NATIONAL INSTITUTE OF FASHION TECHNOLOGY, GANDHINAGAR

PLANT LAYOUT

Submitted to: Submitted by:

Mr.Manoj Tiwari Aryan Singh

Ruchika Tripathi

Swati Singh

DFT- 7
Plant layout is the spatial arrangement and configuration of departments, work
stations, machinery and equipment used in the conversion process. Layout of
an apparel production plant directs the flow of materials and work-in-process
from start till its completion and integrates material handling and equipment.
An efficient 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 plant layout. Fire and safety codes, emergency and accessible
exits, open traffic areas, etc. must all be a part of layout plans.

The following factors should be taken into consideration while planning a

layout:
 Minimization of manufacturing costs
 Efficient work flow
 Minimization of work transfer
 Provision of future expansion

Selection of Factory Site
Demographic, Infrastructural, Natural and Social factors should be
considered before selecting a location for a factory site.
Demographic and Infrastructural analysis is all about understanding
population age groups, per capita income, education level, occupational
structure and availability of skilled and non skilled manpower, technically
qualified and trained supervisors and managers, transportation cost, link
roads, nearness to railway station, airport or sea port, banking and financial
institutes..

Natural and social factors like climatic conditions, pollution, public hazards,
political problems, local laws and regulations, medical services, public
utilities, civic amenities and means of communication should also be
analysed before selection of the layout.

Layout of the Plant

Layout of the plant is decided based on process sequence, building
structure, shop floor transportation, type of layout (product or process
based or a combination of both) and arrangement of machines. The aim of
every layout is to maximize utilization of available space in order to speed
up the material flow. Highly specialized machines and small parts assembly
may be configured with a line arrangement for final assembly.

Factors to be considered for designing an effective layout include number

of workers both male and female, number of machines (size, weight by
models), entrance, exit and passages (size, width, position, number of each
of them) for production as well as administrative wing, change room, lunch
room, lavatories, medical emergency room and provision for those
governed by local laws. Utilities like boiler, air compressor, vacuum pumps,
generator, electric panel, air conditioning machine, underground water
storage tanks for boiler and washing machines, water softening plant,
waste water recycling plant, drainage system are also equally important. 

Other factors that need attention before laying out the factory plan include
ceiling height (3-3.5 metres from floor), lighting (large windows of 2 or 3
stages) and illuminance levels (600 Lux for production and 800 Lux for
inspection areas) besides ventilation. Also, the workplace should have
sufficient number of men’s and women’s toilets and drinking water outlets
in the vicinity.
Objective: To set up a manufacturing unit producing 3500 women’s semi
formal shirt per day

Plot Area: (22*100) 2200 sq m

FSI – 1.2

Ground Coverage: 80%

Total area that can be constructed = 2200 * .80 = 1760 sq m

Specifications of the style studied

Raw Material Specification Consumption/garment

Body Fabric Poplin 1.81 m
Interlining Microdot 0.42 m
Button Plastic (14 L) 16 pcs
Thread (Ticket No. Spun Polyester 35 m
25)
Thread (Ticket No. Spun Polyester 38 m
50)
Thread (Ticket No. Spun Polyester 195 m
100)
Paper Printed tag - 1 pc
Printed Paper 1 pc
Main Label 1 pc
Wash Care Label 1 pc

STORES DEPARTMENT

Process flow chart :

 Stores

Receipt of Bill Of Materials

Package verification against packing list for weight & no of packages

Materials received

Lab test To be inspected Trim card for accessories

Yes No Inspection process

pass Rejected

Inspection fail

Quality checking
Conditionally approved by buyer Rejected

Storage of passed material

Storage in rejected Area
Update status to production

Issues of fabric to cutting section based on lay record

Issues of trims to production

Receipt of left over materials from production

Receipt of end bits from cutting section

In stores department we have to keep an inventory of 15 days for the required

raw material.

Therefore we have to plan the no. of racks required and their dimensions.
Racks for Accessories:

All the accessories will be kept in a box.

