Area Wise Calculation

Fabric Store
For Tshirts

Capacity 2000
GSM (Assumption) 200
Fabric consumption for body
Body length+Sleeve length+Allowances 95.25
1/2 Chest width+Allowance 48.26
Wastage 5%
Fabric consumption / garment(in kg) 0.19306413

Consumption for 2000 garments(kg) 386.12826

Maximum width for knit fabric in inches (Assumption) 60

Fabric
Length of fabric required for 1 garment(m)
Weight/(Width*GSM)
0.6334125
Length of fabric required for 1 garment(cm) 63.34125

For Tank top

Capacity 1000
GSM (Assumption) 200
Fabric consumption for body
Body length+Sleeve length+Allowances 67.31
1/2 Chest width+Allowance 48.26
Wastage 5%
Fabric consumption / garment(in kg) 0.136431985

Consumption for 1000 garments(kg) 136.4319852

60
Maximum width for knit fabric in inches (Assumption)
Fabric
Length of fabric required for 1 garment(m) Weight/(Width*GSM)
0.4476115
Length of fabric required for 1 garment(cm) 44.76115
 For Track Pants

Capacity 3000
GSM (Assumption) 250
Fabric consumption for body
Leg length+Waistband+Allowances(cm) 100.33
(Hip width/4)+Allowances(cm 27.94
Wastage 5%
Body Fabric consumption / Garment(in kg)(a) 0.294338121
Fabric consumption for Pocket
Pocket Length+Allowances(cm) 13.97
Pocket width+Allowances(cm) 11.43

Wastage 5%
Pocket Fabric consumtion / Garment(in kg)(b) 0.016766096
Total fabric consumption /Garment(in kg)(a+b) 0.311104217

Consumption for 3000 garments(kg) 933.3126495

Maximum width for knit fabric in inches (Assumption) 60

Fabric
Length of fabric required for 1 garment(m) Weight/(Width*GSM)
0.8165465
Length of fabric required for 1 garment(cm) 81.65465

For fabric store

Maximum weight of fabric roll (as per
spreading machine specification)(in kg) 50
Maximum diameter of fabric roll (as per
spreading machine specification)(in cm) 40

For Upper wear(tshirt and tank top)

fabric gsm 200
Fabric width(in inch) 60
total consumption of fabric / day 522.5602
total consumption of fabric for 26 days(in
kg) 13586.57
No. of rolls 271
total length of fabric in 26 days 44575.35
length of fabric in one roll 164.042
No. of rolls 271

For bottom wear(trouser and shorts)

fabric gsm 250
Fabric width(in inch) 60
total consumption of fabric / day 933.3126
total consumption of fabric for 26 days(in
kg) 24266.13
No. of rolls 485
total length of fabric in 26 days 63690.63
length of fabric in one roll 131.2336
No. of rolls 485

total no of rolls 756

assumption
each rack has 4*4 shelves
therefore total 16 shelves in rack
Each shelf has 10 rolls arranged in 2 rows
An additional 5 cm allowance has been
taken from both sideways and topside for
easy movement while taking the rolls out
an exta rack will be used to keep rejected fabric

For Upper wear(tshirt and tank top)

Length of shelf(m) 2.05
Height of shelf(m) 0.85
Width of shelf(m)(including allowance) 1.55

no of shelves required for 274 rolls 28

no of racks required 2

total no of shelves available 32

No of shelves required to keep fabric rolls 28
extra no of shelves 4
Therefore, exta shelves can be used for
keeping remnant fabric

For bottom wear(trouser and shorts)

Length of shelf(m) 2.05
Height of shelf(m) 0.85
Width of shelf(m)(including allowance) 1.55

no of shelves required for 485 rolls 49

no of racks required 4

total no of shelves available 64

No of shelves required to keep fabric rolls 49
extra no of shelves 15
Therefore,exta shelves can be used for
keeping remnant fabric

no of rack for rejected fabric 1

total no of racks 7

Length of 1 rack(in ft) 26.896

Margin on one end of line(in ft) 5
Margin for desk area in front(in ft) 6
Length of 1 line 37.896
Width of 1 rack(in ft) 5.084
Width of 1 line(in ft) 5.084
area of 1 line(in sq. ft) 192.6633

No of racks in each line 1

No of lines 7
area of 7 lines(in sq. ft) 1348.643

Aisles in between lines

No. of aisles in between lines 6
Length of each aisle(in ft) 37.896
Width of each aisle(in ft) 3
Area of each aisle(in sq ft) 113.688
Area of aisles in between lines 682.128

margin on 1 side of racks

Width of each margin(in ft) 3
Length of each margin(in ft) 37.896
Area of margins on sideways(in sq ft) 113.688
margin on other side of racks(includes testing lab)
Width of each margin(in ft) 6
Length of each margin(in ft) 37.896
Area of margins on sideways(in sq ft) 227.376
Total area of fabric store 2144.459

