall
flow pattern and flow through each work station must be planned as an integral part of the
overall plan.
Select the specific material handling equipment: Specific methods of material
handling must be decided upon for each move of material or item. Many factors need to
need to be considered in the selection of handling methods.

9. Coordinate the group of related operations: Once the workplaces have been
designed, interrelationships between the work areas, related group of operations or
activities should also be planned. LAYOUT PLANNING CHART is a useful technique at this
point.
10.
Design activity relationships: Production activities need to be inter-related with
auxiliary and service activities with respect to the degree of closeness required by
material, personnel and information flow.
11.
Determine the storage requirements: Plans should now be crystallized in terms
of storage of raw material, WIP and finished products. Square foot and cubic foot
requirements should be calculated, with thought also given to the location of the storage
areas in the layout. Two storage location methods are: RANDOMIZED STORAGE (When an
individual SKU can be stored in any available storage location. The closest available slot is
designated as storage location) & DEDICATED STORAGE (When a SKU is assigned to a
specific storage location or a set of locations. Fixed slot is defined).
12.
Plan the service and auxiliary activities: such as Administration, transportation
and storage. A look at the plant service area planning sheet shows the complexity of this
step. Depending on the size of the plant all of the service activities must be carefully
studied, in order to determine which are needed. Later, during the space planning and
final design aspects of the planning, the details of many of these service activities must be
worked out.
13.
Determine space requirements: At this stage, a preliminary estimate of the total
space required for each activity in the facility can be made and cumulatively, designer can
arrive at a first estimate of the total area. Production space needs are estimated with
the aid of a production space requirement sheet. Space determinations made at this
stage are estimates. So these are on a little higher side to ensure there is sufficient area.
Only the final layout will show accurately the total space needs.
14.
Allocate activity areas to total space: The total space requirement work sheet
provides for an area template for each activity listed. Activity relationship diagram is
helpful in determining the relationships b/w the different area templates. Then an Area
Allocation Diagram can be made based on the above, which depicts the inter-relationships
between the internal flow of materials and the external flow-by means of various
transportation modes. It will also depicts the relationship w/ surrounding facilities e.g.
power plant, parking areas, storage places and adjacent buildings. A preliminary layout
has now been established.
15.
Consider building types: Building type, construction, shape and number of floors
should be considered. Building usually comes after the layout. The layout should never be
squeezed into or altered to fit into a building, if it can be avoided by designing a layout
first. As imp a building might seem to be, it is the layout that forms the basis for the
efficient operation of an enterprise.
16.
Construct the master layout: This step is the culmination of the detailed work
and planning done in the preceding steps. Final Layout is prepared using templates, tapes,
etc. to a scale e.g. = 1 ft. Two dimensional or three dimensional models are prepared.
17.
Evaluate, adjust and check the layout with appropriate personnel: No
matter how carefully or scientifically previous steps have been carried out, there are
always personal and judgmental factors to be considered. Facility designer and his
associates should check over their work at this stage before submitting it for approval.
Preliminary checks might also be made with others who have contributed in designing the
layout (production, methods, and personnel safety).
18.
Obtain approvals: In the final stages, the layout must be formally approved by
certain plant officials, depending on plant facilities and procedures.
19.
Install layout: A layout designer should carefully supervise the necessary work
involved in the installation of the layout to make sure all work is done according to the

plans in the approved layout. Any changes, if desired, should be carefully investigated and
approved by the concerned authorities.

20.

Follow up on implementation of layout:


Just
because layout has been installed as planned, there is no guarantee that will work as
planned. No plant layout is 100% perfect and layout designer must continually take note
of how the layout is affecting the production operations. Scope should be improvement
must always be kept and incorporated if found desirable.

Procurement & Analysis of Basic Data


Product Information:
Tech Pack:

Basic Information:

BUYER ADDRESS: XYZ GARMENT EXPORT COMPANY, NEW DELHI


Full sleeve Mens

Product ID

01126357

Product name

Order Quantity

1500

Group

Plain

Season

Summer

Brand

Local

Size

gender

Male

Fabric

100 % cotton

Date

16/12/14

Fabric weave

Plain

GSM

180

cotton shirt

Style Details:
Base Fabric

Blue & white checks

Stitching Thread

DTM

Button

White colored Shell button

Measurement sheet:
S. No

Description

Tolerance(+

Neck line length

43

.5

Distance b/w Shoulder

45.5

.5

Total Sleeve length

67.5

.5

Armhole height from Neck point

29

.3

Sleeve width

21.5

.3

Bottom Sleeve width

11.8

.1

Chest Width

55

.5

Bottom Width

55

.5

Total Length from HSP

78

.5

10

Back yoke height at neck point

9.8

.1

11

Front cross (at arm)

