Plant Layout

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NIFT, NEW DELHI

PLANT LAYOUT

Formal Men’s Shirt Manufacturing Unit

BY: BHINI YADAV KUNAL NAKRA MAMSHI OSHIN SAMIRAN HAZARIKA VASUNDHRA SHARMA

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Objective: To propose a plant layout for formal men’s 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 department’s 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.

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Steps Involved in facility design

1.

Procure the basic data: like Sales forecast, Quantity to be produced, Production schedule, Inventory policy, Production routing, Operations to be performed, Production time standards and Scrap percentages.

2.

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.

3.

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.

4.

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.

5.

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.

6.

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.

7.

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.

8.

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.

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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. ¼” = 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

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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

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Product Information:   Tech – Pack:

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Style Details:

Base Fabric Blue & white checks

Stitching Thread DTM

Button White colored Shell button

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Measurement sheet:

S. No Description M Tolerance(+ / - )

1 Neck line length 43 .5

2 Distance b/w Shoulder 45.5 .5

3 Total Sleeve length 67.5 .5

BUYER ADDRESS: XYZ GARMENT EXPORT COMPANY, NEW DELHI

Product ID 01126357 Product name Full sleeve Men’s

cotton shirt

Order Quantity 1500 Group Plain

Season Summer Brand Local

Size M gender Male

Fabric 100 % cotton Date 16/12/14

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4 Armhole height from Neck point 29 .3

5 Sleeve width 21.5 .3

6 Bottom Sleeve width 11.8 .1

7 Chest Width 55 .5

8 Bottom Width 55 .5

9 Total Length from HSP 78 .5

10 Back yoke height at neck point 9.8 .1

11 Front cross (at ½ arm) 41.5 .3

12 Back cross (at ½ 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 6 .1

18 Collar Height 4 .1

19 Collar band Height 3 .1

20 Shoulder Slope 4.8 .1

21 Shoulder forward 2.5 0

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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

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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 decision-making 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

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Government and Industry Compliances: Compliance with Labor Laws, Human

Rights, ILO compliance, Vendor Compliance, Government Policies, State Government Laws and Minimum Wages.

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Production Process Design

 Part names and number:

Part name Quantity per Garment Make/buy

Front 2 Make

Back. 1 Make

Yoke (Back). 2 Make

Sleeve. 2 Make

Collar. 1 Make

Collar band. 1 Make

Cuff. 2 Make

Sleeve placket. 2 Make

Pockets. 1 or 2 Make

Front placket (Button/Button hole). 1 Make

Buttons 7-8 Buy

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 Operation Bulletin:

Machine Requirement Calculation for one line

Sewing SAM

26.2

Helper SAM 6.4

Finishing SAM 2.27

Target Output 1500 pieces per day for 4 lines

Shift Time 480 minutes

Operator

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S. No. Manual Qty Sewing Qty Finishing

1. Helper table 14 SNLS w/ubt 30 Button Attach

2. Collar turning m/c 1 SNLS we/c 4 Button Hole

3. Ironing Table 6 SNCS 0

4. FOA 1

5. KANSAI 1

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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 CEO Office

Sewing Trims & Accessories Store Accounts Department

Spreading and Cutting Section HR Department

Sewing Section Medical Room

Finishing Section Training Department

Merchandising Department Conference Room

Sampling & Technical Department Reception

Quality Department Generator, Boiler, Compressor and other utilities Room

CAD Section Security Room

IE Department Toilets

Maintenance Parking

Warehouse

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

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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.

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Machine Requirements & Measurements

Daily output requirement is 1500 pieces.

Fabric Section:

Equipment Quantity Description/ Capacity

Fabric Inspection Machine (72”

width) 1

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:

Plotter 1 FASTJET Plotter (7ft x 2ft)

Digitizer 1 Lectra Digitizer (3.9ft x

5.9ft)

Table 1 4ft x 4ft

Computer 3 HP All-in-One - 18-5201ix

(2ft x 4ft)

Spreading, Cutting & Fusing Section:

Spreading Table & Cutting Table 2

GERBER SY-251 AUTOMATIC SPREADER

110 yards maximum speed per minute, 72" material width, 525 lb. maximum roll

weight 81 in x 180 in Pinning, Numbering, Bundling

Table 2 12m x 1.8m

Fusing Machine 1

ASTEX MODEL 3024SC Continuous Fusing System,

298cm x 96 cm

Band Knife 1

EC-700N, cutting capacity 180 mm, Table size

1500*1800mm

Straight Knife 4 Brute®(Model 627x),

cutting capacity 21.5 cm [Assumption- Automatic Spreading and cutting done on same table.]

