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Apparel Plant Layout

Plant layout is a floor plan that arranges equipment and machinery in garment manufacturing to allow efficient material flow at low cost. A proper layout facilitates smooth workflow from receiving materials to shipping finished garments. It must also consider safety, allowing flexibility for changing production needs. There are basic layouts like flow forward and side-to-side, as well as typical layouts including linear, U-shaped, comb-shaped, block, star, quick response, and hanger conveyor layouts. Effective plant layout planning minimizes costs and transfer time, provides expansion room, and allows one-directional material feeding at high speed.

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47 views3 pages

Apparel Plant Layout

Plant layout is a floor plan that arranges equipment and machinery in garment manufacturing to allow efficient material flow at low cost. A proper layout facilitates smooth workflow from receiving materials to shipping finished garments. It must also consider safety, allowing flexibility for changing production needs. There are basic layouts like flow forward and side-to-side, as well as typical layouts including linear, U-shaped, comb-shaped, block, star, quick response, and hanger conveyor layouts. Effective plant layout planning minimizes costs and transfer time, provides expansion room, and allows one-directional material feeding at high speed.

Uploaded by

zinswe nandar
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Apparel Plant Layout

Plant layout is a floor plan for deciding and orchestrating the chosen equipment
and machinery of garment industry in the best suitable location to permit the quicker flow
of materials at a minimum cost and with the least amount of material handling during the
manufacturing process from the receipt of raw materials to the shipment of the finished
garments. A proper plant layout is directly associated with good workflow, right from
material receiving till the finished goods go out of the factory. An efficient plant layout
has the flexibility to be changed to meet requirements of the product line, delivery
schedules, and anticipated volume. Safety is a major consideration in garment plant
layout. Fire and safety codes, emergency and accessible exits, open traffic areas, etc.
must all be a part of layout plans in garment industry.

Types of Layouts

Basic Layout
1. Flow forward layout: Materials are collected from behind and to the left of each
operator, who then deposits the processed good in front of the next operator on
the table. This strategy is best for large production quantities with few pieces of
equipment used by each operator.
2. Side-to-side flow: In this approach, goods move from left to right or right to left.
This structure allows the operator to move more swiftly while simultaneously
operating multiple machines.

Typical Layout
1. Linear: The sewing space is located in the center of the floor, with cutting and
finishing stations on either end.
2. U-Shaped: When the start and end of the process operations are on the same end,
this architecture is ideal. In these situations, the machines are organized in a U
configuration. The advantage of this architecture is that the same employees may
supply the ingredients as well as handle the final goods. Because resources are
delivered and finished goods are handled at the same time, the production pace
becomes uniform.
3. Comb-shaped: This layout is created by connecting linear lines such that each
component preparation line is likewise a linear line and is connected to the main
line, which runs from where the material flows to where the parts are needed.
4. Block: Individual blocks are formed by combining multiple units, each of which
contains the appropriate sewing machines. This plan is ideal for production group
organization or semi-permanent layouts for small batch manufacturing lines with
frequently changing commodities.
5. Star layout: When many operations begin or conclude in the same operation, this
pattern is employed. The outputs from several departments that require label
attachment are organized around the label attachment department in the example
below. Following the attachment, they all go to the final step.
6. Quick response layout: Several processes are combined in this area to ensure
that the entire line is balanced. To guarantee high production efficiency, an
operator performs two or more processes simultaneously.
7. Hanger conveyor layout: Because it does not use the progressive bundle
concept, this style of layout eliminates the previous Work-in-Progress. allows all
of the materials for a specific garment to be transferred as a unit to any
workstation’s sewing machine. When an operation at one workstation is
completed, the system delivers the unit to the next workstation either
mechanically or automatically. It was created to cut down on material handling
time. Such a system’s layout must be continuous, with no gaps in between. The
materials flow through the layout in a loop shape.

Factors for Planning Plant Layout in Garment Industry


The following factors should be taken into consideration while planning a plant
layout:
1. Minimization of manufacturing cost,
2. Feeding the materials and parts at highest possible speed and in one direction
without any backtracking or overlapping flow of products,
3. Minimization of work transfer among the processes from acceptance of raw
materials till delivery of finished product with properly defined spaces for each
process, and
4. Provision of future expansion plans.
The plant layout planning should be done based on factory site selection and arrangement
of building and machines.

https://intactone.com/plant-layout-objective-of-good-layout-factors-
influencing-layout-and-types-of-layout/

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