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PLANT LAYOUT
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END TERM JURY

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12/4/2017

SUBMITTED BY:
RAHUL RAJ

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VISHWANATH KUMAR SAW

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OBJECTIVE: Preparation of the layout plan for a Shirt Manufacturing Company

DEMOGRAPHY:

 Place – Daman
 Latitude- 20° 25' N
 Longitude - 72° 53' E
 Weather – The temperatures are highest on average in May, at around 30.6 °C. January is
the coldest month, with temperatures averaging 22.3 °C.

 Sunrise/Sunset timing – During summer Sunrise timing on an average is 6:00 am and Sunset
timing on an average is 7:10 pm and during winter Sunrise timing on an average is 7:00 am
and Sunset timing on an average is 6:00 pm.
 Rainfall details –

 Sun Path –
PRODUCT DETAIL:

Fig. - A Full Sleeve Men’s Shirt

S.No. OPERATION SAM HELPER ACTUAL MACHINE
TIME
COLLAR PREPARATION
1 Mark Collar 0.31 Y 0.477 Helper table
2 Make Loop 0.12 N 0.185 Snls w/ ubt
3 Tack Loop&Attach 0.26 N 0.400 Snls w/ ubt
Loop to CLR Patch
4 Top Stitch on collar 0.2 N 0.308 Snls w/ ubt
with Patch
5 Make Collar 0.48 N 0.738 Snls we/c
6 Trim, Turn & Crease 0.31 Y 0.477 Collar turning
Collar machine
7 Topstitch Collar 0.31 N 0.477 Snls w/ ubt
8 Press Neck Band 0.32 Y 0.492 Iron Table
9 Match Band With 0.3 Y 0.462 Helper table
Collar
10 Attach Neckband To 0.48 N 0.738 Snls we/c
Collar
11 Trim & Turn Pick 0.32 Y 0.492 Helper table
12 Ready Cut Collar 0.16 N 0.246 Snls we/c
13 Press Collar 0.47 Y 0.723
Iron Table

CUFF PREPARATION
1 Mark Cuff 0.32 Y 0.492 Helper table
2 Hem Cuff 0.29 N 0.446 Snls w/ ubt
3 Make cuff 0.64 N 0.985 Snls we/c
4 Trim&turn cuff 0.3 Y 0.462 Helper table
5 Press Cuff 0.32 Y 0.492 Iron Table
SLEEVE PREPARTION
6 Notch Sleeve for PLKT 0.32 Y 0.492 Helper table
7 Attach Down Sleeve 0.31 N 0.477 Snls w/ ubt
PLKT
8 Tack Down Sleeve 0.22 N 0.338 Snls w/ ubt
PLKT
9 Press Top Sleeve PLKT 0.65 Y 1.000 Iron Table
10 Attach Top sleeve 0.96 N 1.477 Snls w/ ubt
PLKT&finish
FRONT
11 Hem Pocket Mouth 0.24 N 0.369 Snls w/ ubt
12 Press Patch Pocket 0.29 Y 0.446 Iron Table
13 Make Button Placket 0.3 N 0.462 Snls w/ ubt
14 Attach Top Plkt 0.62 N 0.954 Snls w/ ubt
15 Make Button Hole 0.65 N 1.000 Kansai
placket
16 Mark front For Pocket 0.31 Y 0.477 Helper table
Placment
17 Attach Pocket To 0.79 N 1.215 Snls w/ ubt
Front
BACK
18 Match Yoke to Back 0.32 0.492 Helper table
19 Attach Yoke To Back 0.47 N 0.723 Snls w/ ubt
20 Topstitch Back Yoke 0.46 N 0.708 Snls w/ ubt
21 Attach Patch to Back 0.48 N 0.738 Snls w/ ubt
22 Press Patchlabel 0.32 Y 0.492 Iron Table
23 Attach Patch Label to 0.64 N 0.985 Snls w/ ubt
Back With Main Label
ASSEMBLY
24 Match Front With 0.3 Y 0.462 Helper table
Back
25 Attach Shoulder 0.61 N 0.938 Snls w/ ubt
26 Topstitch Shoulder 0.47 N 0.723 Snls w/ ubt
Panel
27 Match Sleeves With 0.3 Y 0.462 Helper table
Body
28 Attach Sleeves 0.87 N 1.338 Snls w/ ubt
29 Topstitch Armhole 0.81 N 1.246 Snls w/ ubt
30 Tack Wash care Label 0.2 N 0.308 Snls w/ ubt
31 Sew Side Seam 0.79 N 1.215 Foa
32 Make Side Slit 0.81 N 1.246 Snls w/ ubt
33 Match Collar With 0.3 Y 0.462 Helper table
Body
34 Stay Stitch on Neck 0.29 N 0.446 Snls w/ ubt
35 Attach Collar to body 0.45 N 0.692 Snls w/ ubt
36 Close Collar 0.69 N 1.062 Snls w/ ubt
37 Topstitch Collar 0.31 N 0.477 Snls w/ ubt
38 Match Cuff To Body 0.32 Y 0.492 Helper table
39 Make Pleaet on 0.29 N 0.446 Snls w/ ubt
Sleeve
40 Attach Cuff To Body 0.63 N 0.969 Snls w/ ubt
41 Topstitch Cuff 0.58 N 0.892 Snls w/ ubt
42 Hem Bottom 0.65 N 1.000 Snls w/ ubt

