2008

Plant Layout for

Denim Garments
Plant Layout End-Term Submission
Faculty in-charge: Dr. A. K. Khare, Chairperson, DFT, NIFT

Submitted by:
Gaurav Gupta
0
Gunit Ahluwalia
B. F. Tech (AP) – 7, NIFT, Bangalore
 Acknowledgment

We would hereby take this opportunity to thank Dr. A. K. Khare, Chairperson, NIFT, Bangalore & our
faculty for the subject Plant Layout. His initiatives & efforts got us thinking over this project as well as
his continuous support enabled the successful completion of the same.

We would also like to thank Ms. Vibhavari Kumar, Asst. Professor, NIFT, Bangalore for her inputs
related to the project and her timely help and guidance without which our learnings in the project
would have been incomplete.

We also thank our department and NIFT for providing us with the opportunity to learn and succeed
in our work.

Dated – 16th December, 2008

Gaurav Gupta

Gunit Ahluwalia

B. F.Tech (AP) – 7,

NIFT, Bangalore

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 Table of contents

Topics Page no.

1. Product range 3
2. Sketch - Defining the variants 3-5
3. Proposed capacity of the plant 5
4. Business type 5
5. Storages 6–8
a. Incoming raw material storage
i. Fabric 6
ii. Trims 7
b. Finished goods warehouse 8
6. Spreading & Cutting room 8
7. Sewing room 9 – 17
a. Operation bulletin –
(Operation breakdown, SAM, M/C’s required, Flowcharts)
i. Jeans 10 – 12
ii. Skirts 13 – 15
iii. Shorts 16 – 18
8. Washing 19
9. Finishing 19
10. Packing 20
11. Material flow in the plant 21
12. List of Departments & infrastructure within departments 22 – 25
a. Administrative area, store department, sampling, 22
Spreading & cutting, sewing dept
b. Finishing, Finished goods warehouse, canteen, toilets 23
Security cabins
c. Crèche, medical room, housekeeping, lockers, parking, 24
Ramps & platforms, lifts/ staircases
d. Fire exits, water sump & overhead water tank, transformer, 25
Generator room, air compressor
e. Overall Human Resources in the plant 25
13. Important Bye – Laws to be kept in mind 26
14. Activity closeness chart 27
15. Important points of consideration 28
16. Power requirements 29 – 30
a. Lighting requirements 29
b. Fans 30
c. Steam iron/ boilers 30
d. Machinery 30
e. Air conditioning 30
f. Air compressor 30
17. Different levels of technology 31 – 32

Product range
The types of products the facility will make are Denim bottom weights. Mainly basic 5 pocket
Jeans & skirts.
 Basic/fashion 4/5 Pocket Jeans
 Basic ladies denim skirts
 Basic 4/5 pocket denim shorts

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Sketches
Jeans

3
Skirt

Shorts

4
Proposed capacity of the plant
 Jeans – 4400 pieces per day
 Skirts – 1200 pieces per day
 Shorts – 1000 pieces per day

Production schedule – 8 hours per day

Business type
The facility is going to be a 100% domestic manufacturer. That goes to say that all the goods
produced in the premises will be for the domestic market only. And no goods may be exported in
whatsoever circumstances.

Storage
Incoming raw materials
The incoming raw material will be that like denim fabric rolls, pocketing fabric rolls, trims,
accessories, fusing, packaging material, carton boxes etc.

The denim fabric rolls will be quite heavy, since it’s mainly denim fabric, so we cannot have rack
system. We’ll need more floor area, because we cannot store fabric vertically in racks, we need to
store it horizontally on the floor, resting them on wooden pallets. However, we can stack
same/similar fabric rolls one on top of another so as to utilize the store area efficiently. A standard
fabric width of say 60” fabric will thus use 64” X 64” (to accommodate extra roll ends) i.e. 5.33’ X
5.33’ square. We can have such 5.33’ X 5.33’ square blocks all over the store area in a matrix form.

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Now, an average consumption of fabric (60” width) for products can be estimated as below:

 Jeans – 1.3 X 4400 = 5720 m.

 Skirts - 0.6 X 1200 = 720 m.
 Shorts = 0.65 X 1000 = 650 m.

Thus a total of approximately 7090 meters of fabric is being consumed daily. We should adequately
plan to keep a buffer fabric for at least 10 – 12 days in order to facilitate optimum re – order levels &
quantities. Thus, the fabric store should have the capacity for at least 70,000 meters of fabric. One
pallet can hold approximately hold up to 2,000 meters of fabric (each roll being approx. 120 – 130
meters in length). Thus, we need to have at least 35 such pallets (7 rows X 5 columns). Thus, approx.
1000 square feet area (35 X 28.5sq ft.) is required to hold the fabric rolls including pocketing fabric.

In addition we require spacing between any 2 pallets to allow movement of the trolley for loading &
unloading the fabric rolls from/to the pallets. The dimensions of this trolley are approximately 2.67’
wide & 5’ long, which requires an alley of approx. 3 feet width for free trolley movement without
turning. This trolley can transfer rolls of diameter up to 800 mm. Also, an extra aisle space is required
all around the pallet storage area to turn the trolley carrying the rolls, the width of this aisle being 6
feet. Thus, in all the pallet storage area should have minimum dimensions of 46’ X 62’, i.e. 2852 sq. ft.
The loading & unloading to/from the pallet & the trolley will be manually done by 2 workers, holding
the roll from either side.