Spreading And Cutting Section

For Tshirts

Capacity 2000
GSM (Assumption) 200
Fabric consumption for body
Body length+Sleeve length+Allowances 95.25
1/2 Chest width+Allowance 48.26
Wastage 5%
Fabric consumption / garment(in kg) 0.19306413

Consumption for 2000 garments(kg) 386.12826

Maximum width for knit fabric in inches (Assumption) 60

Fabric
Weight/(Width*GS
Length of fabric required for 1 garment(m) M)
0.6334125
Length of fabric required for 1 garment(cm) 63.34125
For 10 way marker
Length of fabric required for 10 garments(cm) 633.41
Length of fabric required for 10 garments(m) 6.3341
Spreading Table length required (Approximate)(in metres) 7

For Track Pants

Capacity 3000
GSM (Assumption) 250
Fabric consumption for body
Leg length+Waistband+Allowances(cm) 100.33
(Hip width/4)+Allowances(cm 27.94
Wastage 5%
Body Fabric consumption / Garment(in kg)(a) 0.294338121
Fabric consumption for Pocket
Pocket Length+Allowances(cm) 13.97
Pocket width+Allowances(cm) 11.43
Wastage 5%
Pocket Fabric consumtion / Garment(in kg)(b) 0.016766096
Total fabric consumption /Garment(in kg)(a+b) 0.311104217

Consumption for 3000 garments(kg) 933.3126495

Maximum width for knit fabric in inches (Assumption) 60

Fabric
Weight/(Width*GS
Length of fabric required for 1 garment(m) M)
0.8165465
Length of fabric required for 1 garment(cm) 81.65465
For 10 way marker
Length of fabric required for 10 garments(cm) 816.55
Length of fabric required for 10 garments(m) 8.1655
Spreading Table length required (Approximate)(in metres) 9

For Tank top

Capacity 1000
GSM (Assumption) 200
Fabric consumption for body
Body length+Sleeve length+Allowances 67.31
1/2 Chest width+Allowance 48.26
Wastage 5%
Fabric consumption / garment(in kg) 0.136431985

Consumption for 1000 garments(kg) 136.4319852

Maximum width for knit fabric in inches (Assumption) 60

Fabric
Weight/(Width*GS
Length of fabric required for 1 garment(m) M)
0.4476115
Length of fabric required for 1 garment(cm) 44.76115
For 10 way marker
Length of fabric required for 10 garments(cm) 447.61
Length of fabric required for 10 garments(m) 4.4761
Spreading Table length required (Approximate)(in metres) 5

Maximum length of spreading table required(in metres) 9

Spreading machine
m/c capacity(in kg) 50
speed(in metre/min) 100
Cutting machine specifiction
Blade height(in cm) 7.2
Average cutting speed(m/min) 8
Maximum length of fabric cut in one min/length of 1 ply(in m) 8

For Tank Top

Planned capacity for spreading and cutting 1500

Length of fabric that can be spread by spreader at a time 164.0419948

Maximum length of 1 ply 8
Maximum no of plies in one lay 21

time required to spread 1 ply(s) 4.8

time required to spread 21 plies/1 lay(min) 1.68
total no of garments in one lay with 10 way marker 210
Spreading sam of 1 garment 0.008
Total sam required per day 12
No of spreading tables required 1

time required to cut one lay(in min) 1

cutting sam of 1 garment 0.004761905
Total sam required per day 7.142857143
No of cutting machine required 1

For Workout Tshirt

Planned capacity for spreading and cutting 3000

Length of fabric that can be spread by spreader at a time 164.0419948

Maximum length of 1 ply 8
Maximum no of plies in one lay 21
time required to spread 1 ply(s) 4.8
time required to spread 21 plies/1 lay(min) 1.68
total no of garments in one lay with 10 way marker 210
Spreading sam of 1 garment 0.008
Total sam required per day 24
No of spreading tables required 1

time required to cut one lay(in min) 1

cutting sam of 1 garment 0.004761905
Total sam required per day 14.28571429
No of cutting machine required 1

For Track Pants

Planned capacity for spreading and cutting 4500

Length of fabric that can be spread by spreader at a time 131.2335958

Maximum length of 1 ply 8
Maximum no of plies in one lay 17

time required to spread 1 ply(s) 4.8

time required to spread 21 plies/1 lay(min) 1.68
total no of garments in one lay with 10 way marker 170
Spreading sam of 1 garment 0.009882353
Total sam required per day 44.47058824
No of spreading tables required 1

time required to cut one lay(in min) 1

cutting sam of 1 garment 0.005882353
Total sam required per day 26.47058824
No of cutting machine required 1

Total no of spreading tables 3

Total no of cutting tables 3
Total no of lines in spreading section 3

Each line will have Dimensions(in ft)

Length Width
spreading table 29.52 6.5
cutting table 17.1 6.5
numbering table 10 6
inspection table 5 5
bundling table 10 6

Length of spreading line(in ft)

margin at the either ends of spreading line(5 ft on each side) 10
spreading table 26.24
cutting table 17.1
Space between cutting and numbering table 3
numbering table 10
inspection table 5
bundling table 10
Total Length 81.34
Width of spreading line (in ft)
Maximum width of tables in line 6.5
Margin on either side of spreading table(2.5 ft on each side) 5
Total width of spreading line 11.5
Area of a spreading line(in sq ft) 935.41

