PLANT LAYOUT

ARCHITECHTURAL
BRIEF FOR
FASHION SHIRT
MANUFATURING
PLANT

Submitted By:
Akriti Sharma (03)

Amit Kumar (04)

Ashish Kumar (07)

1
Vaibhav (28)
 PART 1
INTRODUCTION

2
 Introduction
About The Project

• It is proposed to setup an apparel manufacturing facility for

manufacture of fashion shirts.

• The proposed facility is to be setup within an area of 15,000sft.

• The facility shall perform composite functions of fabricating the

product right from the raw material to its finished state.

• The facility shall cater and be oriented towards domestic as well as

export oriented markets.

• The processes in the manufacturing would be in house with the

exception of the processing of raw material like fabrics which shall
be procured in processed forms.

• The nature of the product is not staple thus variations are possible
in machine requirement as well as the production work flow.

• Type of manufacturing system is proposed to be a combination of

product for assembly line and process type for small parts
construction.

• The required production rate of finished product is to be 3000

pieces/day.

3
Product Analysis
Product Overview

Fig: fashion shirt

Name of the Product Fashion shirt

Category(Men’s/Women’s/Children) Men’s, Women’s and Childrens

Type of Product(Casual/Formal) Casual

Staple/fashion Product Fashion

Fabric (woven),trims like button, fusible

Major rawmaterials
interlining, zipper and sewing threads

4
PRODUCT DESCRIPTION

• The casual or fashion shirt is an apparel for casual/daily wear purpose.

• It must have desirable fashion features such as darts, panels, embroidery, etc
for providing an attractive look to the wearer.

• A standard fashion shirt has around 11 components.

• Variations among these components are done to develop various designs.

• The major raw materials consumed in the manufacturing are fabrics.

• Variety of woven fabrics can be used as raw material for the product.

• The construction of the product can vary from easy to complex depending on
the style variation.

• Small parts like collar and cuffs are separately prepared before being
assemble into the main garment.

• The collar and cuff require fusing machines for attaching the fusible
interlinings to the respective parts.

5
 PARTS LIST

A standard fashion shirt consists of the following parts:

Part number Part name Quantity per final Make/buy

assembly

1. Front 2 Make

2. Back. 1 Make

3 Yoke (Back). 2 Make

4 Sleeve. 2 Make

5. Collar. 1 Make

6 Collar band. 1 Make

7 Cuff. 2 Make

8. Sleeve placket. 2 Make

9 Pockets. 1 or 2 Make

10 Front placket 1 Make

(Button/Button hole).

11 Buttons 7-8 Buy

Other auxiliary parts are:

Labels

o Brand

o Size
12
1+1+1+1 Buy
. o Fit

o Wash care

6
 Sewing Operation Breakdown
The following operations are for sewing a men’s casual (fashion) shirt. These are
general operation irrespective of any variation.

