Académique Documents
Professionnel Documents
Culture Documents
PLANT LAYOUT
Formal Mens Shirt Manufacturing Unit
BY:
BHINI YADAV
KUNAL NAKRA
MAMSHI OSHIN
SAMIRAN HAZARIKA
VASUNDHRA SHARMA
Objective: To propose a plant layout for formal mens shirt manufacturing unit with a capacity
of producing 1500 shirts per day.
4.
5.
6.
7.
8.
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. = 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
plans in the approved layout. Any changes, if desired, should be carefully investigated and
approved by the concerned authorities.
20.
Basic Information:
Product ID
01126357
Product name
Order Quantity
1500
Group
Plain
Season
Summer
Brand
Local
Size
gender
Male
Fabric
100 % cotton
Date
16/12/14
Fabric weave
Plain
GSM
180
cotton shirt
Style Details:
Base Fabric
Stitching Thread
DTM
Button
Measurement sheet:
S. No
Description
Tolerance(+
43
.5
45.5
.5
67.5
.5
29
.3
Sleeve width
21.5
.3
11.8
.1
Chest Width
55
.5
Bottom Width
55
.5
78
.5
10
9.8
.1
11
41.5
.3
12
44.5
.3
13
Cuff height
8.5
.1
14
14.5
.1
15
3.5
.1
16
3.5
.1
17
Collar Point
.1
18
Collar Height
.1
19
.1
20
Shoulder Slope
4.8
.1
21
Shoulder forward
2.5
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
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 decisionmaking 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
Government and Industry Compliances: Compliance with Labor Laws, Human
Rights, ILO compliance, Vendor Compliance, Government Policies, State Government
Laws and Minimum Wages.
Make/buy
Front
Make
Back.
Make
Yoke (Back).
Make
Sleeve.
Make
Collar.
Make
Collar band.
Make
Cuff.
Make
Sleeve placket.
Make
Pockets.
1 or 2
Make
Make
Buttons
7-8
Buy
1+1+1+1
Buy
Operation Breakdown:
Operation Bulletin:
Machine Requirement Calculation for one line
Target Output
Shift Time
Operator
Efficiency
26.2
65%
Sewing SAM
Helper SAM
Finishing SAM
6.4
2.27
S. No.
1.
2.
3.
4.
5.
Total
Manual
Helper table
Collar turning m/c
Ironing Table
Qty
14
1
6
21
Sewing
SNLS w/ubt
SNLS we/c
SNCS
FOA
KANSAI
Qty
30
4
0
1
1
36
Finishing
Button Attach
Button Hole
Fabric Stores
Sewing Trims & Accessories Store
Spreading and Cutting Section
Sewing Section
Finishing Section
Merchandising Department
Sampling & Technical Department
Quality Department
CAD Section
IE Department
Maintenance
Warehouse
CEO Office
Accounts Department
HR Department
Medical Room
Training Department
Conference Room
Reception
Generator, Boiler, Compressor and other utilities Room
Security Room
Toilets
Parking
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
container at the dock with the help of fork lifter and the power pallet truck.
Workflow of Sampling:
Fabric Sourcing:
Fabric Audit:
Accessory Store:
Workflow in CAD:
Cutting
Section:
Production Department:
Material handling equipment is selected based on the requirement with consideration for various
factors like cost, service etc.
Progressive bundle system (PBS)
Quantity
Description/ Capacity
Ramsons Fabric Inspection
Machine RFI 01. Speed
Variable up to 30 meters
per minute.
