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Garment Manufacturing Industry LayoutPlant LayoutSubmitted By,Sumit VermaUjjwal SurinVishal KumarBFT-72009-13FACULTY: Jonalee D.BajpaiPlant DescriptionProposed industry : Apparel industry Type of industry: Manufacturing Product : Mens Casual Shirt Daily Production : 6500 pcs SAM : 20 MINUTES Daily working hours : 8 hrs

Site DetailsPROPOSED LOCATION-DEWAS(near Indore), Madhya PradeshACCESSIBLITY TO DIFFERENT MODESAIRWAYS: Nearest Airport isDevi Ahilya International Airport,Indore(44 K.M)RAILWAYS: Dewas Junction lies onIndore Junction-Ujjain Junctionbranch lineROADWAYS:NH3 Agra Mumbai National highway (A.B. Road) passes through the town. NH 86 starts from Dewas and goes up to UPDistance fromIndore: 35kmDistance fromBhopal: 148kmDistance fromUjjain: 37km

Site DetailsLAND COSTIndustrial area: 1500-2000rs/sq.feet Rural area:500-800s/sq.feet Near by DEAVAS city:500Rs/sq.feet

MINIMUM LABOUR COSTSkilled Labour: 6000/monthUnskilled Labour: 4000/monthSITE AREA- 76850 sq.ft

Site Plan1. Main entrance 2. Back entrance 3. Security room 4. Reception area 5. Administrative Block a. Offices b. Conference room 6. Production block : a. Fabric and trim Store b. Fabric Receipt Area c. Spreading and Cutting room d. Sewing e. Finishing and packagingf. Ware House g. Maintenance Department h. Sampling Departmenti. Trainingj. Qualityk. IEDl. CAD 7. Physical plant: a. Boiler b. Generatorc. General Maintenance 8. Pesonnel block a. Creche b. Canteen

Production Block IE DEPARTMENTMAN POWER REQUIRED IE manager - 1IE Assistant manager 2Helper 2

Object Quantity DimensionArea Chair52ftX2ft20 sq ftComputer Table33ftx5ft45 sq ftCabinets For Storage23ftx2ft12 sq ftVisitors Chair22ftX2ft8 sq ftHanger stand110ftx3ft30sq ftTotal115 sq ftAllowance(50%)57 sq ftTotal172 sq ftPPC MAN POWER REQUIREDPPC manager 1PPC assistant manager 2Helper 1

Object Quantity DimensionArea Chair42ftX2ft16 sq ftComputer Table33ftx5ft45 sq ftCabinets For Storage23ftx2ft12 sq ftVisitors Chair22ftX2ft8 sq ftHanger stand110ftx3ft30sq ftTotal111 sq ftAllowance55sq ftTotal166 sq ftQUALITYMAN POWER REQUIRED Quality manager - 2Helper 2

Object Quantity DimensionArea Chair42ftX2ft16 sq ftComputer Table33ftx5ft45 sq ftInspection Table13ftx8ft24 sq ftCabinets For Storage23ftx2ft12 sq ftHanger stand110ftx3ft30sq ftTotal104sq ftAllowance52sq ftTotal156 sq ft

MAINTENANCEMaintenance manager-1Assistant manager- 1Helper- 1Mechanic - 5Issuer- 1Safety officer-1

Object Quantity DimensionArea Chair52ftX2ft20 sq ftWork Table33ftx4ft36 sq ftCabinets For Storage44ftx2ft32 sq ftShelves for storage22ftx5ft20sq ftTotal 108 sq ftAllowance54 sq ftExt: in Future20 sq ftTotal182 sq ft

CADCad incharge-2Helper - 1

Object Quantity DimensionArea Chair32ftX2ft12 sq ftComputer Table23ftx5ft30 sq ftCabinets For Storage13ftx2ft6 sq ftCad machineDizitizerPlotter8ftx3ft4ftX6ft6ftx3ft24 sq ft24 sq ft18 sq ftTotal114 sq ftAllowance (30%)33sq ftExt: in Future30 sq ftTotal177 sq ft

WAREHOUSEStorage capacity for five daysTotal storage quantity= 30,000 pcsConsidering one carton of dimensions= 1.5*1.5*1.5 ftNumber of units in 1 carton=10Hence total cartons required= 3000Considering pile of 8 cartons one over otherTotal no of rows* columns of cartons= 17*12Total area =(17*1.5)*(12*1.5)sq.ft = 468sq.ftConsidering 150% allowanceHence total area=1170 sq.ft

FABRIC AN TRIM STORE RACKSThe main raw material fabric rolls is to be stored in fabric store in racksDimensions of each roll=5ft*1ftFabric required for 1 day (6000gmts) = 6000*1.7 = 10200mtsStorage policy for fabric store =15days inventoryTherefore the fabric meter age to be stored = 15*10200 = 153000mtsAverage meter age available per roll = 100mtsTherefore the no of rolls required for storage = 1530rollsDimension of each rack=6ft*3.5ft*10ftCapacity of each rack =24 rollsNumber of racks required=64No of such racks required for trims storage =15Area covered by racks=(6*3.5*79) =1659sqft.considering 150%allowance total area=4150 sqftconsidering 30% future extensionArea=5400 sqftStore incharge=1Issuer=2Helpers=3

SPREADING AND CUTTINGTime for spreading 1lay manually = 1.1minsTime for spreading 100 lays manually = 110minsSimilarly, time for cutting 1 mtr of lay = 0.041minsTime for cutting 680mtrs (100lays) = 680*0.041 = 27.88minsTherefore spreading and cutting 400 gmts time required is 27.88mins+110mins = 137.88minsTherefore number of tables required for spreading and cutting is875/176 = 4.97~ 5 tables (approx)Therefore area for spreading and cutting tables = 5*25.6 = 128 sq mts =1378sq ft

SPREADING AND CUTTINGtotal area covered by 2 band knife machines is 2*3.36sqmts = 6.72sqmts = 72 sq ftArea covered by 2 fusing machines is2*(3.26mts * 1.58mts) = 9.68sqmts= 104 sq ft2 checking Table = 2*6 ft * 4 ft = 48 sq ft2 Bundling tables each of dimension 8ft *4 ft *2=64sqft2 ticketing table of dimension 8 ft*4 ft*2 = 64sq ftTOTAL AREA= 1730 sqftConsidering allowance of 150%Total area=4325sqftConsidering 30% future extensionNet total area=5700 sqft

SEWINGTotal number of workers(operators helpers and supervisors)in 1 line= 67 Total workers in sewing = 335No. of machines in 1 line(including SNLS,DNLS,Kansai,FOA)= 51Total No Tables In a Line= 11Total Machine area(including area between the machines)= (51 * 14.8 * 3.5) sq.ft= 856.80sq.ftCentre table length= 75.25ft, Width= 1.60 ftTotal Area of five lines= 6205 sq.ftConsidering future expansion for 1 line, total area= 7446 sq.ftTaking an allowance of 125% for man and material movement,Total area of Sewing floor= (7446+ 125%*7446)= 16754 sq.ft

SAMPLING

Object Quantity DimensionArea (sq ft) Chair212ftX2ft136Work Table13ftx5ft12Cabinets For Storage23ftX2ft12Total160Total Machines138Total298Allowance(100%)300Total600

Administration BlockConference RoomProduction Manager OfficeAccounts an Finance OfficeIT Head OfficeHead HR OfficeAsst. HR OfficeGeneral Manager OfficeFactory Manager OfficeQuality Head OfficeCompliance and ZeroxHousekeeping

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