The fabric rolls are segregated & stacked according to the weight of the fabric, i.e. rolls of fabric
weighing 4 – 8 oz/ sq yd are stacked together, those weighing 8 – 12 oz / sq yd are stacked together,
& those weighing 12 – 16 oz/ sq yd are stacked together.

Trims storage
The trims are classified into 2 categories: garment trims & packing trims. And we will keep enough
stock for 10 – 12 days just as for fabric storage. The various trims & their requirements for 10 days
are listed below. The assumption made is that trims are being stored in boxes of dimensions 2’ X 2’ X
1 ½’ ft.

Trim Consumption per garment Consumption for 10 days Boxes required

Garment trims
Zipper 1 pc 66,000 nos. 5-6
Rivets 10 pcs 4584 gross (660,096 nos.) 5-6

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Buttons 1 pc 460 gross (66,240 nos.) 5-6
Threads 250 m 16,500 cones (1000 m each) 50 – 60
Labels 3 pcs 198,000 nos. 3
Packing trims
Poly bags 1 66,000 nos. 25
Hang tags 2 132,000 nos. 3
Empty cartons 1/24 2,750 nos. Discussed below

The garment trims would require space so as to house approx. 80 cartons of dimension 2’ X 2’ X 1.5’.
In a rack of dimensions 30’ X 12’ X 2’, we can accommodate up to 90 such cartons. Each rack can have
6 shelves vertically of height 2 feet each.

For packaging trims, we require 2 racks, one for placing cartons containing poly bags & hangtags &
the other one for storing empty cartons in folded form, for packing finished goods. The 1 st rack could
be of dimensions 10’ X 12’ X 2’, to store up to 30 cartons.

Now, an empty carton when folded down will occupy dimensions 4’ X 3.5’ X .04’, so the other rack
which stores empty folded cartons should be of dimensions 40’ X 12’ X 4’. Instead of having one rack
of this dimension we can have 2 racks of dimensions 20’ X 12’ X 4’, this will provide flexibility in terms
of space planning. It’s easier to adjust a rack of 20 ft length than to adjust the one of 40 ft length.

Loading & unloading the cartons from the 12 feet high rack can take place with the help of ladders as
the cartons in context are relatively lighter.

Aisle space between these racks should be minimum 4 feet so as to house the ladder as well as for
cartons to move easily. A ladder similar to the one shown below may be used. It’s an aluminium, step
– ladder, with a reach up to 12’ & width of around 24”. Thus, trims storage requires a floor area of
approx. 400 sq. ft.

The total area thus covered by the stores in the whole layout is approx. 4100 square feet (including
office area) and an additional 1500 square feet space is kept for future expansion. This area is on the
ground floor as can be seen from the layouts presented later in the document. This is to reduce and
avoid the excessive material handling of shifting heavy denim fabric rolls.

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Finished goods warehouse
The average estimated production of the plant per day is 6600 pieces including all product ranges.
So, the warehouse should be so made so as to stack goods for at least 2 – 3 days’ production. On an
average a carton (2’ X 2’ X 1.5’) stores 36 Jeans. So, to house say 550 cartons, we need 6 racks of
dimensions 30’ X 12’ X 2’. Thus, each rack occupies floor area of 600 sq ft. A total of 360 sq ft is
required for keeping racks & another 300 sq. Ft., for aisle movements between the racks. Thus, a
total of approx. 660 sq ft. Floor area is sufficient for the warehouse (excluding the office space &
cabin etc.).

Thus in the proposed layout warehouse occupies approx. 1290 sq ft of which 660 sq ft is used for
storage rack, 140 sq. ft. for future expansion, 230 sq ft for office area and remaining for movements.
This floor is also located on the ground floor to ease the outward movement of finished goods from
the plant.

Spreading & cutting room

We saw that average consumption of fabric per day is 7090 meters. Now, at one time, we keep an
average lay length of 6 meters (5 – way marker for Jeans & 10 – way markers for skirts/shorts). Also,
there is restriction of maximum 150 plies per lay (blade length up to 8”), since it’s a thick fabric.
Therefore in a single lay, we can cut 900 meters of fabric. To spread & cut one lay, it requires 1.5 – 3
hours (2 spreaders & 2 cutters). Total number of lays required = 6650/900 = 8 lays approximately.
Thus, in an 8 – hour shift we can cut 4 – 5 lays. So, we require 2 such tables for spreading & cutting to
cut 8 lays in total.

The tables are each 25 meters in length. Each table comprises of 5 smaller tables of length 5 meters
each. This is to accommodate at any time a total of at least 3 lays (6m each) & the last table for
bundling, ticketing & inspection. This is the case where one lay is being spread, one is already spread
(waiting to be cut) and 3rd one is being cut (since spreading is faster than cutting). The width of the
tables will be 70” (to accommodate up to 60” width fabric).
The cutting tables will thus require approximately 1850 sq.
ft. area.

Now, to house cut parts, we require 2 storage racks of

dimensions 15’ X 6’ X 2’. Also, we require a band knife (25
sq ft.) & a continuous fusing machine (30 sq. ft.). Thus, in
all the cutting room occupies an area of approx. 2700 sq ft
including office area as well. The cutting room is essentially
located on the ground floor just next to the fabric store in
order to minimise material movement between store and
cutting room.

Cut parts can be transferred to the sewing floor using these mobile trolleys.