MACHINE
Operation Number Operation name
REQUIRED

A01 Serge front 5Th O/L

A02 Fuse fusible interlining on Fusing m/c

A03 Serge front placket 5Th O/L

A04 Sew front buttonhole placket to front. SNLS

A05 Sew button placket SNLS

A06 Top stitch button hole placket SNCS/SNLS

A07 Serge back 5 TH O/L

B01 Sew shoulder SNLS

B02 Attach pocket SNLS

B02 Sew under sleeve placket to sleeve SNLS

B03 Fold upper sleeve placket IRONINGTABLE

B04 Sew upper sleeve placket SNLS

B05 Sew tack to sleeve mouth SNLS

B06 Sew sleeve SNLS

B07 Counter stitch sleeve SNLS/DNLS

B08 Sew side and under sleeve Feed of the arm

B09 Fold bottom and slit Manual

B10 Sew top of slit SNLS

B11 Top stitch bottom and slit SNLS

B12 Crease label Ironing Table

B13 Sew size label to brand label SNLS

B14 Baste brand label to neck SNLS

Fuse fusible interlining on upper Fusing m/c

B15
collar

7
B16 Run stitch collar SNLS

Collar turning
B17 Cut collar point ,turn & fold collar
m/c

B18 Sew collar bottom SNLS

B19 Sew collar SNLS

B20 Counter stitch collar SNLS/DNLS

B21 Fuse Fusible interlining on cuff Fusing m/c

B22 Sew edge of cuff SNLS

B23 Turn and form cuff Cuff turning m/c

B24 Topstitch cuff SNLS

B25 Sew cuff SNLS

B26 Turn body and mark button position Manual

Button attach
B27 Sew button to point
m/c

Button Holing
B28 Sew button hole to cuff
m/c

Button stitch
B29 Sew button to front and cuff machine

Thread trimming
C01 Trim thread
machine

C02 Inspect Manual

C03 Press body Vacuum Press

C04 Finishing iron Iron

8
 PRODUCT/PART VARIATIONS

Part name Possible Variations

1. Kimono sleeve

2. Pleated shirt

Front and back body 3. Shirt with yokes(front and back)

4. Multi-Panel shirt

5. Gather shirt

1. Sailor collar

2. Shirt collar

3. Peter Pan collar

4. Stand collar
Collar
5. Roll collar

6. Madrin collar

7. Turtle neck

1. Cap sleeve

2. Dart less sleeve

3. Petal sleeves

Sleeve 4. Circular hemline sleeves

5. Lantern sleeves

6. Cowl sleeves

7. Leg-o-mutton sleeves

Sleeve cuffs 1. Basic shirt cuff

9
 2. Self-faced cuff

3. French cuff

4. Contoured cuff

5. Roll-up- cuff

1. Epaulets

2. Zippers

3. Buttons(metallic /plastic)
Decorative trims/parts
4. Patch work

5. Paupers or rivets

6. Hood

10
 Part 2

Production process and Related

Activities

11
 PROCESS INVOLVED / OPERATING ACTIVITIES

Proto type sample Sample approval Order Conformation

development

Pp sample Size sample Size set samples

development approval

Pp sample approval Production Planning Receive raw material

and raw material and inspection
procurement (SCM)

SEWING Cutting Stores

Marker from CAD

Pressing and Finishing Quality checking and Packaging

audit

Dispatch

Standard Production Operations/activities

12
Processes involving specialized operations

Specialized operation required for meeting the requirements of the product variations
are as follows:

• Embroidery

• Printing

• Washing

Embroidery:-Embroidery can be done on any part/component. It is usually done

before sewing/assembly operations. The parts requiring the embroidery are
transported from the cutting to the embroidery section. After embroidery the parts are
transported back to cutting and re bundled with original pieces.

Printing: Printing also can be done on any individual part or component before the
sewing/assembly operations. The parts requiring the embroidery are transported
from the cutting to the embroidery section. After embroidery the parts are transported
back to cutting and re bundled with original pieces and sent for sewing.

Washing: To provide a variety of effects the garments may be given washes or for
providing shrinkage. These operations are usually done after the production
operations are completed and just before the packaging. The garments which are
produced out from the sewing lines are sent directly for washing from where after
washing they are sent to the finishing department for finishing and packaging.

13
Process flow with specialized operations

Proto type sample Sample approval Order Conformation

development

Pp sample development Size sample approval Size set samples

Pp sample approval Production Planning and Receive raw material

raw material and inspection
procurement (SCM)

PRINTING EMBROIDERY Marker from CAD

Sewing Cutting Stores

Quality checking and Packaging

WASHING
audit

Pressing and Finishing Dispatch

14
OPERATION BREAK DOWN FOR MAJOR DEPARTMENTS

FABRIC STORE

Invoice received from the merchandiser

Identification of supplier

Negotiation with supplier

Issue of purchase order

Follow up with the supplier

Receiving of fabric

Storage of fabric

Fabric check

Issuing of the fabric

15
CUTTING DEPARTMENT

Fabric received from the fabric stores

Spreading

Marker Making

Lay Checking

Cutting

Re- cutting (for embroidery and

sometimes checks)

Ticketing

Component checking

Fusing (when required)

Bundling

Issued to sewing batch

16
FINISHING DEPARTMENT

Button Holing/stitching

Washing

Thread cutting

Pressing

Checking

Re- pressing

Measurement check

Thread sucking

Folding

Tagging

Packing

Dispatch

17
Computer Aided Design (CAD)

18
 RFD

19
 SAMPLING

Receive the tech peck from the

merchandiser

Develop the patterns

Developing the fit sample and sending for

approval

Developing the size set

Developing the PP samples

Sealing the patterns and send for production

20
 PART 3

PRODUCTION SYSTEM:

PROGRESSIVE BUNDLE SYSTEM

21
Production System: Progressive Bundle System
The production system proposed for the facility is “Progressive Bundle System” with
the material flow being “zigzag” motion.