41.5

.3

12

Back cross (at arm)

44.5

.3

13

Cuff height

8.5

.1

14

Sleeve placket length

14.5

.1

15

Sleeve placket width

3.5

.1

16

Sleeve placket Box height

3.5

.1

17

Collar Point

.1

18

Collar Height

.1

19

Collar band Height

.1

20

Shoulder Slope

4.8

.1

21

Shoulder forward

2.5

Factory Information:

Foundation: The foundation will be built by digging 6 ft. down. Firstly a base of plain
concrete cement is there for 6 inches and then a reinforced concrete cement block
of 1 ft. The column foundation starts after that and the plinth and normal ground
level are the same.
Location: IMT Manesar Area
Electric Supply: In simple terms, the location has to be in a position to be able to
supply the amount of power that the unit might need. In this example of the
garment unit, the production processes involved in this industry require an optimum
amount of electricity. The electricity supply to the unit is continuous and the rates
are cheap.
Nearness to Labor Supply: All businesses need labor to operate. In some cases, this
labor has to have high levels of skill. It can save a firm both time and cost locating
near to the supply of labor. This can be extended if the local labor supply is
relatively cheap. In the vicinity of the IMT Manesar, cheap labor can be easily found.
The nearness to the villages like Bhiwadi , Khandsa and Manesar fulfills the
requirements of labor.
Proximity to external Economies of Scale: Where industry becomes concentrated in
an area, there are generally a number of supporting or ancillary units set up. In
some cases, these units supply specialized services or products to other firms in the

industry. For example, fabric dyeing, printing, agencies for fabric sourcing/
accessories sourcing, buying houses etc. are also in IMT Manesar. These benefits
can result in lower average costs (costs per unit). This is called external economies
of scale.
Reputation of Area: Certain areas of the country have a reputation for particular
types of business - this might often be due to its industrial past or the density of the
similar kind of industries. There are too many export houses in this area and it is
reputed as a hub for garment manufacturing. Whilst this factor may be seen as
being less important it can still be a factor that a unit might consider.
Transport and Communication Services: Units that rely on good communications
networks either for information transfer or distribution may well look to locate in
areas where such facilities exist. This may include high quality road networks,
access to trains, airports, ports and so on. For other firms, speed of information may
be the crucial factor in their business. Many city areas were the first to have access
to high speed data networks, broadband, cable and satellite services and so on. The
IMT Manesar is well connected to the highway for the transport of the materials. The
information services are also satisfactory.
Government Support: The availability of low rent premises, faster planning
permissions, employment subsidies (a sum of money given for every job created),
grants etc. can make a difference to a company that decides to locate in that area.
IMT Manesar Area is under Haryana State Industrial Development Corporation
(HSIDC).
Opportunities for Expansion: Many businesses might be looking for opportunities to
expand in the future. Access to land, and the ease with which the business can
expand if necessary, might therefore be something that a business will want to find
out before making a location decision, or at least as part of a location decision. In
some areas of the country, planning permission may be difficult to get - there may
be restrictions on expansion into the countryside, various policies to encourage use
of derelict land and so on. Whilst this may be of benefit to society as a whole, it is
not necessarily the most cost-effective solution for a business. In some areas of the
country, land and rental prices can be significant factors in location decisions. IMT
Manesar can be considered a perfect location for the expansion.
Development Agencies and Inward Investment: Regional policy in recent years has
changed its emphasis. The approach is to have a co-ordinate policy to help each
region achieve its full economic potential but at the same time to allow decisionmaking to be devolved to the lowest level, where possible. This means that the
regions themselves will take a lead in encouraging economic development and
supporting businesses in their region. To this end, there is now a network of regional
development agencies (DAs) focusing their attention on improving the economy of
particular regions.IMT Manesar Industries Association is the main association
involved in the development of this area
Government and Industry Compliances: Compliance with Labor Laws, Human
Rights, ILO compliance, Vendor Compliance, Government Policies, State Government
Laws and Minimum Wages.

Production Process Design

Part names and number:


Part name

Quantity per Garment

Make/buy

Front

Make

Back.

Make

Yoke (Back).

Make

Sleeve.

Make

Collar.

Make

Collar band.