Aisles in between lines

No. of aisles in between 2
Length of each aisle(in ft) 81.34
Width of each aisle(in ft) 3
Area of each aisle(in sq ft) 244.02
Area of aisles in between lines 488.04

No of margins on sides of spreading section 2

Width of each margin(in ft) 5
Length of each margin(in ft) 81.34
Area of margins on sideways(in sq ft) 813.4

Total area of spreading and cutting section 2236.85

Sewing Section
Personal = 5%, Machine breakdown = 5%,Fatigue = 7%, Bundle allowance = 3%
Total no of machines required for tank top

Capacity 1000/day

Stitch Machine No of machines

Sno Components SAM
Type used required

Right Shoulder line(Front panel 4 Thread

1 Overlock 0.18
and back panel) Overlock
0.375 1
Single
Needle
2 Bias bound at neckline Lockstitch 0.36
Lock
stitch 0.75 1
Left Shoulder line(Front panel 4 Thread
3 Overlock 0.18
and back panel) Overlock 0.375 1
Single
Needle
4 Bias bound at armhole Lockstitch 0.72
Lock
stitch 1.5 2
4 Thread
5 Side seam Overlock 0.96
Overlock 2 2
3 Thread
6 Hemming Flatlock 0.38
Flatlock 0.791666667 1
Total 2.78 8

Total no of lines 1
No of machines per line 8

Total no of machines required for workout tshirt

Capacity 2000/day

Stitch Machine No of machines

Sno Components SAM
Type used required
Right Shoulder line(Front 4 Thread
1 Overlock 0.18
panel and back panel) Overlock 0.75 1
 Single
Needle
2 Bias bound at neckline Lockstitch 0.36
Lock
stitch 1.5 2
Left Shoulder line(Front panel 4 Thread
3 Overlock 0.18
and back panel) Overlock 0.75 1
3 Thread
4 Sleeve Hemming Flatlock 0.64
Flatlock 2.666666667 3
4 Thread
5 Sleeve Attach Overlock 1.44
Overlock 6 6
4 Thread
6 Side seam Overlock 0.96
Overlock 4 4
3 Thread
7 Hemming Flatlock 0.42
Flatlock 1.75 2
Total 4.18 19

Total no of lines 2
No of machines per line 10

Total no of machines required for track pants

Capacity 3000/day

STITCH MACHINE No of machines

SNO. COMPONENTS SAM
TYPE USED required
4 Thread
1 Hem Pocket bag Overlock 0.36
Overlock 1.5 2
Single
Needle
2 Attach pocket to front panel Lockstitch 1.2
Lock
stitch 5 5
Bar tack at the upper and
3 Bar tack 0.93 Bar tack
bottom edge of pocket 3.875 4
4 Thread
4 Side seam join Overlock 0.72
Overlock 3 3
4 Thread
5 Inseam join Overlock 0.4
Overlock 1.666666667 2
4 Thread
6 Front rise and back rise join Overlock 0.66
Overlock 2.75 3
 Rivet
7 Rivet attachment in waistband 0.36 attaching
machine 1.5 2
Single
Needle
8 Attach elastic at waistband Lockstitch 0.6
Lock
stitch 2.5 3
4 Thread
9 Attach waistband to waist Overlock 0.864
Overlock 3.6 4
3 Thread
10 Waistband finish Flatlock 0.96
Flatlock 4 4
3 Thread
11 Bottom hem Flatlock 0.72
Flatlock 3 3
Total 7.774 21

Total no of lines 2
No of machines per line 11
Width of 1 working station(in ft) 6.233595801
Length of 1 working station(in ft) 3.937007874
Area of 1 work station(in sq ft) 24.54171575
Maximum no of machines in 1 line 11
Total area required by work stations in a line(in sq ft) 269.9588733

Distance between 2 work stations( in ft)(assumption) 1

Area of space between 2 work stations(in sq ft) 6.233595801
No of spaces between workstations in a line 11
Total area of space in a line(in sq ft) 68.56955381

No of inspection table in each line 1

Width of inspection table(in ft) 5
Length of inspection table(in ft) 3
Area of inspection table 15

Total area of 1 line(in sq ft) 353.5284271

Total area of 5 lines(in sq ft) 1767.642135

total aisle length(in ft) 57.30708661

aisle width(in ft)(assumption) 3
aisle area 171.9212598
total no of aisle between sewing lines 7
total area required for aisle 1203.448819
total area for sewing machnes and aisles in between 2971.090954 sq ft

Width of aisle on sides of sewing area(in ft)(assumption) 5

Total length of aisle 57.30708661
No of sideways 2
Total area required on sideways 573.0708661
Width of aisle in front and back of sewing area(in ft) 80.8687664
Length of aisle in front and back of sewing area(in 5
ft)(assumption)
Total area required in front and back 808.687664
Total area required by sewing department 3860.647385 sq ft