Sewing floor
Each line takes up an approximate area of 700 – 800 sq ft. taking it as 800 sq ft; we have 6 lines which
mean 4800 sq ft area. In addition to this, we need another 3000 sq ft (approx.) area to give spacing
between lines for trolleys and people to walk in between. The aisle space is taken as 5 feet to

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accommodate trolleys and space for movement of supervisor etc. Also a table of width 3 feet is kept
between the machines in a line. Thus sewing floor should have at least 8000 sq ft area.

Thus the area occupied by the sewing floor on the 1 st floor of the building is 8,500 sq ft, the sampling
area (comprising of 20 m/c, 3 cutting tables) takes up approx – 650 sq ft. The office cabins of the
Sampling head, Pattern master, CAD room, Technical dept, Production manager, Quality manager &
the Industrial Engineer take up another 1150 sq ft. This is a very space consuming activity hence the
whole 1st floor is dedicated to them alone. The cut panels are transferred from the cutting room to
sewing floor through the goods lift. Within the sewing floor, the materials can be handled using bins,
trolleys and racks as shown below.

Operation bulletins
Jeans
Target - 1100 pieces/line. Total of 4 lines dedicated to Jeans manufacturing.

S.no Operation Machine SMV

BACK
1 Hem back pocket AUTO HEMMER 0.1
2 Crease back pkt I-TABLE 0.45
3 Back yoke attach FOA 0.32
4 Join back rise FOA 0.4
5 Attach back pkt to back SNLS 0.75
6 Make t/s at back pkt DNLS 0.65
7 Bartack at back at pkt (5/8" 4 nos.) BT BROTHER 0.25
8 Serge at backs 3T O/L 0.4
SCOOP PKT
9 Hem coin pkt AUTO HEMMER 0.05
11 Attach coin pkt SNLS 0.38
13 Attach and close facing to pkt bag SNLS 0.6
14 Close pkt bag SNEC 0.32
15 Top stitch pkt bag SNLS 0.42
12 Make Bartack at coin pkt and left fly BT BROTHER 0.3

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 FRONTS
16 Fly ol [lt &rt],rise and top left fly 3T O/L 0.44
17 Zipper attach to fly DNLS 0.25
19 Left fly attach to fronts & e/s SNLS 0.35
20 Tack top left fly to lower left fly SNLS 0.25
21 J'' stitch fronts DNLS 0.28
22 Zip to right front SNLS 0.42
23 E/s front rise SNLS 0.4
25 Attach taper to front scoop pkt DNLS Taper m/c 0.45
26 Lock pkt bag SNEC 0.45
27 Serge at fronts 3T O/L 0.4
ASSEMBLY
28 Inseam 5TO/L 0.45
28 T/S inseam FOA 0.4
29 Side seam chain st SNCS 0.75
30 Crease busted seam I-TABLE 0.4
31 Side seam t/s DNLS 0.75
32 Bottom hem VI.BE.MAC 0.7
33 Label attach to body SNLS 0.25
34 W/B attach- ply W/B VI.BE.MAC 0.8
35 Close w/b ends SNLS 0.7
36 Keyhole KH 0.18
37 Prepare loops FLAT LOCK 0.18
38 Back patch boundary stitch Leather patch att m/c 0.32
39 Loop attach AUTO LP SET 0.4
Total machine SMV 15.36

40 Mark back for pkt TABLE 0.3

41 Mark for second stitch at back pkt TABLE 0.3
42 Q.C inspection Q.C 0.3
43 Q.C inspection Q.C 0.45
44 Match bundles TABLE 0.4
45 Mark waist band.& label TABLE 0.35
46 In out body & mark G.TURNER 0.3
47 Remove chain thread TABLE 0.4
48 Q.C inspection Q.C 0.8
Total manual SMV 3.6
Total SMV 18.96

MACHINE TYPE OPERATORS WORK STATION

SNLS 14 14
SNEC 2.5 3
DNLS 7 7
I-TABLE 2.25 2.5
SNCS 2 2

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FOA 3 3
3T O/L 2.75 3.5
FLAT LOCK 0.5 1
AUTO LP SET 1 1
AUTO HEMMER 1 2
BT BROTHER 1.75 2
KH 0.5 1
W/B VI.BE.MAC 2 2
TOTAL 40.25 44

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Flow chart for Jeans

Skirts

Target – 1200 pieces / line. Total of 1 line dedicated to manufacturing Skirts.

S. no. Operation Machine SMV

BACK
1 Pocket hem SNCS 0.2

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2 Stay st back pkt SNLS 0.35
3 Crease back pkt I-TABLE 0.4
4 Back yoke FOA 0.3
5 Back rise FOA 0.28
6 Pocket attach SNLS 0.7
7 Top stitch pkt SNLS 0.5
8 Bar tack pkt BT BROTHER 0.22
9 Attach size label SNLS 0.28
FRONTS
10 Hem watch pkt SNCS 0.1
11 Attach coin pkt DNLS 0.3
12 Attach facing to bag COVER 0.28
13 Close pkt bag SNEC 0.3
14 Top stitch pkt SNLS 0.38
15 Bartack pkt bag BT BROTHER 0.12
16 Fly ol [left & right] & rise 3T O/L 0.4
17 Zipper attach to fly DNLS 0.25
18 Left fly to fronts SNLS 0.3
19 J'' stitch fronts DNLS 0.3
20 Zip to right Front SNLS 0.35
21 T/S rise DNLS 0.32
22 Pocket attach SNEC 0.4
23 Top st scoop pkt SNLS 0.45
24 Lock pkt bag & basting SNLS 0.7
25 Bartack front & side seam BT BROTHER 0.4
ASSEMBLY
26 Side seam o/l 5T O/L 0.42
27 Side seam t/s SNLS 0.45
28 bottom hem JUKI BTM 0.45
29 W/B attach W/B KANSAI 0.45
30 Keyhole KH 0.18
31 Close w/b ends SNLS 0.7
32 Prepare loops FLAT LOCK 0.18
33 Loop attach AUTO LP SET 0.35
Total machine SMV 11.76