Make

Cuff.

Make

Sleeve placket.

Make

Pockets.

1 or 2

Make

Front placket (Button/Button hole).

Make

Buttons

7-8

Buy

Labels (Brand, Size, Fit, Wash care)

1+1+1+1

Buy

Operation Breakdown:

Operation Bulletin:
Machine Requirement Calculation for one line
Target Output
Shift Time
Operator
Efficiency

1500 pieces per day for 4


lines
480 minutes

26.2

65%
Sewing SAM
Helper SAM
Finishing SAM

6.4
2.27

S. No.
1.
2.
3.
4.
5.
Total

Manual
Helper table
Collar turning m/c
Ironing Table

Qty
14
1
6
21

Sewing
SNLS w/ubt
SNLS we/c
SNCS
FOA
KANSAI

Qty
30
4
0
1
1
36

Finishing
Button Attach
Button Hole

Planning Material Flow Pattern


It depends on the number and type of departments in the manufacturing unit. So the different
types of departments for our proposed layout are:
Production Related

Administration and other departments

Fabric Stores
Sewing Trims & Accessories Store
Spreading and Cutting Section
Sewing Section
Finishing Section
Merchandising Department
Sampling & Technical Department
Quality Department
CAD Section
IE Department
Maintenance
Warehouse

CEO Office
Accounts Department
HR Department
Medical Room
Training Department
Conference Room
Reception
Generator, Boiler, Compressor and other utilities Room
Security Room
Toilets
Parking

Material Flow Pattern

Receipt of palletized fabric to store: Palletized fabric is received at the unloading dock and
is transferred to the fabric store through the articulated fork lifter.
Issue of fabric to cutting section: The required amount of fabric is issued to the cutting
section through fork lifter or the power pallet truck as per requirement.
Transfer of cut parts to parts section: The cut parts are transferred to the parts section
through a vertical trolley system. The cut parts would be lifted by the help of a trolley to
the parts section from where it would be fed to the respective lines. In the parts section,
material is handled via bins, or racks as per requirement.
Transfer of panels to assembly section: From parts to assembly garments are transferred
through use of various bins, racks or trolleys. And in the assembly section, garment panels
move on a mover system.
Transfer of garments to finishing section: Garment is transferred to the finishing section
through the stairs using gravity. There would be slider provided in the stairs for easy
movement of the bins on the stairs. In the finishing section garments will move on mover
system and racks.
Transfer of packed garments to warehouse: The packed and/or palletized cartons are
transferred to the warehouse through the articulated fork lifter or the power pallet truck.
Shipment of palletized cartons: Eventually palletized cartons are shipped and loaded in the
container at the dock with the help of fork lifter and the power pallet truck.

Production Routing- Merchandizing Department:

Workflow of Sampling:

Fabric Sourcing:

Fabric Audit:

Accessory Store:

Workflow in CAD:

Cutting

Section:

Production Department:

Material Handling System

Material handling equipment is selected based on the requirement with consideration for various
factors like cost, service etc.
Progressive bundle system (PBS)

Bundles consist of garment parts


needed to complete a specific
operation or garment component.
Bundles are assembled in the
cutting room where cut parts are
matched up with corresponding
parts and bundle tickets.
The sewing operations are laid out
in sequence. Each operator receives
a bundle, does his work, re-ties the
bundle and passes it to the next
operator.
There is usually a storage facility
such as rack, bin or table for storing
the inter-process work between
each operation. The work is routed
by means of tickets.
Any imbalance in production can be
corrected by using utility workers. It
is used in shirt factories, jeans factories, jacket factories, etc
Advantages:
Operators perform the same operation on a continuing basis, which allows them to
increase their speed and productivity.
This system may allow better utilization of specialized machines, as output from one
special purpose automated machine may be able to supply several operators for the
next operation.
Small bundles allow faster throughput unless there are bottlenecks and extensive
waiting between operations.
Semi skilled labor can be used.
Disadvantages:
Operators who are compensated by piece rates become extremely efficient at one
operation and may not be willing to learn a new operation because it reduces their
efficiency and earnings.
Slow processing, absenteeism, and equipment failure may also cause major
bottlenecks within the system.
Large quantities of work in process.
This may lead to longer throughput time, poor quality concealed by bundles, large
inventory, extra handling, and difficulty in controlling inventory.
It requires a high level of management skill to arrange the workflow and decide on
the number of operators for each operation.

