Steps in facility design

1. Procure the basic data

1. Total area 80m X 100m
2. FS !2
". Possible ground co#erage $0%
&. 'rea to be utili(ed &800 s). m.
*. +rder ,uantity 8000Pcs
$. Production-hr &0
.. /o. of production lines &
8. Total production in single line &008 1 "20
2. Total production in & lines "200&11280
10. Fabric re)uired-garment ! 1.2* metres
11. Fabric re)uired for per day production 1.2*01280 1 1$00 metres
12. Fabric storage for 1*days
1". Total fabric to be stored 1$0001*12&000
14. Time re)uired for production of 8000 pcs in se3ing line $.2*.days 4.
3or5ing days61 Sunday718days
1*. Time re)uired for spreading and cutting11*!81. 4$ 3or5ing days 6 1 Sunday7
1$. /o. of se3ing machine 200
1.. 8ach line &0 m-c
8 m-c front
12 m-c bac5
1$ m-c assembly
& m-c style #ariation
18. Training room m-c 20
12. Sampling room m-c 8
20. m-c in maintenance room 12
21. 9epartments and :an Po3er re)uired
;eception ! 1
Factory 'dministration staff 10
1. <eneral 'dmin &
2. 'ccount "
". =; "
:erchandising "
Product 9e#elopment 2
,uality 9epartment $
.8. 9epartment &
PP> ! "
T 2
Testing ! 2
Sampling 9epartment 8 6161 1 10
Fabric store 2
Fabric nspection ! 2
Trims and 'ccessory Store 2
>'9 1
Training ;oom 20 4m-c761 4Trainer7 1 21
Production
1. Production :anager 1
2. Se3ing 9epartment ! 1.2
1. +perator &0 0& 11$0
2. Super#isor &011 &
". =elper &01 1&
&. roning &01 1&
". >utting ? Spreading *
1. >utting :aster 1
2. =elper &
&. @ashing "
1. @ashing n!charge ! 1
2. =elper ! 2
*. Finishing! 20
1. Finishing in!charge!1
2. Spoting ! 2
". Autton attaching 1
&. ;i#et attaching 1&
$. Pac5ing "
1. Pac5ing n!charge 1
2. =elper ! 2
:iscellaneous 9epartment!
1. 9ispensary ! 1
2. >rBche 1
". Security &
&. >anteen &
*. Aoiler ;oom 1
$. <enerator ;oom 1
.. 8lectrical ;oom 1
8. :aintenance 9ept "
2. =ouse Ceeping Staff ! 10
OPERATIONAL BREAKDOWN OF 5-POCKET JEANS
D+C8 A'>C A'>C P+>C8T F;+/T P+>C8T F;+/T @'ST
A'/9
Aac5 Do5e 'ttach =em Aac5 p5t >o#er St Facing Fly +-E ? rise Eabel 'ttach
Aac5 ;ise 'ttach >rease Aac5 p5t >lose P5t Aag Fipper attach to fly Autton 'ttach
'ttach Aac5 Poc5et Top st Aag Eeft Fly attach
Top Stitch Aac5 Poc5et bt bag G!stitch front
Aar!tac5 rh fly to front
Top Stitch rise
Poc5et 'ttach
Top Stitch Poc5et
Eoc5 P5t Aag
nseam
Side seam
Aottom =em
@aist Aand 'ttach
>lose @aist Aand ends
Aar!tac5 Front flyH side seam
Eoop 'ttach
Autton =oling
ASSEMBLY CHART
LAYOUT PLANNING CHART
SL.
NO.
O T I D
S Operations

BACK
1 9
bac5 yo5e attach
2 9
bac5 rise attach

PKT
3 9
hem bac5 p5t
4 9
crease bac5 p5t
5 9
attach bac5 p5t
6 9
top st bac5 poc5et
7 9
bar tac5 bac5 p5t

FRONT PKT
8 9
co#er st facing
9 9
close p5t bag
1 0 9
top st bag
11 9
bt bag

FRONTS
12 9
fly ol Ileft ? rightJ ? rise
13 9
(ipper attach to fly
14 9
left fly attach ? e-s
15 9
GKK stitch fronts
16 9
rh fly to fronts
17 9
t-s rise
18 9
scoop p5t attach
19 9
t-s scoop p5t
20 9
loc5 p5t bag
21 9
base stitch

