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OBJECTIVE
The objective of the project is to make a layout for anapparel manufacturing unit which produces 500 shirts per day. The aim of this project is to have a detailed knowledge about the departments of the apparel manufacturing unit and also knowing their importance in the factory. The space allocations for each department is very essential to know about the specifications of the work area. The detailed layout of the production ara of the factory helps in gaining the knowledge about the equipments used in the manufacturing of apparels as well as the whole process of producing them. Tha layout not only tells about the departments and equipments but also makes aware of the human conditions and human needs of the workers. This project is being very helpful in gaining the inside knowledge of the pparel manufacturing.
TABLE OF CONTENTS
TOPIC
PAGE NO.
1.INTRODUCTION
DEFINITION IMPORTANCE ESSENTIALS TYPES OF LAYOUT 2. FACTORS INFLUENCING LAYOUT 3. DYNAMCS OF A FACTORY LAYOUT 4. MAKING A FACTORY LAYOUT 5. GENERAL STEPS OF MAKING A PLANT LAYOUT 6. PRODUCT SPCIFICATIONS 7. DEPARTMENTS INVOLVED IN MANUFACTURING 8. WORK FLOW PROCESS
9.MACHINES REQUIRED 10.
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INTRODUCTION
The efficiency of production depends on how well the various machines; production facilities and employees amenities are located in a factory. Only the properly laid out factory can ensure the smooth and rapid movement of material, from the raw material stage to the end product stage. Factory layout encompasses new layout as well as improvement in the existing layout. An ideal factory layout should provide the optimum relationship among the output, floor area and manufacturing process. An efficent factory layout is one that aims at achieving various objectives like efficient utilization of available floor space, minimizes cost, allows flexibility of operation, provides for employees convenience, improves productivity etc.The entrepreneurs must possess the expertise to lay down a proper layout for new or existing plants. It differs from one factory to another. But basic principles to be followed are more or less same. While deciding for layout for factory or unit or store, a small entrepreneur has to consider the factors like the nature of the product, production process,size factory building, human needs etc
DEFINITION
A factory layout can be defined as follows; Factory layout refers to the arrangement of physical facilities such as machinery, equipment, furniture etc. with in the factory building in such a manner so as to have quickest flow of material at the lowest cost and with the least amount of the finished product. According to Ringgs, the overall objective of factory layout is to design a physical arrangement that most economically meets the required output-quantity and quality. According to J.L.Zundi, Factory layout ideally involves alloction of space and arrangement of equipment in such a manner that overall operating costs are minimized.
IMPORTANCE
Factory layout is an important decision as it represents long-term commitment. An ideal factory layout should provide the optimum relationship among output, floor area and manufacturing process.It facilitates the production process, minimizes material handling, time and cost, and allows flexibility of operations, easy production flow, makes economic use of the building, promotes effective utilization of manpower, and provides for employees convenience safety, comfort at work, maximum exposure to natural light and ventilation. It is also important because it affects the flow of material and processes, labour efficiency, supervision and control, use of space and expansionpossibilities etc.
ESSENTIALS
An efficient factory layout is one that can be instrumental in achieving the following objectives; a) Proper and efficient utilization of available floor space
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b) To esure that work proceeds from one point to another point without any delay c) Provide enough production capacity d) Reduce material handling cost e) Reduce hazards to personnel f) Utilise labor efficiently g) Increase employee morale h) Reduce accidents i) Provide for volume and product flexibility j) Provide ease of supervision and control k) Provide for employee safety and health l) Allow ease of maintenance m) Allow high machine or equipment utilization n) Improve productivity
TYPES OF LAYOUT
The factory layout facilitates the arrangement of machines, equipment and other physical facilities in a planned manner within the factory premises. An entrepreneur must possess an expertise to lay down a proper layout for new or existing plants. It differs from plant to plant, from location to location and from industry to industry. But the basic principles govering factory layout are more and less more. Manufacturing units In case of manufacturing units, factory layout may be of four types: 1) Product or line layout 2) Process or functional layout 3) Fixed position or location layout 4) Combined or line layout Product or line layout: Under this, machines and equipments are arranged in one line depending upon the sequence of operation required for the product . The materials move form one workstation to another sequentially without any backtracking or deviation. Under this, machines are grouped in one sequence. Therefore matereals are fed into the first machine and fineshed goods travel automatically from machine to machine, the output of one machine becoming input of the next. The raw material moves very fast from one workstation to other station with a minimum work in progress storage and material handling. The grouping of machines should be done keeping in mind the following general principles: a) All the machine tools or other items of equipments must be placed at the point demanded by sequence of operations. b) There should no points where one line crossed another line. c) Materials may be fed where they are required for assembly but not necessarily at one point. d) All the operations including assembly, testing packing must be included in the line.