Machine Requirements & Measurements


Daily output requirement is 1500 pieces.
Fabric Section:
Equipment

Quantity

Fabric Inspection Machine (72


width)

Description/ Capacity
Ramsons Fabric Inspection
Machine RFI 01. Speed
Variable up to 30 meters
per minute.
(2000x1950x1750 mm)

[Assumption- one garment requires 1.6 meters of fabric]


CAD section:
Equipment
Plotter

Quantity
1

Digitizer

Table

Computer

Description/ Capacity
FASTJET Plotter (7ft x 2ft)
Lectra Digitizer (3.9ft x
5.9ft)
4ft x 4ft
HP All-in-One - 18-5201ix
(2ft x 4ft)

Spreading, Cutting & Fusing Section:


Equipment

Quantity

Spreading Table & Cutting Table

Pinning, Numbering, Bundling


Table

Fusing Machine

Description/ Capacity
GERBER SY-251 AUTOMATIC
SPREADER
110 yards maximum speed
per minute, 72" material
width, 525 lb. maximum roll
weight
81 in x 180 in
12m x 1.8m
ASTEX MODEL 3024SC
Continuous Fusing System,
298cm x 96 cm

EC-700N, cutting capacity


Band Knife
1
180 mm, Table size
1500*1800mm
Brute(Model 627x),
Straight Knife
4
cutting capacity 21.5 cm
[Assumption- Automatic Spreading and cutting done on same table.]
Sewing Section:
[Refer to operation bulletin for machine requirements. Assumption- 65% efficiency]

Finishing Section:
Equipment

Quantity

Fork Lift

Iron Table

Thread Sucking

Stain Remover

Needle Detector

Automatic Steam Generator

Description/ Capacity
Caterpillar P5000 Forklift, 7ft
x 4ft
Ramson 4.3ft x 3.2 ft
DST TS-01 Avg Capacity>
2000 pcs / 8 hrs; 650 X 1435
X 1275 mm
Ramson-CL7
HM-6000
1,600(L)1,050(W)920(H)
mm
Capacity for 2 irons, 2ft x
1.5ft x 4ft

Machine Measurement:
Machine Type
SNLS
DNLS
DNCS
SNEC
B/H
B/S
B/S feeder
B/H B/S Tandem without feeder
B/H B/S Tandem with feeder
Auto Jig
Front Pressing
Sleeve plkt Pressing
Contour
Collar Notch
Kansai
Back Stacker
Cuff Stacker
Collar blocking
Cuff Blocking
Checking table
Iron Table 1
Iron Table 2
Table
Folding Table
Collar and Cuff Press
Collar Press
Stain Remover
Needle Detector
A-type Trimming Table
Washing Mc
Dryer

Length
Inches
Feet
42
3.5
42
3.5
42
3.5
42
3.5
47
3.9
47
3.9
47
3.9
48
4
60
5
43
3.6
52
4.3
42
3.5
35.5
3
42.5
3.5
42
3.5
42
3.5
53.5
4.5
42
3.5
24
2
47
3.9
41
3.4
51
4.3
48
4
60
5
60
5
36
3
60
5
72
6
48
4
24
2
24
2

Width
Inches
Feet
21.2
1.8
21.2
1.8
21.2
1.8
21.2
1.8
22.5
1.9
22.5
1.9
23
1.9
28
2.3
40
3.3
32.5
2.7
45
3.8
21.2
1.8
23.5
2
24.5
2
21.2
1.8
21.2
1.8
21.2
1.8
34
2.8
33.5
2.8
38
3.2
25
2.1
31
2.6
31
2.6
36
3
48
4
24
2
48
4
48
4
36
3
18
1.5
18
1.5

Light Box

28.8

2.4

Proposed Workstation Layout For Assembly Section


Sewing Workstation:

Note:

Area consumed by each workstation = 2 sq meters.


Feet space is being provided for operators sitting and movement.
On right hand side of workstation main aisle of 3 feet is being provided.

Checking Workstation (Supervisor and QC):

20.4

1.7

Note:

1.5 feet is being


provided supervisor
or checkers sitting
and movement.
Area consumed by
each workstation =
1.7 sq meters.
On right hand side
of workstation main
aisle of 3 feet is
being provided.