PBS system is exactly what its name implies, a system whereby the garments are
gradually assembled as they move through successive sub-assembly and main
assembly operations in bundle form. The principles of this system are:

• The various sections are positioned according to the main operation

sequence, with each section having a layout according to the sequence of
operations required to produce a particular component.

• A work store is positioned at the start and the end of every section of these
buffers is used to store work received from a preceding operation and to hold
work complete by that section.

• Due to these work stores or buffers, each section is not directly dependent on
the preceding section, but can absorb slight variation in output via the stocks
held within the section.

The reasons for using PBS system are highlighted below:

• Labors of all levels, that is skilled, unskilled, semi-skilled labors are involved in
this system where the operations are broken into small simple operation.
Hence the cost of labor is cheap.

• The quantity and quality of each component is checked during the individual
operation itself, so the quality is good.

• The component are moved in bundles from one operation to the next
operation, so there is less chance for confusion like, lot mix-up, shade
variation, size variation etc.

• Specialization and rhythm of operations in PBS increase the overall

productivity

22
 • Bundle tracking is possible, so identifying and solving problems becomes
easy.

The material flow is zigzag movement of material. In case of the zig zag movement
the straight line is divided into two lines such that if the first operation is on the right
side of the centre table, the subsequent operation is done on the opposite side of the
table. The completed parts are placed on the table and the next operator picks up the
same.

• The system is very useful in terms of ergonomics as it requires minimum

operator’s motion.

• The workflow is also improved and the chances of the bundles breaking in the
middle of the line are minimized.

The pattern is well explained by the following illustration. For example if there are 6
operation in manufacturing a part. Let ,the operations be Op1, Op2, Op3, Op4, Op5
and Op6, and the operators be 1,2 ,3 4, 5 and 6 respectively, the material flow would
be
OP2

OP6
OP4
2

6
4

Centre table

Material Flow
OP1

OP3

OP5

Operators for the

operation
1

Machines for operations

Illustration of the zig zag movement of the

material

23
 PART 4

MAN MACHINE AND MATERIAL

CALCULATIONS

24
Man Machine and Material Calculations
• The calculations for the man, machine and material have to be done
department wise depending.

• The type and quantity of equipment desired is to be determined by deriving

information from the process breakdown compiled.

• The desired Production capacity is of 3000 garments per day.

• Thus it is necessary to plan the capacity of the various production related

departments such that they have a capacity of 3000 garments at 100%
efficiency.

• This is required in order to synchronize the material flow among departments

and avoid excess WIP.

DEPARTMENT WISE CALCULATION

FABRIC STORE

Equipments Required

Storage pallets

• The main raw material fabric is to be stored on plastic pallets in the fabric store
by piling up rolls or arranging bales.

• The pallets have to be of moulded 4-way type.

• It has been preferably proposed to procure Sintex pallet (model-9PNR4-1012-

02).

• Dimension of each pallet- 1000mm X 1200mm X 200 mm (L X B XH).

25
 • Fabric required for one day (3150gmts)=3150*2=6300 mts

• Storage policy for fabric store= 7 days inventory.

Therefore,

• The required fabric meter age to be stored= 7*6300= 44100 mts.

• Average meter age available per roll= 100 mts

• There for the number of rolls required for storage= 441 (approx)

• Capacity of each plastic pallet=300-400 kgs.

• Average weight of fabric rolls of 150mts = 30 kgs.

• Thus, per pallet quantity to be stocked= 10 rolls

• Thus , Quantity of pallets required= 44

• Area covered in sft= 567.072 sft (approx).

• Benefits of plastic pallets for storage:

• Cost effective
• Compatible with all existing lifting systems
• Easy to clean & wash
• Excellent resistance to most chemicals
• Maintenance-free
• Rot proof
• Extensive testing to ensures quality standards
• Secure
• Robust design to render long service
• Meets all GMP requirements
• Hygienic
• Water proof
• High impact strength and rigidity

26
Fabric Checking Machine

• A fabric inspection machine would be required for the purpose of inspecting

the received fabric in order to certify the quality of the fabric and help in
making the batches of fabric as per shades.
• The fabric inspection machine that is to be procured is of Paramount (Model-
CheckMate Basic™).
• Dimension of each inspection machine- 2100 mm X 1475 mm X 1800 mm. (L X
B XH).