Here we have assumed the dimension of the box and approximately the no. of
pcs that can be accommodated in the box.

Accessories Required Dimensio No. of pcs that Volume Required

Amount n of box can be of box(in volume
for 15 (inches) accommodated cubic (in cubic
days l*b*h inch) inch)
Button 840000 3*2.5*2 2000 15 6360
Thread(Tk 1837500 8*8*2.5 30000 160 9800
No. 25)
Thread(Tk 1995000 8*8*2.5 30000 160 10640
No. 50)
Thread(Tk 10237500 8*8*2.5 30000 160 54600
No. 100)
Printed 52550 4*3*2 100 24 12612
Paper Tag
Printed 52550 16*16*1 200 256 67264
Paper
Main Label 52550 5 Dia*2 375 157 22000
Wash Care 52550 5 Dia*2 375 157 22000
Label
205276
Therefore total required volume (in cubic inch)
Dimension of racks for accessories = 34*21*66(inches) or 0.86*0.53*1.6
meters

Total Volume required (in cubic inch) = 205276

Therefore 4 racks will be required.

Racks for body fabric and interlining

Fabric Interlining
Required length for 15 95025 22050
days (m)
Length in a roll (m) 300 100
No. of rolls req. 317 220
Diameter of roll (inch) 12 6
Length of roll (inch) 64 40
No. of rolls in one 7 10
shelf(assumed)
Length of the rack(as per 84 60
given rolls/shelf) (inch)
Ease of roll movement 5 5
lengthwise (inch)
Final Length of 89 65
shelf(inch)
Ease of roll movement 6 6
heigthwise (inch)
Distance b/w two 18 12
successive shelfs (inch)
Required no. of shelves 45 22
Height of the rack(inch) 90 75
No. of shelves in one 5 6
rack
Width of the rack 69 45
Dimension of the 89*69*90 65*45*75
rack(inches)
Dimension of the 2.26*1.75*2.28 1.65*1.14*1.90
rack(meters)
No. of racks required 9 4

There will be two fabric inspection machines in stores department of

dimension 2.43*1.82 meters

CUTTING DEPARTMENT
 Receive fabrics from stores

Sample cutting

Approval of sample cutting

Receipt of cut file & pattern ( CAD Process)

Plan for cutting based on basic cutting plan & fabric allocation

Release lay record

Receipt of fabric

Laying & spreading Marker inspection

Lay inspection

Cut parts inspection

Numbering

Panel checking
 Re cutting

Embroidery / printing / fusing

Fusing inspection

Sorting

Storage

Issue to sewing

Dimension for cutting room furniture

For fabric:

Length=Marker length + allowance for fabric rolls

We have taken marker length (4 way marker) = 7.15m

Allowance = 1.5 m

Total length = 8.65 m

Width =Width +Allowance

Width=1.52 m

Allowance=0.3 m

Total width =1.82m

Dimension of cutting table for fabric =8.65*1.82*0.84 meters

For fusing:
Consumption= 0.42 mt

Total consumption per day = 0.42 * 3500

= 1470 mt per day

Since fusing has to be used only on cuff and collar, hence only one table, of
dimension 8.65*1.82*0.84 has been taken for spreading and cutting

No. of tables required

Total no. of minutes=480

Width(m) 1.52
Components of 28
garments
Cut capacity/day 3500
Marker Length(m) 7.15
No. of garments in a 4
marker
Av. Fabric 1.81
consumption(m)
No. of plies in lay 135
No. of lays 7
Av. Time for laying 140
/lay(mins)
Av. Time for cutting 100
/lay(mins)
Total time for cutting & 240
laying (mins)
 Total no. of tables for 4
laying & cutting
Av. Tim for sorting 1 1
garment/person(min)
Av. Time for sorting 500
500 garments(min)
Sorting and bundling 2
tables
No. of fusing machines 2
(3.3 x 1.6 mt)
Band knife machine s 1
(2.25 x 1.5)
Fusing assisting tables 2
Trolleys

In cutting dept. there will be fabric temporary storage.