Material Handling Equipments


Material is handled during the production process, warehouses or storage, in transport, during
packing and when goods are returned by the customer for one reason or the other. This would
insure cost reduction in the operation of the overall material handling function and increase
productivity. Material handling equipment is all equipment that relates to the movement,
storage, control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. Material handling equipment is generally
separated into four main categories:

Storage and handling equipment: The equipment that falls under this description is
usually non-automated storage equipment. Products such as Pallet rack, shelving, carts,
etc. belong to storage and handling.
Engineered systems: Conveyors, Handling Robots, AS/RS, AGV and most other
automated material handling systems fall into this category. Engineered systems are often
a combination of products integrated to one system.
Industrial trucks: Industrial trucks usually refer to operator driven motorized warehouse
vehicles, powered manually, by gasoline, propane or electrically. Industrial trucks assist
the material handling system with versatility; they can go where engineered systems
cannot. Forklift trucks are the most common example. Tow tractors and stock chasers are
additional examples of industrial trucks.
Bulk material handling: Bulk material handling equipment is used to move and store
bulk materials such as ore, liquids, and cereals. This equipment is often seen on farms,
mines, shipyards and refineries.

Material handling equipments are chosen on the basis of following three criteria: Material
Characteristics, Move Requirements and Method (Equipment) Capabilities
The type of equipment will materially affect the layout; hence the layout planner should be
familiar with the characteristics and capabilities of each type. Usually the best, most economical
and most efficient handling is accomplished by an integration of different types of handling
equipments. For the selection of specific material handling equipments following points should
be checked:

Cost of the equipment delivered and installed complete with power and fuel facilities.
Cost of operation
Cost of maintenance
Ability to do a specific job
Safety aspect of material and operator
Effect on working conditions
Dependability of performance

Material Handling Equipment for the proposed

Industrial trolleys (hand trucks, panel carts,


Storage bins
Pallets (wooden and plastic)

Layout:
ladders)

Activity Relationship Chart


It is important for:

Preliminary allocation of sequence


Relative location of work centers or departments
Location of activities
Location of work centers
Showing which activities are related to each other and why
Providing basis for subsequent area allocation

A
E
I
O
U
X
Where,

U
O
A
O
O
I
U
U
U
U
O
U

A
U
O
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I
A
I
U
A
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I

I
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I
A
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I

O
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U

U
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A
I
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O
U
U
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U
O

U
U
O
U
?

Absolutely Necessary
Especially Important
Important
Ordinary Important
Unimportant
Undesirable

U
U
I
A
U
U
U
U
U
U
O
U
?

U
U
U
U
U
U
U
U
U
U
U
U
U

U
U
I
A
O
U
O
U
O
U
U
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U

O
O
U
U
U
U
U
U
U
U
O
U
U

PPC

Export

Finance

IE

Cad
U
U
A
U
U
O
U
U

ce Maintenan

I
I
I
I
I

Quality

U
A
U
A

Sampling

O
O
A

sing Merchandi

A
U

Finishing

Sewing

U
A
O
U
O
O
I
U
U
U
U
O
U

& Cutting Spreading

Fabric Store
Trim Store
Spreading & Cutting
Sewing
Finishing
Merchandising
Sampling
Quality
Cad
IE
Finance
Maintenance
Export
PPC

Trim Store

Activities

Store Fabric

The various activities identified as above may now be arranged in an activity relationship chart
based on their need to be close to each other. Before actually making the chart, it is necessary to
analyze what all departments need to be close to each other and also the reason for the need of
their proximity needs to be known. For this purpose, an analysis has been done.

U
U
I
I
U
U
U
O
O
O
U
U
U

Storage Requirements
Fabric Storage Area Calculation:

Rolls to be stored in palletized form


Inventory of 10 days

Assumptions:

Aisle space between racks = 1 m


Main aisle = 1 m
Roof Height = 15 m
Average fabric consumption per shirt = 1.6m

Calculations:

Total production per day = 1500 shirts


Total fabric required per day = 1500 * 1.6 = 2400 m
Total consumption of fabric for 10 days inventory = 2,400 * 10 = 24,000 m

Roll Data:

Total yardage = 120 m


Roll diameter = 7 inches
Roll height = 62 inches
Roll weight = 25 Kg

Pallet Data:

Wooden Pallet Weight = 20 Kg


Length = 62 inches, Width = 62 inches, Height = 5 inches
Total rolls in a pallet = 56 rolls (Rows = 7, Columns = 8)
Final Height of palletized rolls = 56 inches
Weight of one pallet = 56* 20 + 20 =1140 Kg (It can sometimes go up to maximum of
1500 Kg)
Total yardage of fabric in one pallet = 56 * 120 m = 6720 m (It can be maximum of
7000m)
One block of the rack will be having: Length = 62 inches + 6 inches (allowance) =68
inches, Height = 56 inches + 6 inches (allowance) = 62 inches, Depth = 62 inches
Rail Girdles on all sides = 3 inches
Ground clearance = 3 inches
Roof Clearance = 1 feet = 12 inches