ASSEMBLY
22 9
inseam F+'
23 9
side seam c-s
24 9
t-s side seam ? tape attach
25 9
bottom hem
26 9
labler attach
27 9
lable attach to 3-b
28 9
button attach to 3-b
29 9
match 3aist band ? body
30 9
3-b attach
31 9
close 3-b ends
32 9
bartac5 front flyHside seam
33 9
loop attach
34 9
5ey hole
PROCESS FLOW

Order received with specification
sheet
Sampling
Testing
Trims & accessories in-house
Fabric in-house
Production planning meeting
Thread consumption & thread in-
house
Pattern making and modification
Fabric & trim issued through challan
to cutting floor
spreading
CA marker preparation
Cutting
!and knife cutting"fusing
Ticketing
Pattern issued to sewing floor
Sorting
Panels issued for to sewing floor
#ine setting
Actual sewing
!ar tacking"button hole & attaching
$ashing
Thread cutting
Finishing
WORK FLOW OF FABRIC STORE/CUTTING DEPARTMENT
Fabric storing on rack a"c to bu%er
Fabric issued for cutting
&nwinding the roll or metre fold for
rela'ation
Spreading of fabric
(arker spreading on la%
Cutting
Ticketing
Audit
Fabric in-house
Packing
Shipment sent
WORK FLOW CHART OF SEWING ROOM
Cut panel received from cutting
through )e*uisition Slip
(arking or sorting is done
according to color &si+es
Feed to input level of line
Sewing
,n line checking
Output of the garment
-nd line checking
Pass Fail & )e check
Fail Pass
,ssued to production floor
)e.ect
!ar-tacking"embroider% /ma% be
come in between sewing line0
!utton hole
!utton attach
1arment issued for washing
Thread-cutting /ma%be first step of
the finishing0
WORK FLOW OF WASHING DEPARTMENT
1arment received from sewing with
)e*uisition Slip
$et process in washing machine
Softening with softener
2%dro -e'traction
Tumble dr%
1arment issued for finishing
WORKFLOW CHART OF FINISHING DEPARTMENT


Thread cutting
Spotting
)e-checking
Pressing
Trims & accessories check
Folding
Tagging
Checking
)e-pressing
(easurement
Stitching r%-clean (ending Spotting )e.ect
Part
change
1arment received through
)e*uisition slip from washing
Putting in pol% bags
Putting in carton a"c to their si+e or
color or as bu%er re*uire
Closing the carton with tape & seal
Sent for shipment
OPERATION MACHINE
BACK
Do5e attach F889 +F ';:
Aac5 rise attach F889 +F ';:
=em bac5 poc5et 9/>S
'ttach bac5 poc5et S/>S
Aar tac5 A-T :'>=/8
FRONT
Poc5et bag close S/8>
Top stitch bag S/ES
Fly o#erloc5 " T=;8'9 +-E
Fipper attach 9/ES
Fly attach S/ES
LGM stitch 9/>S
;-= Fly to front S/ES
Top Stitch rise 9/ES
Top stitch poc5et 9/ES
ASSEMBLY
nseam F889 +F ';:
Side seam S/>S
Aottom hem AT:
@aist band attach S/9F
>lose @aist band end S/>S
Aar tac5 A-T :'>=/8
Eoop attach S/8>
Cey hole C8D =+E8 :'>=/8
Se3 bac5 rise & T=;8'9 9/>S
Tac5ing at crotch T'>C/< :'>=/8
Aottom heming A-S :'>=/8
SNLS = single needle lock stitc
SN!S = single needle c"in stitc
SN#S = single needle edge stitc
SNN$ = single needle needle %eed
DN!S = do&'le needle c"in stitc
SN#! = single needle edge c&tte(
SND$ = single needle di%%e(enti"l %eed
)*+, )T+ = )"( T"ck +"cine
LINE WISE NUMBER OF MACHINES

N!"er o# !a$%ine per &ine is as #o&&o's(
MACHINE NUMBER OF MACHINE
SNLS )*
SNEC +
DNCS ,
B/T -
K/H )
SNDF )
FOA ,
, THREAD O/L )
DNCS +
TACKING MACHINE .
B/S .
ACTIVITY RELATIONSHIP CHART
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8 8specially mportant
mportant
+! +rdinary mportant
N! Nnimportant
X! Nndesirable