34 Mark back for pkt TABLE 0.25

35 Q.C inspection Q.C 0.3
36 Mark pocket facing TABLE 0.25
37 Q.C inspection Q.C 0.4
38 Match bundles TABLE 0.4
39 Mark waist band TABLE 0.3
40 In out body & mark G.TURNER 0.22
41 Remove chain thread TABLE 0.4
42 Q.C inspection Q.C 0.8
Total manual SMV 3.32

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 Total SMV 15.08

MACHINE TYPE OPR WORK STATION

SNLS 16 17
SNEC 2 2
DNLS 4 4
I-TABLE 1 1
5T O/L 1.5 2
FOA 2 2
3T O/L 1 1
SNCS 1 1
COVER 1 1
FLAT LOCK 1 1
AUTO LP SET 1 1
BT BROTHER 2.5 3
JUKI BTM 1.5 2
KH 0.5 1
W/B KANSAI 1.5 2
TOTAL 37.5 41

Flow chart for Skirts

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Shorts
Target – 1000 pieces / line. Total of 1 line dedicated to manufacturing Shorts.

S .No Operation Machine SMV

BACK
1 Sew darts SNLS 0.3
2 E/S darts SNLS 0.35
3 Serge facing 3T O/L 0.3
4 Bone attach AUTO 0.35
5 Lock welt SNLS 0.6
6 E/S lower welt SNLS 0.44
7 Bone & facing to bag SNLS 0.7
8 Keyholes KH 0.32
9 R/S pkt bag SNEC 0.8

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10 Turn & T/S bag SNLS 0.7
11 E/S upper welt SNLS 0.44
12 Lock bag @ top SNLS 0.35
13 Bartack BT BROTHER 0.35
14 O/L back rise 5TOL 0.3
15 T/S back rise FOA 0.4
SCOOP POCKET
16 Attach facing to bag COVER 0.6
17 Close pkt bag SNEC 0.32
18 Top stitch pkt SNLS 0.44
FRONTS
19 Fly ol [left & right] & rise 3T O/L 0.44
20 Zipper attach to fly DNLS 0.25
21 Right fly to fronts SNLS 0.35
22 J'' stitch fronts DNLS 0.32
23 Zip to left Front SNLS 0.45
24 T/S rise SNLS 0.3
25 Att slant pkt SNEC 0.32
26 T/S slant pkt DNLS 0.4
27 Lock pkt bag SNEC 0.7
28 Bartack pkt end BT BROTHER 0.25
ASSEMBLY
29 Inseam 5T O/L 0.48
30 E/S inseam SNCS 0.55
31 Side seam o/l 3T O/L 0.7
32 Att side seam SNCS 0.75
33 Side seam T/S SNLS 0.5
34 Crease bottom I-TABLE 0.45
35 Bottom hem SNLS 0.5
36 W/B attach VI.BE.MAC 0.5
37 Keyhole KH 0.18
38 Close w/b ends SNLS 0.7
39 Serge loop 3T O/L 0.22
40 T/S loop DNLS 0.25
41 Loop attach AUTO LP SET 0.4
Total machine SMV 18.02

42 Mark back for pkt TABLE 0.3

43 Q.C inspection Q.C 0.3
44 Mark pocket facing TABLE 0.25
45 Q.C inspection Q.C 0.45
46 Match bundles TABLE 0.4
47 Mark waist band TABLE 0.35
48 In out body & mark G.TURNER 0.25
49 Remove chain thread TABLE 0.4
50 Q.C inspection Q.C 0.8

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 Total manual SMV 3.5

Total SMV 21.52

MACHINE TYPE OPERATOR WORK STATION

SNLS 19.5 21
SNEC 6 6
SNCS 3.5 4
DNLS 2.5 4
SNEC 6 6
FOA 1 1
AUTO 1 2
3T O/L 4.5 5
5T O/L 1.5 2
COVER 1.5 2
FLAT LOCK 1.5 0
AUTO LP SET 1 1
BT BROTHER 1.5 2
KEYHOLE 1.5 2
VI.BE.MAC 1.5 2
TOTAL 54 60

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Flowchart for Shorts

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Washing
As such washing is outsourced, but we require a lot making area where sewn pieces can be made
into lots to be sent for washing. Also, we’ll need another receiving area where washed lots can be
received & sent for finishing. Now, we’re assuming that garments go out for washing at the end of
any working day, i.e. entire production for a day is sent to washing unit at the end of that particular
day after checking for any defects or so. And the vehicle will take the sewn goods for washing & bring
back washed goods from the washing unit to be processed for finishing the next working day. Thus,
in order to make lots of one day’s production (6600 pcs), we need approximately 66 lots (assuming
one lot to be of 100 pieces). These lots can be stored in a rack structure, each cell in the rack being 4’
X 2’ X 3’. It can have 3 shelves in a column, thus, total height of rack being 9 feet. With each column
housing 3 lots, we can have 2 racks with 11 columns each, fulfilling the lot making requirements.
Thus, effective dimensions of each rack will be 44’ X 2’ X 9’. 2 such racks can suffice the requirements
of lot making and also 2 more such racks can suffice the requirements of lot receiving when washing
is finished. So, a total of 4 racks are required in the lot making/ receiving area. Also, an alley of 3 feet
to move in between the racks is required. The lots can be transferred in net bags containing about
100 garments each. Same bags may be loaded into the truck manually while shifting the goods.