Conclusion:

Total number of pallets for storing = 25 pallets


Max rack height = 7 m = 23 feet = 275 inches (But 7.5 m height racks to be made, so that
smaller size pallets can be stored there)

In the single block of a rack, 1 pallet needs to be stored. Total blocks required = Number of
pallets
In one column, we will have 4 blocks.
Total no of columns= 50
In a row, we will have 10 such columns.
Total no of racks = 5
Total minimum height consumed = 266 inches
Length of racks = 18m

Other equipments in a store are:

Lab = 1 (125 sq feet)


Office = 1 (125 sq feet)
Articulated Fork Lifter = 1
Fabric inspection table = 1 (10 feet x 6 feet)

Warehouse Area Calculation (Palletized Cartons):


Assumptions:

Dimension of a carton = 60 cm x 40 cm x 30cm


18 shirts per carton
Peak Total Inventory = 10 days
Roof Height = 8 m
In a single pallet 18 cartons would be there (3*2*3)
In a pallet, number of shirts = 18* 18 = 324
Aisle space between 2 racks would be 2 m for the movement of fork lifter.
The main aisle of 3.5 m
Rail Girdles on all sides = 3 inches
Ground clearance = 3 inches
Roof Clearance = 1 feet = 12 inches
Total number of shirts in 10 days = 150000 shirts
Total no of cartons in warehouse at a time = 1, 20,000/18 = 6,666 cartons.
Total no of pallets to be stored = 6,666/18 = 150 pallets
Racks dimension: Length = 14 m Breadth = 0.9 m Height = 1m Total Height = 7m
Pallet Dimension, Length = 1.8m, Width = 0.8m, Height = 1.0m
Total production per day = 1500 pieces

Space requirements
HR department:

Area Required: 35*20 =700 Sq Ft


Man Power required
1 HR manager
2 HR People
1 Helper
1 Cabin for HR manager of 10*10
Furniture
Table
Chair
Almirah
Cubicle

Quantity
1
7
4
1

Equipment
Desktop
Printer
Copier Machine

Quantity
3
1
1

Dimensions( in feet)
4*3
1*1
3.5*3
10*10
Total
Dimensions( in feet)
3*3
Total

Area Req. (Sq. ft)


12
7
42
100
162
Area Req. (Sq. ft)
9
9

General Admin:

CEO Cabin of dimension 20*10=200 Sq Ft


Furniture/
Equipment
Table
Chair
System

Quantity

Dim (ft)

Area Required (Sq. ft)

1
3
1

4*3
1*1
Total

12
3
15

Export Import Department:

Area Required: 17*15 = 255 Sq Ft


Man Power Required: 2 people
Furniture/ Equipment
Table
Chair
System
Cabinet

Financial Department:

Quantity
2
3
2
1

Dim (ft)
4*3
1*1
3.5*3
Total

Area Required (Sq. ft)


24
3
10.5
35.5

Area Required : 17*15= 255 Sq Ft


Man Power Required:
1 Head
2 Accountants
Furniture/ Equipment
Table
Chair
System
cabinet

Quantity
4
4
3
1

Dim (ft)
4*3
1*1
3.5*3
Total

Area Required (Sq. ft)


48
4
10.5
62.5

Merchandising & Sourcing Department:


A. Merchandising:
Area Required : 20*10 +20*31=820 Sq Ft
Man power required:
1 Head
2 Merchandiser
1 Helper
Cabin for Head of 10*10 Sq Ft
Furniture/ Equipment
Table
Chair
System
Cabinet
Cubicle
Hanger Stand

Quantity
1
4
4
2
1
2

Dim (ft)
4*4
1*1
3.5*3
10*10
10*3
Total

Area Required (Sq. ft)


16
4
21
100
60
201

Dim (ft)
1*1
3*22
4*3
Total

Area Required (Sq. ft)


4
284
24
71

B. Sourcing:
Man power required
2 sourcing Persons
1 Helper
Reception:

Area Required: 10*10= 100 Sq Ft


Man Power Required: 1 Receptionist
Furniture/ Equipment
Chair
System
Cabinet
Table

Quantity
4
3
4
2

Fabric Store & Inspection:

Area Required: 72*20= 1440 Sq Ft


Man Power Required:
1 Head
2 Data entry Personnel
2 Inspection operators
2 Helpers
Furniture
Table
Chair
Racks

Quantity
3
7
10

Equipment
Trolley
Weighing Machine
Inspection Machine
Color matching Cabinet

Quantity
2
1
1
1

Dim (ft)
4*3
1*1
6*3.3
Total
Dim (ft)
3*4.5
3.2*1.6
7*4.6
13.12*13.
12
Total

Area Required (Sq. ft)


36
7
198
241
Area Required (Sq. ft)
27
5.12
32.2
172.5
236.56

Dim (ft)
5*2*6
4*4
1*1
1*1
Total

Area Required (Sq. ft)


100
16
1
3
120

Trim Store:

Area required = 19 x 13 sq ft = 247 sq ft


Man power requirement
1 In-charge
1 inspection personnel
1 Helper
Furniture/ Equipment
Racks
Table
Chair
Stools

Quantity
10
1
1
3

Cad Department, Cutting Department& Fusing Department:

Area required = 75 x30 sq ft= 2250 sq ft


Man power requirement
1 In-charge
2 personnel
Equipment
Plotter

Quantity

Digitizer

Furniture

Quantity

Dim (ft)
7.36*2.15*3
.83
3.91*5.90
Total
Dim (ft)

Area Required (Sq. ft)


15.82
23.08
38.9
Area Required (Sq. ft)

Table
Chair
Cabinet
System

2
4
1
13

4*4
1*1
3.5*3*6.5
Total

32
4
10.5
46.5

Furniture
Spreading/ Bundling Table
Table
Chair
Racks
Cabinet

Quantity
4
1
3
5
1

Equipment
Straight
Knife
Band Knife
Fusing Machine

Quantity
3
1
1

Dim (ft)
10*5*3
4*4
1*1
4*2*6
3.5*3*6.5
Total
Dim (ft)
7.49*4.89
7.38*2.78*
4.0
Total

Area Required (Sq. ft)


200
16
3
40
10.5
269.5
Area Required (Sq. ft)
36.62
20.57
57.19

Dim (ft)
3*5
7*3
5*2
Total
Dim (ft)
3*2
3*2
3*2.1

Area Required (Sq. ft)


30
84
50
164
Area Required (Sq. ft)
185.4
24.72
6.30

Cutting Department:

Man power requirement


1 In-charge
4 Spreaders
3 Cutting operators
2 Ticketing operators
2 Bundling operators
2 Fusing operators
2 helpers
1 person for data entry

Sewing Department:

Area required = 75 x 40 sq ft = 3000 sq ft


Man power requirement:
1 In-charge
4 supervisor
221 workers
Furniture
Ironing Table
Inspection Table
Trolleys

Quantity
2
4
5

Equipment
SNLS W/UBT
SNLS WE/C
FOA

Quantity
30
4
1

KANSAI

3*2.1
Total

6.30
222.72

Quality Department:

Area required = 20 x 10 sq ft ; Total Area = 200 sq ft


Manpower requirement:
1 Quality manager
8 checkers
Furniture
Table
Chair
Cabinet

Quantity
1
5
1

Dim (ft)
4*4
1*1
3*3.5
Total

Area Required (Sq. ft)


16
5
10.5
31.5

Dim (ft)
4*4
1*1
Total

Area Required (Sq. ft)


32
4
36

Dim (ft)
4*4
1*1
3.5*3
Total

Area Required (Sq. ft)


16
3
10.5
29.5

Industrial Engineering Department:

Area required = 20 x 20 sq ft= 400 sq ft


Manpower requirement
1 In-charge
6 people
Furniture
Table
Chair

Quantity
2
4

Maintenance Department:

Area required = 20 x 25 sq ft = 300 sq ft


Manpower requirement
1 In- charge
4 personnel
Furniture
Table
Chair
Cabinet

Quantity
1
3
1

PRE-PRODUCTION:

Area Required = 20 x 10 sq ft ; Total Area = 200 sq ft


Manpower requirement = 2 people
Furniture
Table

Quantity
1

Dim (ft)
4*4

Area Required (Sq. ft)


16

Chair

1*1
Total

3
19

Sampling Department:

Area Required = 40 X 18 sq ft = 720 sq ft


Manpower requirement
1 Sampling Head
1 Pattern master
20 operators
1 cutter
Furniture

Quantity

Dim (ft)

Area Required (Sq. ft)