43 Mark Front For Button 0.32 F 0.492 Helper table

Hole
44 Attach Button on Cuff 0.22 F 0.338 Button Attach
45 Make Button Hole on 0.21 F 0.323 Button Attach
Cuff
46 Make Button Hole 0.65 F 1.000 Button hole
47 Mark Front For Button 0.24 F 0.369 Helper table
Att
48 Attach Button on Front 0.63 F 0.969 Button Attach
Placket
TOTAL 26.2 40.308
DEPARTMENT DETAIL

DEPARTMENT DETAIL MANPOWER SIZE (feet)

Fabric Storage 8 132.5x100
Spreading & Cutting 29 62 x 132.5
CAD 7
Sewing – 287
Sewing Helper – 63 156 x 132.5
Others - 24
Finishing 65 60 x 102.5
Packing 28 50 x 60
Warehouse 4 54 x 50
Merchandising(Product
3 20’ × 20’
development)
Merchandising(Producti
4 20’ × 20’
on)
Sourcing 4 20’ × 20’
IE 6 20’ × 20’
Quality 8 20’ × 20’
PPC 4 20’ × 20’
533

DEPARTMENT AND MATERIAL HANDLING EQUIPMENT DETAILS

o Conveyor Belt (in Production)

o Roller Conveyor (in Packing and Warehouse)
o Overhead Rail (in Finishing)
o Underground Conveyor for Trims
o Fork Lift

SEWING DEPARTMENT MACHINE DETAILS

Furniture (Size) Machine(Size) Material Handling

Equipment
3 Spreading Table – 40ft * 6.5ft 2 Fusing Machine – 14ft * 5ft Fixed Roller Stand
1 Recutting Table 1 Plotter – 10ft * 4ft Pallet Jack
1 Checking Table 3 Band Knife -6.5ft * 5ft Trolley
2 Ticketing & Bundling Table
SEWING DEPARTMENT MACHINE DETAILS

Equipment Name Length(feet) Width(feet)

SNLS 3.5 1.8
DNLS 3.5 1.8
DNCS 3.5 1.8
SNEC 3.5 1.8
Button Hole 3.9 1.9
Button Stitch 3.9 1.9
Kansai 3.5 1.8
Checking table 8 4
Iron Table 3.5 2.3

DETAILED ACTIVITIES FLOW CHART (Department wise).

A) Fabric Arrived
1 Truck arrived at Gate
2 DC checked by security guard
3 Register entry and informing the concerned person

B) Fabric In-House
1 Truck Parking
2 Checking of order quantity with BOM
3 Unloading of raw materials into trolley/pallete
4 Fabric stored in In-house Inventory
Fabric Inspection (4-point, shrinkage, shade
5 variation)
6 Sent to Merchant for approval
7 i.) If accepted
a) Data entry into ERP system
b) Roll allocation according to the lot and shade
8 Fabric Requisition
9 Fabric issue according to requisition
10 Fabric kept in one-day inventory rack
(If relocation or washing required (one day before))

C) Cutting/ Spreading Dept.

1 Fabric issue to cutting Dept (Data entry)
2 Fabric spreading according to lay report
3 Lay pulling (If required)
5 Numbering/ Ticketing of panels
6 Inspection
a) Fabric defect (Data recorded)
 b) Cutting defect
7 Recutting (Recutting of rejected panel)
8 Fusing (If required)
9 Final Cutting Inspection
10 Bundling
11 Ready for issue to sewing (Trolley or Racks)
(Data Recorded)

D) Sewing
1 Super Market Area
2 Panelling according to style
Prepratory Section (Small part section/ Independent
3 Operations)
Loading of Panels to trolley inorder to move to
4 machine
5 Pairing of Panels
6 Assembly of Parts
7 Inspection (In-line and End-line)
8 i.) Accpeted
a) Button Hole marking and making
b) Trimmimng
c) Recording and Storage