• The area covered by inspection machine=2.1*1.47= 3.087mt2

• Quantity of inspection machines=2

• Area covered in sft= 70 sft (approx).

Inspection tables

• Dimension of each inspection table- 12’x6’

• The area covered by inspection table=.72’

• Quantity of inspection machines=2

• Area covered in sft= 144 sft (approx).

Manpower (Personnel and labour)

• Quality Inspection- 3

• Quality assuarance-1

• Department in charge -1

• Office Clerks-3

• Helpers-5
27
 • Total manpower - 13

Material

• The raw material that is stored in the fabric store is only fabric for production.

• The material is available in rolls and bale form.

Accessory Store

Storage cabinet

• A storage cabinet is required for storing the required trims for production.

• A storage cabinet with multi level rack is apt for its compactness and less space
consumption.

• Preferably storage cabinets would be procured from Kompact systems.

• The dimension of 11 rack storage cabinet = 70”x30”(5.8’x2.5’)

• Total Area covered= 14.5 sft

Inspection tables

• Dimension of each inspection table- 12’x6’

• The area covered by inspection table=.72’

• Quantity of inspection tables =4

• Area covered in sft= 288 sft (approx).

28
 Man(Personnel and labour)

• Quality Inspection- 4

• Quality assuarance-2

• Department in charge -1

• Office Clerks-3

• Helpers-5

• Total manpower - 15

Material

• The raw material that is stored in the accessory store is only the trims and
accessory required for production.

• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.

29
 Thread Store

Storage cabinet

• A storage cabinet is required for storing the required threads and thread boxes
for production.

• A storage cabinet with multi level rack is apt for its compactness and less space
consumption.

• Preferably storage cabinets would be procured from Kompact systems.

• The dimension of 11 rack storage cabinet = 70”x30”(5.8’x2.5’)

• Total Area covered= 14.5 sft

Inspection tables

• Dimension of each inspection table- 12’x6’

• The area covered by inspection table=.72’

• Quantity of inspection tables=4

• Area covered in sft= 288 sft (approx).

30
 Man power(Personnel and labour)

• Quality Inspection- 2

• Quality assuarance-1

• Colour matching assistant-2

• Department in charge -1

• Office Clerks-2

• Helpers-5

• Total manpower - 13

Material

• The raw material that is stored in the accessory store is only the trims and
accessory required for production.

• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.

31
 Spreading and Cutting

Spreading and cutting tables

• Spreading and cutting will be done on the same table only

• The required capacity for 8 hrs shift is 3000 pieces.

• The average consumption for a shirt= 2mts.

• The length of the marker for a 4-way marker= 8mts.

• Preferable Number of plies per lay=100

• Number of garment required per hour= 3000*60/480= 375 gmts/hr.

Now,by Time standards

• Time for spreading 1 lay manually= 1.1 mins

• Time for spreading 100 lays = 110 mins.

Similarly

• Time for cutting 1 mts of lay= 0.041 mins.

• Time for cutting 800 mts(100 lays) of a lay= 800*0.041=32.8 mins

There fore

• For spreading and cutting 400 garments time required= 32.8+110=142.8mins.

• For spreading and cutting 1 garment time required= 142.8/400=0.35mins

Hence

• Number of garments spread and cut in an hour=60/0.35=171

• Thus, the required number of tables for spreading and

cutting=375/171=3( approx).

• The length of the table (assuming 4 way marker with allowances)=12 mts.

32
 • The width of the table (assuming max width of 60”) =162.5 cm=1.6mts.

• Area of spreading tables= 12*1.6mts= 19.2*3mts2= 57.6mts2=618.62sft

• The tables are to be of ceramic surface for smooth operations.

Cutting Equipments

• Each table has single straight knife cutting machine.

• Straight Knife cutting machine can be stored under the table and don’t need
separate storage.

• 2 band knife machines for recutting purpose.

• Area covered by band knife= 2.10mts*1.6mts= 3.36 *2mt2 =6.72mt2 =72.17sft

• 2 continuous Fusing machine required for fusing the fusible interlining on collar,
cuffs and placket.