Process layout: In this type of layout machines of similar type are arranged together at one place. The process or functional layout is followed from historical period. It evolved from the handicraft method of production. The work has to be allocated to each department in such a way that no machines are chosen to do as many different job as possible i.e. the emphasis is on general purpose machines. The grouping of machines according to the process has to be done keeping in wind the following principles: a) The distance between departments should be as short as possible for avoiding long distance movement of materials b) The departments should be in sequence of operations c) The arrangement should be convenient for inspection and supervision. Fixed Position or Location Layout: In this type of layout, the major product being produced is fixed at one location. Equipment labour and components are moved to that location. All facilities are brought and arranged around one work center. This type of layout is not relevant for small scale entrepreneur. Combined layout: Certain manufacturing units may require all three processes namely intermittent process the continuous process and the representative process combined process. In most of industries, only a product layout or process layout process or fixed location layout does not exist. Thus, in manufacturing concerns where several products are produced in repeated numbers with no likelihood of continuous production, combined layout is followed. Generally a combination of the product and process layout or other combinaion are found, in practice, e.g. for industries involving the fabrication of parts and assembly, fabrication tends to employ the process layout, while the assembly areas often employ the product layout.
e) Repairs and maintenance: Machines should be so arranged that adequate space is avaible between them for movement of equipment and people required for repairing the machines. f) Human needs: Adequate arrangement should be made for cloakroom, washroom, lockers, drinking water, toilets and other employee facilities, proper provision should be made for disposal of effluents, if any. g) Plant environment: Heat, light, noise, ventilation and other aspects should be duly considered, e.g. paint shops and plating section should be located be in another hall so that dangerous fumes can be removed through proper ventilation etc. Adequate safety arrangement should also be made. Thus, the layout should be conducive to health and safety of employees. It should ensure free and efficient flow of men and materials. Future expansion and diversification may also be considered while planing factory layout.
Lux for production and 800 Lux for inspection areas) besides ventilation. Also, the workplace should have sufficient number of mens and womens toilets and drinking water outlets in the vicinity.
PRODUCT SPECIFICATIONS
PRODUCT: mens shirt STYLE NO.: AX123 FABRIC: 100% cotton BRAND: Armani exchange COLOUR: royal blue STYLE DESCRIPTION: slim fit, full sleeves CAPACITY: 500 pcs./ day
MERCHANDISING
SAMPLING
CAD
PRODUCTION FLOOR
CUTTING
PINNING
SEWING
KAJ-BUTTON
LAYERING
PREPARATORY LINE
ASSEMBELY LINE
THREAD CUTTING
FINISHING
STITCHINGALTER
SPOTTING SECTION
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PRESENTATION CHECKING
PACKAGING
TAGGING
PACKING AREA
WAREHOUSE SECTION
SHIPMENT
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Fusing attach
Topstitch
Turning
Neck band
Collar back
Marking
Turning
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Ready cuff
Top stitch
FRONT
Left front
Right front
Placket attached
BACK
Yoke
Label attach
Placket
Pattern- 2 pcs.
Second placket
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ASSEMBELY LINE
SLEEVE ATTACH
SIDE SEAM
COLLAR ATTACH
CUFF ATTACH
KAJ- BUTTON
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FRONT
2 Single needle lock stitch machines
BACK
3 single needle lockstitch machines
SLEEVE 2 single needle lock stitch machines 1 pressing unit ASSEMBELY LINE
9 single needle Lock stitch machines
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Reception area: 30ft * 15ft VIP lounge: 30ft* 20ft CAD department: 15ft * 25ft Conference room: 15ft * 30ft Washrooms: 10ft *30ft Administration and finance office: 35ft *30ft Production, planning and control department: 35ft * 20ft Merchandising department: 37.5ft *25ft Sampling department:35ft *25ft Fabric store for sampling: 15ft *15ft Canteen: 37.5ft* 15ft
SPECIFICATIONS OF THE PRODUCTION FLOOR Accessories store: 15ft* 20ft Fabric store: 40ft* 20ft Fabric audit room: 20ft* 10ft Sorting and bundling: 3 tables Each table: 5ft* 3ft Cutting area: 2 tables Each table: 12ft* 6ft
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Sewing area: 50ft* 10ft In process Pressing area: 3 press stations Each press station: 5ft *5ft
Thread cutting area: 6.25ft* 16.25ft Finishing department: 29ft* 40ft 1. Post press checking: 5ft* 12.5ft 2. Rework and alterations: 5ft* 12.5ft 3. Spotting section: 5ft* 12.5ft 4. Pressing and folding: 10ft *15ft 5. Quality check: 10ft *15ft
Packaging department: 29ft * 50ft 1. Tagging section: 5ft* 7.5ft 2. Dyeing lot segregation table: 17.5ft *7.5ft 3. Storage area(warehouse section): 29ft* 20 ft
Production managers office: 10ft *10ft Maintenance department: 10ft * 20ft Medical room: 10ft *8ft Washrooms: 10ft* 40ft
DESIGNING THE WORKSTATION A workstation in the layout consists of the machine or equipment and the chair for the worker. It also includes some extra space for the sake of workers comfort during performance of the operation. DIMENSIONS: 3.5 ft* 3.75 ft
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The workstations are arranged in the layout in accordance to the workflow of the garment to be manufactured. The racks are arranged the two workstations in order to keep the parts of the garment. The rack also consist of a lower shelf so that the parts of both the workers should not mix with each other and it also provides convenience in work. The workstations are arranged in the sewing area with total of 28 machines covering the area of 50 ft* 10 ft.
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