In the final layout a total of 600 sq ft is allocated to the lot making area. This area houses racks as
well as office area. This is also preferably on the ground floor since it requires frequent outsourcing
of sewn garments to washing unit and back to the plant.
Hence, it is kept next to the lift for easy access to the
sewing floor and also placed near the finishing room
because goods coming back from washing are next sent
to finishing. It also has a platform outside the rolling
shutter for lorry to be parked and easy loading of goods
into it.

A bulk truck as shown here can be used to transfer sewn

garments from sewing floor to the lot making area as
well as washed garments from lot making to the finishing
room.

Finishing
There will be 2 finishing lines, one dedicated to Jeans, other one for shorts & skirts. Each line
containing the following machines in the same sequence:

1. Stain removing m/c – 1 no. (48” X 24”)

2. Checking tables – 1 no. (60” X 48”)
3. Thread sucking machines – 1 no. (4’ X 4’)
4. Rivet attaching machine – 1 no. (2’X3’)
5. Button attaching machine – 1 no. (2’X3’)
6. Ironing tables – 3 nos. (52” X 32”)
7. Folding tables – 2 nos. Dimensions – 60” X 48”.
8. Packing tables – 2 nos. Dimensions – 60” X 48”.
9. Packaging material storage – One rack adjacent to each folding/packing table. (2’ X 2’ X 3’)
10. Metal detector – 1 no. common for both lines (6’ X 4’)

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 11. Quality audit – 2 tables with lights. Dimensions – 8’ X 4’ (2 checkers on one table)
12. A steam boiler to cater to 6-9 steam irons. – 1 no. Dimensions – 2.33’ X 2.66’
Thus, total space requirement for machines only is around 488 sq. ft. per line. In the final layout,
finishing room has a total area of approx 1450 sq ft including aisle space as well as machines. It is
located on the ground floor essentially close to the lot making/receiving area and the finished goods
warehouse.

Packing
A major requirement of space is for packing finished garments into cartons to be shifted to
warehouse. This packing is done usually 3 – 4 times in a working day shift of 8 hours. So, to pack a
total of 6600 garments in a day, we’ll pack around 1650 garments at once, repeating the same
procedure 4 times a day. To pack 1650 garments at once, we need to pack approx. 45 cartons
containing 36 garments each. Now, they can be arranged in to 3 rows of 15 cartons each. And a
walking space of 3 feet width in between two rows of cartons. Thus, approximately an area of 384 sq.
ft. is required to pack these cartons. After packing, the cartons can be transferred to the warehouse
one by one manually.

In the planned layout, it occupies approx – 400 sq ft of area including the space to keep open cartons
and aisle for worker to walk in between the rows.

Material flow in the plant

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 STORE ROOM
RECEIVING GOODS OFFICE AREA

SAMPLING ROOM SPREADING & CUTTING ROOM CANTEEN

MAINTENANCE ROOM
SEWING ROOM CRECHE

LOT MAKING FOR WASHING

FINISHING ROOM MEDICAL ROOM

LOCKER ROOM

SHIPPING WAREHOUSE REST ROOMS

PARKING

SECURITY CABINS

Departments and list of infrastructure required

Administrative area or office area:
 Reception – To seat receptionist & 11 other people – on the ground floor
 CEO’s cabin – To seat Director & up to 12 other people
 Head Merchandiser’s cabin – To seat Merchandiser & 6 others

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  Chief Finance Officer’s cabin – To seat CFO & 6 others
 Factory manager’s cabin – To seat FM & 6 others
 Human resource department – To seat HOD & 6 other working staff
 Purchase department – To seat HIOD and 6 others
 Design & development – To seat HOD and 6 others
 Production planning & control – To seat HOD and 6 others
 Board room for meeting - To seat up to 25 members
 Rest rooms (Male, Female) – At least 2 toilets in each
 Place to keep printer, Photocopy m/c. – 2 Xerox machines & printers.
The administration block is on the 2 nd floor occupying 2800 sq ft area approx., the reception is
however on the ground floor just near the main entrance occupying approx 600 sq ft. This is to
provide easy access to admin block to visitors.