• Area covered by fusing machines = 3.26mts*1.58mts= 4.84*2= 9.68mt2

=103.96sft

Storage racks

• 2 End bit racks of dimension = 1.17mts*0.61 mts=0.7137 sq mts= 15.33 sft (2

racks).

• 1 rack for remnant fabric pieces=1.17mts *0.61 mts= 0.7137 sq mts=7.62sft

Quality checking Tables

• 1 table = 2.45*1mts.58mts=3.871 sq mts=41.57 sft.

Bundling and ticketing tables

• 2 Bundling tables of dimensions= 2.45mt*1.58 mts

• Thus area for bundling tables= 7.742 sq mts= 83.14 sft.

• 1 Ticketing tables of dimensions= 2.45mt*1.58 mts= 3.871 sq mts= 41.57 sft

33
Man power (Personnel and labour)

• Master spreader - 3(1 per each table).

• Cutting master – 3 (1 per each table).

• Spreading helper-3(1 per each table).

• Cutting helper-3 (1 per each table).

• Department in charge -1.

• Office Clerks-3.

• Fusing machine operators-4.

• Recutting operator- 1.

• Total Manpower - 21

Material

• The raw material that is stored in the cutting room is only fabric for production.

• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.

34
 SEWING

Equipment Required

Sewing Machines

The following list provides the amount and type of machines required for
production /sewing of a single garment based on the sewing operation breakdown
(refer Product analysis).

The list is also representative of the machines required in setting a single sewing line

Sno Type of machine Quantity

1 SNLS 21
2 DNLS 4
3 SNCS 1
4 Feed of the Arm 1
5 Button attach 2
6 Button hole 2
7 5TH O/L 3
Total sewing machines 34

35
Specialized machines

Machines required for catering to special purposes such as collar turning , cuff
turning and ironing .

Sno Type of machine Quantity

1 Collar turning 1
2 Cuff turning 1
3 Ironing 2
Total specialized machines 4

Inspection tables

• 2 inspection tables of mid line and end line inspection of dimension ( ).

Manual operation Tables

• 2 tables for performing manual operation per sewing line.

Sewing lines

• Required production rate = 3000 garments /day

• Working hours per day= 8hrs (480 mins).

• Standard allowed Minute for Production of single garment= 20 mins.

• Minutes required for production of 3000 garments= 3000*20= 60,000 mins.

• Number of sewing machines/operators required to perform production in single

sewing line= 34.

• Efficiency desired for production= 60%

Therefore,

36
 • Total labour required for producing 3000 gmts in 480 mins using the efficiency
formula= Minutes required/Minutes available

• Hence total sewing operators= 3000*20/480*0.6=208 operators.

• Since, 34 operators are required per sewing line, the number of sewing lines
required for desired production level =208/34= 6 sewing lines (appox).

Sewing Work station

• In line with the production system proposed (PBS –zigzag motion), considering
the machines are arranged in two rows separated by a centre table.

• For calculation purpose, a single unit of a sewing line consists of two machines
on either side of the centre table inclusive of the centre table measurement
and operator workspace allowance.
OP6

Centre table
OP5

Operators for the

operation
5

Machines for operations

Illustration of a single unit of a sewing line

37
 • Measurement of the single unit of sewing line :

• Width- 1.20 mts(machine width -0.60mts+ operator allowance=0.60mts)

• Length-2.04mts (2* Machine length(2mts)+ centre table width-0.40

mts).

• Area of a single unit= 1.20mts*2.04mts= 2.88 sq mt-30.93 sft.

• There are such 17 units in a single sewing line

• Thus area of a single line= 525.83 sft.

• Since, there are 6 sewing line, working area= 3154.98sft.

Manpower

• Sewing Operators- 208

• Operator for specialized machines-30

• Helpers -30

• Quality checkers-12

• Supervisors- 1 per line=6

• Production manager-1

• Assistant Production manager-1

• Quality Assurance personnel – 3

• Total sewing department manpower = 291

38
 FINISHING

Finishing machinery list

Machine Model number quantity

Washing machine WS 35 fabcare 2

Hydro extractor HDS 25 fabcare 2

Tumble dryer DTS-60 fabcare 1

Pressing machine RAMSONS VEIT 4255- 5

65

Boiler RAMSONS diesel 1

steam generator

Machine requirements-

Different machines required are washing machine, hydro extractor, tumble dryer,
pressing machine, boiler.