Sewing Section:

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Finishing Section:

Fork Lift 1 Caterpillar P5000 Forklift, 7ft

x 4ft

Iron Table 4 Ramson 4.3ft x 3.2 ft

Thread Sucking 1

DST TS-01 Avg Capacity> 2000 pcs / 8 hrs; 650 X 1435 X 1275 mm

Stain Remover 1 Ramson-CL7

Needle Detector 1

HM-6000

1,600(L)×1,050(W)×920(H) mm

Automatic Steam Generator 2 Capacity for 2 irons, 2ft x

1.5ft x 4ft

Machine Measurement:

Machine Type Length Width

Inches Feet Inches Feet

SNLS 42 3.5 21.2 1.8 DNLS 42 3.5 21.2 1.8 DNCS 42 3.5 21.2 1.8 SNEC 42 3.5 21.2 1.8 B/H 47 3.9 22.5 1.9 B/S 47 3.9 22.5 1.9 B/S feeder 47 3.9 23 1.9

B/H B/S Tandem without feeder 48 4 28 2.3

B/H B/S Tandem with feeder 60 5 40 3.3

Auto Jig 43 3.6 32.5 2.7 Front Pressing 52 4.3 45 3.8 Sleeve plkt Pressing 42 3.5 21.2 1.8 Contour 35.5 3 23.5 2 Collar Notch 42.5 3.5 24.5 2 Kansai 42 3.5 21.2 1.8 Back Stacker 42 3.5 21.2 1.8 Cuff Stacker 53.5 4.5 21.2 1.8 Collar blocking 42 3.5 34 2.8 Cuff Blocking 24 2 33.5 2.8 Checking table 47 3.9 38 3.2 Iron Table 1 41 3.4 25 2.1 Iron Table 2 51 4.3 31 2.6 Table 48 4 31 2.6 Folding Table 60 5 36 3

Collar and Cuff Press 60 5 48 4

Collar Press 36 3 24 2

Stain Remover 60 5 48 4

Needle Detector 72 6 48 4

A-type Trimming Table 48 4 36 3

Washing Mc 24 2 18 1.5

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Light Box 28.8 2.4 20.4 1.7

Proposed Workstation Layout For Assembly Section

Sewing Workstation:

Note:

 Area consumed by each workstation = 2 sq meters.

 Feet space is being provided for operator’s sitting and movement.

 On right hand side of workstation main aisle of 3 feet is being provided. Checking Workstation (Supervisor and QC):

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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.

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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 Layout:

 Industrial trolleys (hand trucks, panel carts, ladders)  Storage bins

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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

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.

Activities Fa b ri c S to re Tr im S to re S p re a d in g & C u tt in g S e w in g Fi n is h in g M e rc h a n d i si n g S a m p lin g Q u a lit y C a d IE Fi n a n ce M a in te n a n ce E x p o rt P P C Fabric Store U A O U I U U U U U U O U Trim Store U U O A I O O U U U U O U

Spreading & Cutting A U A U I O I A I U I U I

Sewing O O A A I O A U A U A U I Finishing U A U I I O I U U U O U U Merchandising O O O I O A O O U U U U U Sampling O O O I U A I U U U O U U Quality I I I A I O I U U U U U O Cad U U A U U U U O U U O U O IE U U I A I U U U U U U U O Finance U U U U U O U U U U U O U Maintenance U U A A A U O O O O U U U Export O O U U U O U U U U U U U PPC U U I I U U U O ? ? U U U Where, A Absolutely Necessary E Especially Important I Important O Ordinary Important U Unimportant X Undesirable

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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)

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 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

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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 Quantity Dimensions( in feet) Area Req. (Sq. ft)

Table 1 4*3 12

Chair 7 1*1 7

Almirah 4 3.5*3 42

Cubicle 1 10*10 100

Total 162

Equipment Quantity Dimensions( in feet) Area Req. (Sq. ft)

Desktop 3 -

-Printer 1 -

-Copier Machine 1 3*3 9

Total 9

General Admin:

 CEO Cabin of dimension 20*10=200 Sq Ft Furniture/

Equipment Quantity Dim (ft) Area Required (Sq. ft)

Table 1 4*3 12

Chair 3 1*1 3

System 1 -

-Total 15

Export Import Department:

 Area Required: 17*15 = 255 Sq Ft  Man Power Required: 2 people

Furniture/ Equipment Quantity Dim (ft) Area Required (Sq. ft)

Table 2 4*3 24 Chair 3 1*1 3 System 2 - -Cabinet 1 3.5*3 10.5 Total 35.5 Financial Department:

(34)

 Area Required : 17*15= 255 Sq Ft  Man Power Required:

 1 Head

 2 Accountants

Table 4 4*3 48

Chair 4 1*1 4

System 3 -

-cabinet 1 3.5*3 10.5

Total 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

Table 1 4*4 16 Chair 4 1*1 4 System 4 - -Cabinet 2 3.5*3 21 Cubicle 1 10*10 100 Hanger Stand 2 10*3 60 Total 201 B. Sourcing:

 Man power required 2 sourcing Persons 1 Helper

Reception:

 Area Required: 10*10= 100 Sq Ft  Man Power Required: 1 Receptionist

Chair 4 1*1 4

System 3 -

-Cabinet 4 3*22 284

Table 2 4*3 24

(35)

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 Quantity Dim (ft) Area Required (Sq. ft)

Table 3 4*3 36

Chair 7 1*1 7

Racks 10 6*3.3 198

Total 241

Trolley 2 3*4.5 27

Weighing Machine 1 3.2*1.6 5.12

Inspection Machine 1 7*4.6 32.2

Color matching Cabinet 1 13.12*13.