Calculation of Fabric Temporary Storage

Fabric
Cutting days inventory 1.5
Required fabric 9502
length(m)
Length in a roll (m) 300
No. of rolls req. 31
Diameter of roll (inch) 12
Length of roll (inch) 64
No. of rolls in one 2
shelf(assumed)
No. of rolls in a rack 15
No. of racks 2
Ease for roll 6
 movement(inches)
Length of rack(inches) 66

Therefore the dimensions of the rack = 66*60*42 inches or 1.32*1.2*0.84

meters

SEWING DEPARTMENT
 Receipt of cut parts from cutting section

Receipt of machine layout

Study of layout & set the batch

Load pilot run lot

Approval of pilot run

Load bulk cutting

Monitor production as per target

End line checking

Total SAM = 23.27 minutes

Total operations (including ironing, marking) = 48

Total time available = 480 minutes

Total pieces required = 3500

 Pieces per minute = 3500/480

= 7.30 pieces

Operation breakdown and line balancing has been done keeping in mind the
pieces required and the SAM of the individual operations. Accordingly, number
of machines required for each operation has been found out.

Line Layout:
The layout that has been chosen for the line is the most common method of
arranging machines with centre table option; here all operators are facing in
one direction. For one column of workers the centre table is on left, while for
the other column of operators the centre table is on right, hence differential
ease of bundle pickup and disposal. Centre table on the left side of the
operator is always better for larger component. For operations involving a two
component assembly where picking has to be done from both right and left of
the operators, the service table at right is advisable, this is because additional
extension space can be created at left side with comparative ease but creating
additional space at right side of machine is difficult. Generally wiring is done
underneath the centre table, and sewing machine motor is on right side of
sewing machine table, so wiring for one column of sewing machine is
cumbersome. Material movement in this type of layout is
lateral/vertical/zigzag. Light source has to be separate for two columns of
machine, thus infrastructure cost for lighting will be more. As operators are
facing same sides (regimental seating) they are less prone to talk. The
arrangement is ‘vaastu-friendly’.
 FINISHING SECTION

Receive garments from sewing section

Middle checking

AQL inspection

Receipt of poly packing approval

De dusting with blower

De dusting & removal of cut thread

Pressing

Measurement checking

Folding

Tagging

Poly bag packing

Presentation checking

To packing section
Operation SAM Pcs/min Required Dimesnion of Table No. of
People (mt) tables

Thread Trimming 0.43 2.33 3.13 4 by 2 1

Primary Inspection/ 0.64 1.55 4.70 8 by 2 1

Spotting

Ironing 0.64 1.56 4.67 1.16 by 0. 65 5

Measurement 0.85 1.18 6.19 8 by 2 1

Check/
Final Check

Final Ironing 0.96 1.05 6.97 1.16 by 0.65 7

Total 3.52 25.66

Pices 3500
Minutes/day 480
Pieces/min 7.29

Warehouse space calculation:

Length –0. 26 mt

Width = 0.41 mt

Height= 0.05 mt

Volume = 0.26 * 0.41 *0.0 5 = 0.005 cubic mt

Dimension of box :

Length = ,71

Breadth = .51 mt

Height = .51 mt

Volume of box = .185 cubic mt

Number of garments in one box = 0.185/0.005 = 37

Number of boxes for 3500 garments = 3500/37 = 95

Number of boxes for 15 days’ inventory = 95 * 15 = 1425

Area of one box = 0.36 sq mt

Area of 1425 boxes = 513 sq mt

Now, we decide to keep the boxes in a stack of 8, then :

1425/8 ~ 179

Area = 178 * 0.36 =64.08 sq mt

Hence, a room of 9mt by 8 mt has been made for warehouse.

 LIGHTING DIAGRAM

Definition

A light source emits a flow of energy measured by a unit of power called a

lumen. The density of light that falls on a surface is measured in foot candles,
or lux. A foot candle is one lumen of light density per square foot. A lux is one
lumen of light density per square meter. The foot candle is an older British
measurement that is largely being replaced by the metric-based lux.