Pattern Table

5*4

20

Cutting Table
Stools
Cabinet

1
15
1

Equipment
SNLS W/UBT
SNLS WE/C
Button hole
Button Attach
FOA
KANSAI
Mini Boiler Cum

Quantity
12
4
1
1
1
1
1

5*4
1*1
3.5*3
Total
Dim (ft)
6.18
6.18
6.18
6.18
6.30
6.30
5*3
Total

20
15
10.5
65.5
Area Required (Sq. ft)
74.16
24.72
6.18
6.18
6.30
6.30
15
138.84

Dim (ft)
4*4
1*1
Total
Dim (ft)
3*2
3*2
3*2.1
3*2.1
Total

Area Required (Sq. ft)


16
23
39
Area Required (Sq. ft)
92.7
18.54
6.30
6.30
123.84

Training Room:

Area Required = 35 x 18sq ft= 630 sq ft


Man Power Requirement:
1 Training head
2 Trainers
Furniture
Table
Chair

Quantity
1
23

Equipment
SNLS W/UBT
SNLS WE/C
FOA
KANSAI

Quantity
15
3
1
1

Conference Room:

Area Required = 31x20 sq ft


Total Area = 620 sq ft
Furniture
Table
Chair
Mannequins

Quantity
1
16
2

Dim (ft)
10*5
1*1
2*2
Total

Area Required (Sq. ft)


50
16
8
74

Quantity
1
8

Dim (ft)
10*7
1*1
Total

Area Required (Sq. ft)


70
8
78

Meeting:

Area Required = 10x10 sq ft


Total Area = 100 sq ft
Furniture
Table
Chair

Finishing:

Area Required = 75x18 sq ft= 1350 sq ft


Man power required:
1 In charge
2 Spotters
8 Thread cutters
8 Pressing operators
3 Checker
5 Packers
Furniture/ Equipment

Quantity

Dim (ft)

Area Required (Sq. ft)

Table

8*4

128

Stool
Iron table
Thread Sucking machine
Button hole
Button Attach
Stain Removing Station
Needle Detector
Carton Packing

8
8
1
4
4
1
1
1

1*1
7*3
4*5
6.18
6.18
8*8
3*2
3*2
Total

8
168
20
24,72
24.72
64
6
6
449.44

Washing:

Area Required = 25x15 sq ft=375 sq ft

Man Power Required


1 In Charge
4 Washers
2 Finishing helpers
Furniture/Equipment
Table
Washing Machine
Dryer

Quantity
1
3
1

Dim (ft)
8*4
8*12
5*7
Total

Area Required (Sq. ft)


32
288
35
355

Dim (ft)
5*3*3
1*1
10*2*4
Total

Area Required (Sq. ft)


150
100
20
270

Dim (ft)
4*4
1*1
3.5*3
Total

Area Required (Sq. ft)


16
2
10.5
28.5

Kitchen:

Area Required: 20*4 = 80 Sq Ft


Man Power Required: 5 people

Canteen:

Area Required = 50 x 30 sq ft= 1500 sq ft


Man Power Requirement: 5 people
Furniture
Table
Chair
Serving Table

Quantity
10
100
1

Security Department:

Area Required 10 * 10 = 100 Sq Ft


Man Power Requirement: 2 Security guards
Furniture
Table
Chair
Cabinet

Quantity
1
2
1

Generator:

Total Required Area = 300 Sq ft

[It is outside the main building.]

Checklist for Evaluating Plant Layout:


INDUSTRIAL ENGINEERING

Not

OK

Machinery and equipment arranged to make full use of

Ok

Machinery and equipment accessible for material supply and

Ok

Machinery and equipment located for maximum operator

Ok

Line production used where practical?


Proper use made of mechanical handling?
Minimum walking required of operators?

Ok

Processing combined with transportation?

Ok

Finished work of one operator easily accessible to next?

Ok

Machinery and equipment block in any operators?

Ok

Machine over travel extend into aisles or interfere with


Adequate storage space at work stations?

Ok

Efficient work place layouts?

Ok

Service area conveniently located tool room, tool crib,

Ok

Easy to supervisor to oversee his area?

Ok

Machine arrangements permit maximum flexibility in case of

Ok

Space allocation for foremen and production control records?

Ok

Related activity located near each other?

Ok

All required equipment included in layout?

Ok

Floor area fully utilized?

Ok

Provisions made for expansion?

Ok

Provision for scrap removal?

Ok

Crowded condition anywhere?

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