• The washing machine which will be utilized is of fabcare, model number- WS

35.

Area of the washing machine = 1050 mm * 1200 mm=1260000 mm2

39
Number of washing machine used = 2

Therefore, area used = 2520000 mm2 = 27.11520 sq ft.

• The hydro extractor which will be utilized is of fabcare, model number- HDS 25.

Area of the machine = 1200 mm * 1350 mm=1620000 mm2

Number of machine used = 2

Therefore, area used = 3240000 mm2 = 34.86240 sq ft.

• The tumble dryer which will be utilized is of fabcare, model number- DTS-60.

Area of the machine = 1350 mm * 1690 mm= 2281500 mm2

Number of machine used = 1

Therefore, area used = 2281500 mm2 = 24.54894 sq ft.

• The pressing machine which will be utilized is of ramsons, model number- VEIT
4255-65.

Area of the machine = 110 cm * 32 cm =3520 cm2

Number of machine used = 5

Therefore, area used = 17600 cm2 = 18.93760 sq ft.

• The boiler which will be utilized is of ramsons diesel steam generator.

Area of the machine = 1150 mm * 1350 mm = 1552500 mm2

Number of machine used = 1

Therefore, area used = 1552500 mm2 = 16.70490 sq ft.

• Inspection Tables are required for different purposes which are initial checking,
thread trimming and final inspection.

40
Number of tables required = 12 (4 for 1st inspection+ 4 for thread cutting +4 for final
inspection)

Area of the table = 2.1 mts* 1.47 mts = 3.087 mt2 = 33.21612 sq ft.

• Sewing machines are also required for reworking if any.

Number of machine required = 5

Area required = 5* 1*0.60mts=3 sq mt= 32.22sft

Packaging

• 1 Metal detector for detecting metal parts within garments before packaging

• Dimensions of metal detector= 0.6mts *0.9 mts=0.54 sft=5.77 sft.

• 8 packaging tables of dimension 2.1mts * 1.47 mts

• Dimension of Packaging tables= 8*2.1*1.47=24.696mt2 = 265.23 sft

Total area required for the finishing machinery = 27.11 sq ft. +34.86 sq ft. + 24.54sq
ft. +18.93 sq ft. + 16.70 sq ft. + 33.21 sq ft. + 32.22 sft +265.23 sft = 452.80 sft.

MANPOWER

• Washers – 7

• Pressers-5

• Helpers -20

• Quality checkers- 10

• Quality assurance-5

• Finishing incharge =1

• Packers- 20

• Total manpower= 68
41
 PRINTING

Machinery details

Printing machines

• M&R challenger II –(16 colour) automatic

Curing machines

• Transwift mini curing machine

• M&R sprint 2000 – automatic continuous curing machine

Fusing /Heat Transfer Machines

• Cheran fusing machines-2

• HIX fusing machine

Screen development machinery

• Nu-Arc tri-light exposing machine

• M&R Digikote’T’ automatic coating machine

• 1 chamber heater.

• 4 Inspection tables

Total Area for Printing department= 1870 sft

42
Manpower

• Printers-5

• Colour developer-2

• Screen developers-5

• Curing machine operators-5

• Heat transfer operators=5

• Helpers -8

• Total manpower- 30

43
 Embroidery

Machine details

Embroidery machines

• Barudan (18 head 9 thread)-2

• Barudan (6 head 9 thread)-1

• Amaya XT (16 colour)-2

Patch cutting machine

• Golden laser cutting machine-1

Needle detector machine

• Hashima metal detector

Total Area for embroidery department= 1200 sft

Manpower

• Embroiders-5

• Patch cutters-2

• Laser cutting operator-2

• Helpers-6

• Total manpower- 15

44
 SAMPLING

Machinery Details

S.no Machine Quantity

1. Flat locks 8
2. Over lock 10
3. Feed of the arm 3
4. SNLS 17
5. Riveting machine 1
6. Straight knife 1
7. Ramsons veit iron table 1
8. Picotting m/c 1
9. buttonhole 1
10. buttoning m/c 1
Total machines 44