E) Finishing
1 inside trimming
2 initial pressing
3 marking button
4 button attaching
5 initial checking
6 spotting and alteration
7 final checking
8 measurement checking
9 final audit
10 record and store

F) Packing
1 taggng
2 inspection
3 folding
4 polybag packing
5 metal detection
6 carton packing as per specs,stickering
7 carton inspection-sealed
8 place cartons on pallets
9 send to warehouse
 G) Warehouse
1 pallets received in warehouse-data entry
2 arrange cartons as per product
3 carton inspection before shipping
4 loading in container and data entry
5 shipment ex-factory and inform buyer

FACILITY DETAILS (Administration , Canteen, Toilet, Medical, Parking, Creche)

FACILITY CAPACITY QUANTITY SPACE

CEO Office CEO, Personal
1 table and chair for the CEO
Assistant, Waiter or 1 television 1 television stand
casual labour. 4 chairs
Can accommodate2 Sofas
about 10 guests at a2 tables
time. 1 table and 1 chair for the Personal
Assistant
2 chairs in the waiting room.
Medical Can accommodate 3 3 Beds
Room people at once 3 side tables
1 medical assistant 1 chair and 1 table for the medical
assistant
2 cupboards for the first aid ,basic
medicines and equipments.
HR Office 4 officials 4chairs for officials
1 HR Manager 4 tables for officials
10 other People 1 chair for HR Manager
1 Table for HR Manager
10 extra chairs
1 side table in the HR Managers
room
2 cupboards + 1 cupboard in the
HR Manager’s cabin
IT 2 20”× 20”
ACCOUNTS 2 20”× 20”
LOGISTICS 4 20”× 20”
GREEN BUILDING CONCEPT

 RAINWATER HARVESTING

A rainwater harvesting system comprises components of various stages - transporting rainwater

through pipes or drains, filtration, and storage in tanks for reuse or recharge. The common
components of a rainwater harvesting system involved in these stages are illustrated here.

 DAYLIGHT

While daylighting design can be relatively technical, we will use the following basic principles to
develop designs that address daylighting opportunities:

1. The effective daylighted area extends into the building only about 2 times the width of a
window and about 2 to 2.5 times its height.

2. Minimize the size of the east and west sides of the building and maximize the south and
north sides of the building. Because of the seasonally varying paths of the sun in the sky, it is
difficult to design east- and west-facing windows.

3. Simple top-light skylights should occupy 3% to 5% of the total roof area in order to provide
adequate levels of interior lighting.

4. Protect the interior from too much natural light—2.5 times or higher the level of ordinary
electric light—by employing appropriate window glass, exterior shading devices, interior
shading devices, or a combination of these.

The different state of the art of designing daylight building varies widely with climate and latitude. These
types are classified according to the following that will be used in factory:

o Shading Systems Using Diffuse Light

o Automated Blinds.
o Optical shutters.
o Shading Systems Using Direct Sunlight
o External Light Shelves.
o Internal light shelf ( redirecting daylight).
o Angular selective Skylight.
o Light pipes (duct / well).
SOLAR PLATE

Solar panels absorb the sunlight as a source of energy to generate electricity or heat. The most common
application of solar panels is solar water heating systems.
Daman receives a generous amount of sunlight for 8 out of 12 months in a year and shows a possibility of
harvesting the direct energy to run for a good part of the year.
Harvesting direct sunlight reduces the number of chargeable electricity units consumed, which in turn
reduces the bill we pay for it. Along with the most important aspect that is cost reduction, solar panels are
also environment friendly.
 LAND SCAPING AND GARDENING

LABOUR LAWS
 The State Government may, in respect of any factory or class or description of factories
make rules requiring the provision therein of suitable place for keeping clothing not worn
during working hours and for the drying of wet clothing.
 In every factory wherein more than five hundred workers are ordinarily employed there
shall be provided and maintained an ambulance room of the prescribed size, containing the
prescribed equipment and in the charge of such medical and nursing staff as may be
prescribed and those facilities shall always be made readily available during the working
hours of the factory.
 First Aid boxes or cupboards to be provided and maintained shall not be less than one for
every one hundred and fifty workers ordinarily employed at any one time in the factory.
 The shelters or rest-room or lunch-room to be provided shall be sufficiently lighted and
ventilated and shall be maintained in a cool and clean condition.
 Creche - In every factory wherein more than thirty women workers are ordinarily employed
there shall be provided and maintained a suitable room or rooms for the use of children
under the age of six years of such women.
 Such rooms shall provide adequate accommodation, shall be adequately lighted and
ventilated, shall be maintained in a clean and sanitary condition and shall be under the
charge of women trained in the care of children and infants.
 Provision of facilities for washing and changing their clothing and requiring the provision in
any factory of free milk or refreshment or both for such children.
 All floors, steps, stairs, passengers and gangways shall be of sound construction, and
properly maintained and shall be kept free from obstructions and substances likely to cause
persons to slip and where it is necessary to ensure safety, steps, stairs, passages and
gangways shall be provided with substantial handrails.
  Drinking Water - All such points shall be legibly marked "drinking water" in a language
understood by a majority of the workers employed in the factory and no such points shall be
situated within six metres of any washing place, urinal, latrine, spittoon, open drain carrying
effluent or any other source of contamination unless a shorter distance is approved in
writing by the Chief Inspector.