Lumen: a unit of luminous flux equal to the amount of light given out through a
solid angle of 1 steradian by a point source of 1 candela intensity radiating
uniformly in all directions

Outdoor light levels, as measured by a light meter, can range from 107,527 lux
in bright sunlight to 107 lux on a very dark day. Recommended light levels (in
lux) for indoor work spaces are 500 for personal computing work; 750 for
supermarkets; 1,500 to 2,000 for detailed drawing work; and 10,000 to 20,000
for visual tasks in extremely low contrast using small-sized objects. Direct,
intense lighting is required for the latter tasks.

Activity Illumination (lux, lumen/m2)

Public areas with dark surroundings 20 – 50

Simple orientation for short visits 50 – 100

Working areas where visual tasks are

only occasionally performed 100 – 150

Warehouses, Homes, Theaters, Archives 150

Easy Office Work, Classes 250

Normal Office Work, PC Work,

Study Library, Groceries, Show Rooms, Laboratories 500

Supermarkets, Mechanical Workshops, Office Landscapes 750

Normal Drawing Work, Detailed Mechanical Workshops,

Operation Theatres 1,000
Detailed Drawing Work, Very Detailed Mechanical Works 1500 -
2000

Performance of visual tasks of low contrast 

and very small size for prolonged periods of time 2000 – 5000

Performance of very prolonged and exacting visual tasks 5000 - 10000

Performance of very special visual tasks of extremely low

contrast and small size 10000 – 20000

Lux requirements in the industry:

Task Group Standard Reflectance Errors will Rask of

Service Contrast have serious short
Illumination usually low consequence duration
(Lux) (Lux) s (Lux) (Lux)
Storage area and plant room with 150 - - -
no continuous work
Casual work 200 - - -
Rough work, rough machining and 300 500 500 300
assembly
Demanding work, inspection of 500 750 750 300
medium machining
Fine work: Colour discrimination, 1000 1500 1500 750
textile processing and fine
machining
Very fine work: hand engravings, 1500 3000 3000 1000
inspection of fine machining and
assembly
Minute work, inspection of very 3000 3000 3000 1500
fine assembly

Levels specific to garment industry:

Operations Lux level

Sewing 300 - 500 for normal
1000-1500 for critical operations
Embroidery 700
Processing 150
Packing 150 – 300
Inspection 700 for routine
1000 for critical/minute inspection
Cutting 800
COMPLIANCE REQUIREMENT:

Exemptions

75 hour O.T. Exemption

Exemption for Time Card
Exemption for Ambulance
Exemption for Creach

Building
Name Sign to All Rooms / Area
Indicators / Direction from Security Gate onwards
Storage above Storage limit Carton Box etc.
Aisle marking
Aisle width minimum 112 cm.
Indicators Arrows in the passage
Aisle without block

Health
Drinking Water
At least4.5 Litres water provided per day per employee
Water Testing Certificate
Drinking water not in plastic pot
Drinking Water, Cup availability
Drinking Water centre (one place to every 150 employees upto 500)
Drinking Water centre (one place to every 500 employees above 500)
Water Cooler / Heater available at every canteen, dining hall, rest room etc.
Drinking Water Signage in English and a local language
Locate from 20 feet away from toilet
Locate maximum 50 meters distance from work spot
Drinking Water vessels cleaned at least once in a day
Water Reservoir or Tank Cleaned at least once in a week
Water centre cleaning condition
Water Vessal Cleaning log sheet
Water Centre Incharge person with cleanliness

Suggession Box Register

Toilets
Toilet Seat to Every 20 Women
Toilet Seat to Every 20 men upto 100
Toilet Seat to Every 50 men beyond 100
All toilet seat with proper privacy and lock facility
Urinal Accommodation Min. 61 cm for every 50 employees upto first 500
Urinal Accommodation Min. 61 cm for every 100 employees for above 500
Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
Dust Bins
Buckets with mug at toilets
Toilet White Washed once in every four month
Tiles/Mosaic floors washed with Detergent or disinfectant once in four month
Daily Cleaning Log sheet provided
Adequate Water Tabs
No smoking Sign in Gents Toilet
Awareness Quotes in Toilets
Ladies / Gents Toilet Name Sign in Dual Language and Picture