Storage Racks

• 2 storage racks

Table

• 2 pattern making tables

Area
• Total area of sampling department = 3700 sft

45
Manpower planning

• Cutting master – 2

• Pattern maker – 5

• Stitching master – 50

• Helpers – 10

• Sampling head – 1

• Total manpower – 68

46
 CAD DEPARTMENT

Machinery

• Gerber digitizer (16 button cursor)

• Gerber Plotter (Infinity series)

• 4 Desktops

Area covered by Cad department – 96 sft

Manpower Details

• CAD operators- 4

• Helper – 2

• Total operators - 6

47
 AMENITIES REQUIREMENT

Different amenities requirements are as follows:

• 2 water cooler per floor

• 4 toilets per floor

• 2 for operators (men and women)

• 2 for supervisors and officers (Men and women)

• Worker’s canteen on the top floor, area of 1000 sft

• Parking space at the basement

Total Setbacks of entire building is proposed to be 2000 sft with an estimate of 44 ft

at each side. This set back is for transport parking and loading/unloading of the
trucks.

48
 PART 5

Area allocation

49
 Store department–

Fabric store

Area covered by pallets 567.072 sq ft

Area covered by fabric checking 70 sq ft

machine

Area covered by Inspection table 144 sq ft

Accessory store

Area covered by storage cabinet 14.5 sq ft

Area covered by inspection tables 288 sq ft.

Thread store

Area covered by storage cabinets 14.5 sq ft

Area covered by inspection tables 288 sq ft.

Office area 200 sq ft

Total area 1586.072 sq ft

Total area with 20% allowance for 1903.286 sq ft

walking and storing auxiliary items

50
 Spreading and cutting department-

Area covered by the tables 618.62 sq ft

Area covered by the fusing machine 103.96 sq ft

Area covered by the band knife 72.17 sq ft

machine

Area covered by the end bit racks 15.33 sq ft

Area covered by the remnant racks 7.62 sq ft

Area covered by the quality checking 41.57 sq ft

tables

Area covered by the bundling and 83.14 sq ft

ticketing tables

Office area 200 sq ft

Total area 1142.41 sq ft

Total area with 20 % allowance for 1370.892 sq ft

walking and storing auxiliary items

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 Sewing department –

Area covered by the sewing floor 3154.98 sq ft

Office area 200 sq ft

Total area 3354.98 sq ft

Total area with 20 % allowance for 4025.976 sq ft

walking and storing auxiliary items

Finishing department –

Area covered by the washing 27.115 sq ft

machine

Area covered by the hydro extractor 34.86 sq ft

Area covered by the tumble dryer 24.548 sq ft

Area covered by the pressing 18.937 sq ft

machine

Area covered by the boiler 16.70 sq ft

Area covered by the inspection tables 33.21 sq ft

Area covered by the sewing machine 32.22 sq ft

Area of metal detector 5.77 sq ft

Area of packaging tables 265.23 sq ft

Office area 200 sq ft

Total area 658.585 sq ft

Total area with 20 % allowance for 790.21 sq ft

walking and storing auxiliary items

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 Printing and embroidery department -

Printing department area 1870 sq ft

Embroidery department area 1200 sq ft

Total area 3070 sq ft

Total area with 20% allowance for 3684 sq ft

walking and storing auxiliary items

Sampling and cad department-

Area of sampling department 3700 sq ft

Area of CAD department 96 sq ft

Total area 3796 sq ft

Total area with 20% allowance for 4555.2 sq ft

walking and storing auxiliary items

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 Auxiliary departments-

Reception area 100 sq ft

Merchandizing and marketing 200 sq ft

HR 150 sq ft

Finance and accounts 200 sq ft

IE 200 sq ft

Quality assurance 100 sq ft

Design 200 sq ft

Administrative 300 sq ft

PPC 200 sq ft

Canteen 50 sq ft

Total area 1700 sq ft

Total area with 20 % allowance for 2040 sq ft

walking etc.

Auxiliary-

The auxiliary block consists of various departments such as merchandizing,

marketing, PPC ,HR ,financial accounts,IE,Production,Design,Reception area and
etc.these consist of the offices where the various personnel perform their job.
The offices only consist of working desks and desktops for performing the job.
Each workspace is separate by a cabin wall. Preferably each cabin space must
be ergonomically of 2 cu meters.

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