GENERAL REQUIREMENTS

• Occupant load per 100 sq. feet of covered area for industrial building Is 10.
• Industrial Buildings Ceiling height 3.6 m, except when air-conditioned, 3 m (Factory
Act,1948)
• Bathrooms and Water-Closets
• Height of bathroom or water-closet measured from the surface of the floor to the lowest
point in the ceiling (bottom of slab) not less than 2.1 m
• The area of a bathroom shall not be less than 1.8 m2 with a minimum width of 1.2 m. The
floor area of water-closet shall be 1.1 m2 with a minimum width of 0.9 m. If bath and water-
closet are combined, its floor area shall not be less than 2.8 m2 with a minimum width of
1.2 m
• Meter Rooms -For all buildings above 15 m in height and in special occupancies, like
educational, assembly, institutional, industrial, storage, hazardous and mixed occupancies
with any of the aforesaid occupancies having area more than 500 m2 on each floor,
provision shall be made for an independent and ventilated meter (service) room, as per
requirements of electric (service) supply undertakings on the ground floor with direct
access from outside for the purpose of termination of electric supply from the licensee’s
service and alternative supply cables. The doors have to be fire resistant.
• Minimum width of staircase for industry Is 2 meter, minimum tread 300 mm and maximum
riser 150 mm and minimum number of steps per flight is 12.
• Minimum 2 staircases required for an industry with area more than 500 m sq.
• Minimum aisle space 1.5m

EXITS

– If there are any bends or curves in the approach road, sufficient width shall be
permitted at the curve to enable the fire tenders to turn, the turning circle shall be
at least of 9.0 m. radius
– Main entrance to the premises shall be of adequate width to allow easy access to the
fire tender and in no case it shall measure less than 5 m. The entrance gate shall fold
back against the compound wall of the premises, thus leaving the exterior access
way within the plot free for movement of the fire service vehicles. If archway is
provided over the main entrance, the height of the archway shall not be of height
less than 5.0 m
– Lift and escalator are not considered as exits
– Exits shall be arranged so that a person doesn’t pass through another occupied unit.
– Maximum travel distance on the floor between fire exits is 30m
– Travelling distance from a remote point to the exit should not exceed 6m
– Every exit should open into an enclosed stairway , horizontal exit or corridor
passageway.
 – Exit width should be ore than 1000mm in width and 1000 mm in height

FIRE SAFETY

Section 38 of Factories Act, 1948 - Precautions in case of fire

38. PRECAUTIONS IN CASE OF FIRE

(1) In every factory, all practicable measures shall be taken to prevent outbreak of fire and its
spread, both internally and externally, and to provide and maintain - (a) safe means of escape for all
persons in the event of a fire, and (b) the necessary equipment and facilities for extinguishing fire.

(2) Effective measures shall be taken to ensure that in every factory all the workers are familiar with
the means of escape in case of fire and have been adequately trained in the routine to be followed
in such cases.

(3) The State Government may make rules, in respect of any factory or class or description of
factories, requiring the measures to be adopted to give effect to the provisions of sub-sections (1)
and (2).

(4) Notwithstanding anything contained in clause (a) of sub-section (1) or sub-section (2), if the
Chief Inspector, having regard to the nature of the work carried on in any factory, the construction
of such factory, special risk to life or safety, or any other circumstances, is of the opinion that the
measures provided in the factory, whether as prescribed or not, for the purposes of clause (a) of
sub-section (1) or sub-section (2), are inadequate, he may, by, order in writing, require that such
additional measures as he may consider reasonable and necessary, be provided in the factory
before such date as is specified in the order.

• Our plant area is - 24426 square foot

• Our assumptions- for 314 square foot , 1 fire extinguisher is installed .
• So, total fire extinguishers will be- 77 extinguishers