12 172.5

Total 236.56

Trim Store:

 Area required = 19 x 13 sq ft = 247 sq ft  Man power requirement

 1 In-charge

 1 inspection personnel  1 Helper

Racks 10 5*2*6 100

Table 1 4*4 16

Chair 1 1*1 1

Stools 3 1*1 3

Total 120

Cad Department, Cutting Department& Fusing Department:  Area required = 75 x30 sq ft= 2250 sq ft

 Man power requirement  1 In-charge

 2 personnel

Plotter ₁ 7.36*2.15*3

.83 15.82

Digitizer 1 3.91*5.90 23.08

Total 38.9

(36)

Table 2 4*4 32 Chair 4 1*1 4 Cabinet 1 3.5*3*6.5 10.5 System 13 - -Total 46.5 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

Spreading/ Bundling Table 4 10*5*3 200

Table 1 4*4 16

Chair 3 1*1 3

Racks 5 4*2*6 40

Cabinet 1 3.5*3*6.5 10.5

Total 269.5

Straight Knife 3 - -Band Knife 1 7.49*4.89 36.62 Fusing Machine 1 7.38*2.78* 4.0 20.57 Total 57.19 Sewing Department:  Area required = 75 x 40 sq ft = 3000 sq ft  Man power requirement:

 1 In-charge  4 supervisor  221 workers

Ironing Table 2 3*5 30

Inspection Table 4 7*3 84

Trolleys 5 5*2 50

Total 164

SNLS W/UBT 30 3*2 185.4

SNLS WE/C 4 3*2 24.72

(37)

KANSAI 1 3*2.1 6.30

Total 222.72

Quality Department:

 Area required = 20 x 10 sq ft ; Total Area = 200 sq ft  Manpower requirement:

 1 Quality manager  8 checkers

Table 1 4*4 16

Chair 5 1*1 5

Cabinet 1 3*3.5 10.5

Total 31.5

Industrial Engineering Department:  Area required = 20 x 20 sq ft= 400 sq ft  Manpower requirement

 1 In-charge  6 people

Table 2 4*4 32 Chair 4 1*1 4 Total 36 Maintenance Department:  Area required = 20 x 25 sq ft = 300 sq ft  Manpower requirement  1 In- charge  4 personnel

Table 1 4*4 16

Chair 3 1*1 3

Cabinet 1 3.5*3 10.5

Total 29.5

PRE-PRODUCTION:

 Area Required = 20 x 10 sq ft ; Total Area = 200 sq ft  Manpower requirement = 2 people

(38)

Chair 3 1*1 3 Total 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

Pattern Table 1 5*4 20

Cutting Table 1 5*4 20

Stools 15 1*1 15

Cabinet 1 3.5*3 10.5

Total 65.5

SNLS W/UBT 12 6.18 74.16 SNLS WE/C 4 6.18 24.72 Button hole 1 6.18 6.18 Button Attach 1 6.18 6.18 FOA 1 6.30 6.30 KANSAI 1 6.30 6.30

Mini Boiler Cum 1 5*3 15

Total 138.84

Training Room:

 Area Required = 35 x 18sq ft= 630 sq ft  Man Power Requirement:

 1 Training head  2 Trainers

Table 1 4*4 16

Chair 23 1*1 23

Total 39

SNLS W/UBT 15 3*2 92.7

SNLS WE/C 3 3*2 18.54

FOA 1 3*2.1 6.30

KANSAI 1 3*2.1 6.30

(39)

Conference Room:

 Area Required = 31x20 sq ft  Total Area = 620 sq ft

Table 1 10*5 50 Chair 16 1*1 16 Mannequins 2 2*2 8 Total 74 Meeting:  Area Required = 10x10 sq ft  Total Area = 100 sq ft

Table 1 10*7 70

Chair 8 1*1 8

Total 78

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

Table 4 8*4 128

Stool 8 1*1 8

Iron table 8 7*3 168

Thread Sucking machine 1 4*5 20

Button hole 4 6.18 24,72

Button Attach 4 6.18 24.72

Stain Removing Station 1 8*8 64

Needle Detector 1 3*2 6

Carton Packing 1 3*2 6

Total 449.44

Washing:

(40)

 Man Power Required  1 In Charge  4 Washers

 2 Finishing helpers

Furniture/Equipment Quantity Dim (ft) Area Required (Sq. ft)

Table 1 8*4 32 Washing Machine 3 8*12 288 Dryer 1 5*7 35 Total 355 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

Table 10 5*3*3 150 Chair 100 1*1 100 Serving Table 1 10*2*4 20 Total 270 Security Department:  Area Required 10 * 10 = 100 Sq Ft

 Man Power Requirement: 2 Security guards

Table 1 4*4 16

Chair 2 1*1 2

Cabinet 1 3.5*3 10.5

Total 28.5

Generator:

 Total Required Area = 300 Sq ft [It is outside the main building.]

Checklist for Evaluating Plant Layout:

(41)

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

(42)