(2000x1950x1750 mm)
Quantity
1
Digitizer
Table
Computer
Description/ Capacity
FASTJET Plotter (7ft x 2ft)
Lectra Digitizer (3.9ft x
5.9ft)
4ft x 4ft
HP All-in-One - 18-5201ix
(2ft x 4ft)
Quantity
Fusing Machine
Description/ Capacity
GERBER SY-251 AUTOMATIC
SPREADER
110 yards maximum speed
per minute, 72" material
width, 525 lb. maximum roll
weight
81 in x 180 in
12m x 1.8m
ASTEX MODEL 3024SC
Continuous Fusing System,
298cm x 96 cm
Finishing Section:
Equipment
Quantity
Fork Lift
Iron Table
Thread Sucking
Stain Remover
Needle Detector
Description/ Capacity
Caterpillar P5000 Forklift, 7ft
x 4ft
Ramson 4.3ft x 3.2 ft
DST TS-01 Avg Capacity>
2000 pcs / 8 hrs; 650 X 1435
X 1275 mm
Ramson-CL7
HM-6000
1,600(L)1,050(W)920(H)
mm
Capacity for 2 irons, 2ft x
1.5ft x 4ft
Machine Measurement:
Machine Type
SNLS
DNLS
DNCS
SNEC
B/H
B/S
B/S feeder
B/H B/S Tandem without feeder
B/H B/S Tandem with feeder
Auto Jig
Front Pressing
Sleeve plkt Pressing
Contour
Collar Notch
Kansai
Back Stacker
Cuff Stacker
Collar blocking
Cuff Blocking
Checking table
Iron Table 1
Iron Table 2
Table
Folding Table
Collar and Cuff Press
Collar Press
Stain Remover
Needle Detector
A-type Trimming Table
Washing Mc
Dryer
Length
Inches
Feet
42
3.5
42
3.5
42
3.5
42
3.5
47
3.9
47
3.9
47
3.9
48
4
60
5
43
3.6
52
4.3
42
3.5
35.5
3
42.5
3.5
42
3.5
42
3.5
53.5
4.5
42
3.5
24
2
47
3.9
41
3.4
51
4.3
48
4
60
5
60
5
36
3
60
5
72
6
48
4
24
2
24
2
Width
Inches
Feet
21.2
1.8
21.2
1.8
21.2
1.8
21.2
1.8
22.5
1.9
22.5
1.9
23
1.9
28
2.3
40
3.3
32.5
2.7
45
3.8
21.2
1.8
23.5
2
24.5
2
21.2
1.8
21.2
1.8
21.2
1.8
34
2.8
33.5
2.8
38
3.2
25
2.1
31
2.6
31
2.6
36
3
48
4
24
2
48
4
48
4
36
3
18
1.5
18
1.5
Light Box
28.8
2.4
Note:
20.4
1.7
Note:
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
Layout:
ladders)
A
E
I
O
U
X
Where,
U
O
A
O
O
I
U
U
U
U
O
U
A
U
O
O
I
A
I
U
A
U
I
I
I
I
A
U
A
U
A
U
I
O
U
I
U
I
U
A
U
U
A
O
U
U
O
U
O
U
U
O
O
O
O
A
I
U
U
U
O
U
U
U
O
I
A
I
O
I
O
U
U
O
U
O
U
U
O
U
?
Absolutely Necessary
Especially Important
Important
Ordinary Important
Unimportant
Undesirable
U
U
I
A
U
U
U
U
U
U
O
U
?
U
U
U
U
U
U
U
U
U
U
U
U
U
U
U
I
A
O
U
O
U
O
U
U
U
U
O
O
U
U
U
U
U
U
U
U
O
U
U
PPC
Export
Finance
IE
Cad
U
U
A
U
U
O
U
U
ce Maintenan
I
I
I
I
I
Quality
U
A
U
A
Sampling
O
O
A
sing Merchandi
A
U
Finishing
Sewing
U
A
O
U
O
O
I
U
U
U
U
O
U
Fabric Store
Trim Store
Spreading & Cutting
Sewing
Finishing
Merchandising
Sampling
Quality
Cad
IE
Finance
Maintenance
Export
PPC
Trim Store
Activities
Store Fabric
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.