Store department
 HOD’s cabin – To seat HOD, one assistant & 3 others
 Fabric storage – 2852 sq. Ft. Area (As discussed earlier)
 Testing lab - Outsourced
 Trims storage – 400 sq. ft. (As discussed earlier)
 Other material’s storage (Computers, stationery etc.) – 1 Rack (Dimensions - 30’ X 12’ X 2’)
 Maintenance department – 1 rack same as above

Sampling department
 Pattern making tables – 6 tables of dimensions 48” X 60” each
 Sampling machines – One machine of each type as discussed in Operation Bulletin for Jeans
 CAD department cubicle – To house 4 people with computers & one plotter
 Seating area for Pattern master – To seat PM & 3 others

Spreading and Cutting department

 Spreading tables – As discussed earlier
 Cutting tables - As discussed earlier
 Sorting tables - As discussed earlier
 Matching - As discussed earlier
 Bundling - As discussed earlier
 Ticketing - As discussed earlier
 Band knife / straight knife cutters – One Band Knife & 4 Straight knife cutting machines

Sewing department
 Assembly lines - As discussed earlier
 Sub assembly sewing lines - As discussed earlier
 Production manager’s cabin – To seat PM & 4 others
 Technical department – To seat HOD & 4 others
 Quality department – To seat HOD & 4 others
 Industrial engineering department – To seat HOD & 4 others
 Rest rooms – According to Bye - laws
 Racks for cut parts & trims storage

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Finishing department
 Washing of denim Jeans - Outsourced
 Stain removing m/c – 2 nos. (48” X 24”)
 Checking tables – 2 nos. (60” X 48”)
 Thread sucking machines – 2 nos.
 Rivets attach machine– 2 nos. (36” X 24”)
 Button attach machine – 2 nos. (36” X 24”)
 Ironing tables – 6 nos. (52” X 32”)
 Folding tables – 4 nos. Dimensions – 60” X 48”.
 Packing tables – 4 nos. Dimensions – 60” X 48”.
 Packaging material storage – One rack adjacent to each folding/packing table. (2’ X 2’ X 3’)
 Metal detector – 1 no. (6’ X 4’)
 Quality audit – 4 tables with lights. Dimensions – 8’ X 4’ (2 checkers on one table)
 Cabin for Finishing – To seat Head with 4 others

Finished goods ware house - As discussed earlier

Canteen – Two canteens

 Labour canteen - To seat maximum 200 labourers at a time. Factory following a staggered
lunch break. Approx – 1500 sq ft area.
 Staff canteen – To seat maximum 60 staff members. Approx – 800 sq ft.
 Common kitchen – for both the canteens occupying around 350 sq ft.

This is located on the 2nd floor with ample ventilation and fresh air circulation to avoid odours.

Toilets
Toilets are provided according to state bye – laws. On the ground floor there are 6 toilets (3 each for
male/females) for the workers and 2 for the staff members. Also there is one toilet at the reception
for visitors etc.

Similarly on the first floor there are 6 toilets (3 each for male/ females) for workers and 2 toilets for
the staff members.

On the 2nd floor, there are 20 toilets (10 each for male and female) for workers. There are 4 toilets (2
each for male/ females) for staff members in the admin block. Each toilet occupies around 12 sq ft.

Security guards
To provide housing for 4 security guards at entrance to check the goods moving inward & outwards.
Also, one guard at reception area & one guard at fabric/ trims store.

Crèche
According to state bye – laws, one crèche is provided on the 2 nd floor for the children up to an age of
6 years of female workers. The crèche occupies as area of approx – 350 sq ft. it is properly ventilated
and well maintained.

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Medical room
According to state bye – laws, one medical room, fully equipped with all necessary first aid
requirements, beds, nurse, water supply, washing area & proper ventilation. The room occupies an
area of 180 sq ft.

House keeping
A store room for housekeeping is provided to stock supplies etc on the 2 nd floor. This room occupies
approx – 150 sq ft of space.

Locker room
Around 500 lockers are provided for the workers of various departments. This is provided on the
ground floor so that at the beginning of each working day, the workers don’t have to climb up only
for the lockers. The lockers occupy a space of 250 sq ft.

Parking
A full basement is provided for the parking requirements of the plant. The height of the basement is
15 feet. It provides car park measuring 18’ X 9’ each and to house 23 such cars. Also, the basement
has 2 slots for parking Lorries, measuring 25’ X 12’ each. There is also parking space measuring 72’ X
18’ provide to park all types of 2-wheelers (approx – 150 bicycles & motorcycles).

A ramp is provided from the ground floor into the basement measuring 20’ X 12’ to get vehicles in
and out of the basement.

Ramps & platforms

Ramps plus platforms measuring 16’ X 4’each are placed at all major entrances/ exits on the ground
floor to ease the loading/ unloading of goods from the lorry. The platforms measure 10’ X 4’ and the
ramp measures 4’ X 4’ each. There are 4 such ramps/ platforms placed adjacent to the opening of
fabric stores, finished goods warehouse & lot making area.

Lifts/staircase
2 lifts are provided in the layout. One is the main goods lift in which only gods to be processed i.e.
fabric, cut parts or sewn garments will be transferred from one floor to another. This is situated in
the working area of the building. The lift measures 8’ X 8’ so as to house any trolleys or racks for
transporting goods. Also there runs a staircase around this lift which measures 4’ in width. The stairs
have a tread of 0.88’, rise of 0.5’.

The other lift is the staffs lift to be used only by the administration staff. This is thus situated in the
admin block and provides easy access to admin block from the reception as well as sewing floor etc.
This lift measures 4’ X 4’ and a staircase of width 4’ runs all around it. The tread of the staircase is
around 0.5’ and the rise is around 0.625’ i.e. 7.5”.

Fire exit
As per bye laws, one fire exit is provided at the other end of the plant, diagonally away from the
admin block & reception. This fire exit measures 25’ X 10’ and is made on a metal frame just outside
the exit from the main building. The staircase running on this exit is 5 feet wide and has a tread of 1
feet and a rise of 0.5 feet. Also, all the corridors that lead to it are minimum 5 feet wide as in
accordance with the bye – laws.