Spittoons
Adequate Spittoons
Spittoons filled by Sand or Suitable disinfectant
Spittoons covered by bleaching powder layer
Spittoons scrapped or cleaned at least once in every day

Others
500 Cubic feet for every employees
Disposal of Wastes and effluents
Room Temperature
Lighting facility
Trees on factory campus

Safety Guards
Metal Glows on good Condition
Rubber Mat to ironers
Rubber Glows to ironers
Ironers wearing slipper
Motar Guard
Needle Guard
Eye Guard
Scissors and trimmers are tied
Broken Needle Register
Dining Hall
Dining Hall with sufficient Space
Dining Hall with Sufficient Chair/Table
Water Facility
Ambulance Room
Doctor Visit
Nurse
Medicines
Medicines Issuing Record
Creach

Fire
Sufficient Fire Extinguisher
Fire Extinguisher all in good Condition
Fire Extinguisher Location List
Fire Extinguisher Service Checklist
Fire Extinguisher kept in 3 feet
Fire Signage in English & Local Language.
Usage Guide in dual language
Fire Extinguisher Color Background Marking
Space beneath marked
Space beneath kept empty
Refilling Service Done
Fire Certified persons photo
Evacuation Drill (External) Every Six Month
Evacuation Drill (External) File
Evacuation Drill (Internal) Every Three Month
Evacuation Drill (Internal) File
Fire safety trained employees name & Photo List
Fire Buckets to Diesel Storage Area with Water and Sand
Fire Buckets to Boiler Room with Water and Sand
Fire Buckets to Generator room with Water and Sand
Diesel Storage area floor filled by sand
Evacuation Plan in all Floor / Area
Emergency Exit
Emergency Exit on Open
Emergency Exit Signage
Emergency Exit with outside open facility
Emergency Light to All room / Area Adequate
Emergency Light to All staircase
Emergency Light to All Exit & Emergency Exit

H.R.
Personnel File to All
Application Form
Passport Size Photo
Educational Qualification Certificate
Age Proof
I.D. Proof
Address Proof
Technical Certificate
Previous Company Experience/Relieving order
Old Salary Slip
ESI Nomination Form 1
PF Nomination Form 2
Gratuity Nomination Form F
Factory Act Nomination Form 34
Track Record
Appointment Order
Insurance
NDA with Signature
Employee Manual
I.d. Card to All
Adequate Swiping machine
Punching Card to All
ESI Card to All
PF Slip to All
Awareness Programme
Stress Relieve Counseling
Meetings
Performance appraisal
Leave Card
Full & Final Settlement
Exit Interview
Gratuity
Bonus
Salary Breakup
Salary on Date
Induction Programmer
Induction Register
Manpower
Manpower Department wise Male/Female Strength Report
Attendance Report
Late Report
Absentism Report
Daily Staff In-Out Register
Is there Under Age
Contract Employees
Punch report
Leave card to each employee
MIR (Material Issue Register)

Salary
Salary date before 7 every month
Bank Salary Account to all
Salary Registers with employees signature monthwise
Minimum Wages
Basic
D.A.
Other Salary Breakups
Over Time
Double Salary to Over Time
Any unwanted deduction for employee
Unpaid salary are reversed
Pay Cover Availability
Security
Adequate Securities
Lady Guards
Staff Movement Register
Visitors Note
Others In-Out Register
Material Inward Register
Material Outward Register
Vehicle Movement Register
Visitor Pass
Visitor Slip
Guards Knowledge about their Roles & Responsibilities
Securities Personnel File
Securities Uniform/Cap/Shoe/Belt etc.
Securities Knowledge about Fire Evacuation & Fire Safety
Security Agreement file (If outsourced)
Security Salary register file (If outsourced)
Security ESI, PF Challan (If Outsourced)