U
U
I
I
U
U
U
O
O
O
U
U
U
Storage Requirements
Fabric Storage Area Calculation:
Assumptions:
Calculations:
Roll Data:
Pallet Data:
Conclusion:
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
Space requirements
HR department:
Quantity
1
7
4
1
Equipment
Desktop
Printer
Copier Machine
Quantity
3
1
1
Dimensions( in feet)
4*3
1*1
3.5*3
10*10
Total
Dimensions( in feet)
3*3
Total
General Admin:
Quantity
Dim (ft)
1
3
1
4*3
1*1
Total
12
3
15
Financial Department:
Quantity
2
3
2
1
Dim (ft)
4*3
1*1
3.5*3
Total
Quantity
4
4
3
1
Dim (ft)
4*3
1*1
3.5*3
Total
Quantity
1
4
4
2
1
2
Dim (ft)
4*4
1*1
3.5*3
10*10
10*3
Total
Dim (ft)
1*1
3*22
4*3
Total
B. Sourcing:
Man power required
2 sourcing Persons
1 Helper
Reception:
Quantity
4
3
4
2
Quantity
3
7
10
Equipment
Trolley
Weighing Machine
Inspection Machine
Color matching Cabinet
Quantity
2
1
1
1
Dim (ft)
4*3
1*1
6*3.3
Total
Dim (ft)
3*4.5
3.2*1.6
7*4.6
13.12*13.
12
Total
Dim (ft)
5*2*6
4*4
1*1
1*1
Total
Trim Store:
Quantity
10
1
1
3
Quantity
Digitizer
Furniture
Quantity
Dim (ft)
7.36*2.15*3
.83
3.91*5.90
Total
Dim (ft)
Table
Chair
Cabinet
System
2
4
1
13
4*4
1*1
3.5*3*6.5
Total
32
4
10.5
46.5
Furniture
Spreading/ Bundling Table
Table
Chair
Racks
Cabinet
Quantity
4
1
3
5
1
Equipment
Straight
Knife
Band Knife
Fusing Machine
Quantity
3
1
1
Dim (ft)
10*5*3
4*4
1*1
4*2*6
3.5*3*6.5
Total
Dim (ft)
7.49*4.89
7.38*2.78*
4.0
Total
Dim (ft)
3*5
7*3
5*2
Total
Dim (ft)
3*2
3*2
3*2.1
Cutting Department:
Sewing Department:
Quantity
2
4
5
Equipment
SNLS W/UBT
SNLS WE/C
FOA
Quantity
30
4
1
KANSAI
3*2.1
Total
6.30
222.72
Quality Department:
Quantity
1
5
1
Dim (ft)
4*4
1*1
3*3.5
Total
Dim (ft)
4*4
1*1
Total
Dim (ft)
4*4
1*1
3.5*3
Total
Quantity
2
4
Maintenance Department:
Quantity
1
3
1
PRE-PRODUCTION:
Quantity
1
Dim (ft)
4*4
Chair
1*1
Total
3
19
Sampling Department:
Quantity
Dim (ft)
Pattern Table
5*4
20
Cutting Table
Stools
Cabinet
1
15
1
Equipment
SNLS W/UBT
SNLS WE/C
Button hole
Button Attach
FOA
KANSAI
Mini Boiler Cum
Quantity
12
4
1
1
1
1
1
5*4
1*1
3.5*3
Total
Dim (ft)
6.18
6.18
6.18
6.18
6.30
6.30
5*3
Total
20
15
10.5
65.5
Area Required (Sq. ft)
74.16
24.72
6.18
6.18
6.30
6.30
15
138.84
Dim (ft)
4*4
1*1
Total
Dim (ft)
3*2
3*2
3*2.1
3*2.1
Total
Training Room:
Quantity
1
23
Equipment
SNLS W/UBT
SNLS WE/C
FOA
KANSAI
Quantity
15
3
1
1
Conference Room:
Quantity
1
16
2
Dim (ft)
10*5
1*1
2*2
Total
Quantity
1
8
Dim (ft)
10*7
1*1
Total
Meeting:
Finishing:
Quantity
Dim (ft)
Table
8*4
128
Stool
Iron table
Thread Sucking machine
Button hole
Button Attach
Stain Removing Station
Needle Detector
Carton Packing
8
8
1
4
4
1
1
1
1*1
7*3
4*5
6.18
6.18
8*8
3*2
3*2
Total
8
168
20
24,72
24.72
64
6
6
449.44
Washing:
Quantity
1
3
1
Dim (ft)
8*4
8*12
5*7
Total
Dim (ft)
5*3*3
1*1
10*2*4
Total
Dim (ft)
4*4
1*1
3.5*3
Total
Kitchen:
Canteen:
Quantity
10
100
1
Security Department:
Quantity
1
2
1
Generator:
Not
OK
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok
Ok