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Water sump & overhead water tank
There is one underground water sump in the basement, to store up to two lacs litres of water at any
given time. Also, there are 4 overhead water tanks on the 2 nd floor with a capacity to store up to
25,000 litres of water each. This much amount of water is sufficient to run the plant for 4-5 days.

Transformer
The main line for power is received in the transformer which is situated at one corner of the plot.
From there, the electrical lines are distributed in the entire plant. The transformer chamber
measures 8’ X 8’ and is located at a suitable distance from the rest of the building on the plot.

Generator room
The generator room is situated at another corner of the plot diagonally opposite of the transformer.
The electrical line extends from the generator to a main distributing location near the transformer &
provides back up to the entire plant in case of power failure. The generator room measures 8’ X 8’
also.

Air compressor
The air compressor is placed in the utility room on ground floor. The compressor is capable of
providing air at a pressure of 700 KPa and an air flow rate of up to 58 L/min. The dimensions of the
compressor are 270 X 128 X 188 mm.

Approximate Human Resources in each department

Department Staff Workers

Administration 60 3
Stores 5 5
Sampling including CAD 10 30
Cutting 21 15
Sewing, QC, IE, Technical 24 250
Lot making 2 4
Finishing & packing 5 44
Warehouse 3 5
Canteen & kitchen 5 10
Security - 6
Crèche , Medical room 2 4
Maintenance (Housekeeping) 2 10
Total 139 386

Thus, a total of approximately 525 employees including workers and staff both will be there working
on the plant at any given point of time.

Some Bye Laws to be kept in mind (Karnataka State Factory Act)

No. Type of facility Workmen required Nos. to be provided.

1 Drinking water points Adequate supply at 5litres/worker

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 2 Cooled supply of water >250 One for 150

3 Latrine accommodation One for 25 separately for male and

female

4 Urinal accommodation One for 50 workers.

5 First aid appliances One equipped first aid box per 150
persons.

6 Ambulance room >500 With all amenities and personnel.

7 Rest room/shelter/lunch room >150 With adequate accommodation and

facilities

8 Crèche >30 female With adequate facilities and

personnel

9 Canteen >250 With adequate facilities and

personnel

10 Occupational Health Centers >50 With adequate facilities and

personnel

Special officers required

S Particulars No. required Qualification
no.
1 Safety officers (for factories One per thousand Diploma in Industrial
employing more than 1000 Safety.
workmen and notified factories)
2 Welfare Officers ( for factories One per 500 up to 2000 and one Degree or diploma in social
employing more than 500 additional per every 1000. A lady science with personnel
workmen) welfare officer wherein 500 women management.
workers are employed
3 Factory Medical Officer (in One for 500 workers and one more Degree under the Medical
respect of industries involving for additional 1000 Degree Act and certificate
hazardous processes) course in occupational
health.
4 First aid trained personnel Adequate Nos. Workers of the factories
shall be trained in the
recognized institutions.
5 Qualified nursing staff (wherever One woman in charge & one Women in charge should
crèche facilities are provided) female attendant for every 20 possess nurse’s
children. qualification.

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Activity closeness chart

27
Important points of consideration
Plot area available - 25,000 sq.ft. (2250 sq.mt.)

Area available for building erection – 14,850 sq ft. (1339 sq mt.)

No. of floors planned – 3 floors & a basement

Height of the building – approx. 48 ft. (height of each floor being 15 ft.)

Setback - 5 m (16.67 ft.) provided on all sides (minimum setback required for the given area and
height of the building according to state bye – laws)

Dimensions of each floor, after considering minimum setbacks – 165 X 90 sq.ft.

FAR calculated – total floor area / plot area (=1.5 approx.)

Walls - made of concrete blocks of thickness 8”

Grid beam with pillars – of thickness 8”, at an interval of 30-40 square feet

Main entrance – There are 2 entrances; one for vehicles to go into the basement parking and the
other for workers & other persons to enter the plant. Both the entrances are 20 feet wide.

Rolling shutters – Each opening of the building except reception is using rolling shutters of width
either 10’ or 6’. The 10’ shutters are where material movement is taking place and 6’ where only
workers are to move.

Windows & ventilators – The windows & ventilators are planned together as one unit only.
Adequate ventilation is provided in each room or department.

Roof top garden/ cafeteria – The vacant area on the 2nd floor is used to develop a roof top garden
cum cafeteria for employees to relax and refresh with a light coffee break.

Number of fire exits – One fire exit and two normal stairway exits as shown in the layout.

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Lighting requirements
LIGHTING REQUIREMENT
Department Components Area (sq. ft.) - A Lux (E) No. of tubes required
Fabric Store Fabric storage 3350 150 75
Trim storage 616 150 14
Inspection 196 1500 44
Office 280 500 21
General 126 200 4
Cutting Room Spreading & cutting 984 750 111
Office 67.5 500 5
General 1621.5 200 49
Finishing Finishing 1178 750 133
Storage & packing 420 200 13
Warehouse Storage 1035 150 23
Office 160 500 12
Lot making Storage 476 300 21
Office 64 500 5
Reception Reception 578 300 26
Toilets 96 500 7
Locker room 220 200 7
Sewing Office area 1212.8 500 91
Sewing line 8568 1000 1285
Sampling room 392 1000 59
Admin Block Office area 2912 500 218
Laborer's canteen 1480 300 67
Admin canteen 810 500 61
Crèche & Medical
room 522 300 23
Toilets 504 300 23
Parking 10,000 100 144
Total no. of tube lights required= 2540
Power consumption= 101,600 Watts

No. Of tube lights required = Lux required (E) x Area of room in sqm (A) / (Coefficient of utilization x
Dep. Factor x Wattage of tube x Efficiency)

Coefficient of utilization = 0.5

Dep. Factor = .75

Wattage of tube = 4o watts

Efficiency = 40 lumens / watt

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Fans requirement
Ground floor – 30 fans; First floor – 81 fans; Second floor – 51 fans

Total number of fans = 162 fans of power consumption 100 watts each. Thus total power
consumption in fans is approximately 16,200 watts.

Steam irons & boilers

A total of 20 steam irons in the whole plant are there. There are 6 in the finishing room and 14 on
the sewing floor (including sampling). 1 steam iron on an average consumes 1 KW of power. Thus, 20
steam irons consume 20 KWs. The steam requirements are approximately 50-55 kg/hr at an
operating pressure of 5 Bars.

There are two boilers in the plant. One is in the finishing room with a maximum steam output
capacity of 24kg/hr. This boiler consumes 18 KW of power and is suitable for catering to 4-8 steam
irons.

The other boiler is in the sewing room with a maximum steam output of 50 kg/hr. This boiler
consumes 36 KW of power and is suitable for catering to 14-16 steam irons.

Machinery requirements
There are a total of 280 cutting, sewing & finishing machines, with a consumption of an average of
750 VA of power per machine. Thus the power requirements of the sewing machines are around
210,000 watts.

Air conditioning
There are 9 localized air conditioners of 1.5 tonnes in each of the offices in the admin block, & one
air conditioner of 2 tonnes in the conference room. Also there is one air conditioner of 2 tonnes at
the reception. All these total up to 24 KW of power consumption.

Air compressor
We need one air compressor for the pneumatic machines of finishing room etc which will take up a
load of approx 750 watts.

Total power requirements

Area/ Department Power consumption
Lighting 101.6 KW
Fans 16.2 KW
Steam irons/boiler 74 KW
Machinery requirements 210 KW
Air conditioning 24 KW
Air compressor 0.75 KW
Total power consumption of plant 422 KW
Thus a sanction of 75% of the maximum load is to be taken from the electricity board, which comes
out to approximately 316 KW.

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Different levels of technology and their implications on space & manpower
1. Spreading
a. Manual spreading
 Space required- 33 X 6 sq. ft. – 2 nos.
 Manpower required – 2
 Max. Spreading speed –33 ft/min (10 m/min)
 Power consumption – Nil
b. Automatic spreading machine
 Dimension- 160-220 x 188 x145 (cm)
 Space required- 33 X 6 sq. ft. – 1 no.
 Manpower required – 1
 Max. Spreading speed – 333 ft/min (100m/min)
 Power consumption – 3 KW

In comparison with manual cutting which will require 2 tables of dimensions 33 x 6 ft, the automatic
Gerber spreader will require only one table of same dimensions as the speed is way more than
manual spreading. The man power requirement also reduces from 4 spreaders to 1 only.

However, a cost benefit analysis is to be made to choose between the two levels. The cost of the
automatic spreading is very high because of the extra investment in machinery as well as running
costs of electricity & maintenance of machine.

2. Cutting
a. Straight knife cutting machine
 Blade size – 6” to 13”
 Cutting capacity – 4.5”-11.5”/ min
b. Band knife cutting machine
 Max. Thickness of Cutting – 200mm
 Table size – 1200X1800 mm
c. Automatic cutting machine
 Standard table length- 12’
 Standard width – 6’
 Maximum cutting speed – 60”/min
 Compressed air requirement – 160 psi

In comparison to 4 straight knives & one band knife, we’ll need only one automatic Gerber cutter.
The capacity of cutting is many folds that of manual cutting and thus increases capacity &
productivity. Also, in automatic cutting, we do not need any man power except one supervisor who
just monitors the cutting process. However, an automatic cutter costs much huger as compared to
straight knives and band knives. Also, additional costs of software, power consumption, maintenance
and spares are very high in case of automatic cutters. Thus, a proper cost-benefit analysis is to be
made as to which one to choose. Space requirements are more or less similar.

3. Sewing
 Material handling systems
o Use of trolleys for keeping bundles
o Use of conveyor belts
o Use of overhead clamps/ rails or SwitchTrack Systems.

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The use of trolleys is prominent in a PBS (Progressive Bundle System), depending on the WIP
between two stations. Whereas a SwitchTrack system will come handy when you are following UPS
(Unit Production System) i.e. one part moves between workstations at a time through overhead rails/
clamps. Hence, it results in better space utilization. However, there are additional costs of one time
investments, software, maintenance etc. Also, a SwitchTrack system increases the indirect labour
costs.

 Special sewing machines VIBEMAC:

o VI.BE.Mac automatic pocket setter machine for jeans & trouser
o VI.BE.Mac Automatic loading and label setting and pocket designing.
o VI.BE.Mac Automatic Loop attaching machine for jeans and trouser
o Automatic pocket hemming unit

These machines help in reducing the cycle time of an operation and provide consistent superior
quality as compared to manual operations. However, there are onetime costs involved in machine
costs. The running cost and spares parts cost are more or less comparable to ordinary machines.

 Special attachments like folders, guides etc.

These attachments help in reducing the operation cycle time and give a consistent and superior
quality. Overall, SAM of the operation as well as throughput time is reduced.

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