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PLANT LAYOUT
ASSIGNMENT-2
ARCHITECTS BRIEF
FACILITY DESIGN AND REQUIREMENTS FOR A PROGRESSIVE-BUNDLE TROUSER
MANUFACTURING UNIT
SUBMITTED TO:
MR. K. RAMMOHAN
SUBMITTED BY:
HARSHDEEP SINGH
SHUBHAM ARYAN
SUBHOJIT DAS
SUPRIYA NANDA
VAISHNAVI SINGH
B.F.TECH (A.P), SEMESTER-VII
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INTRODUCTION
An architects brief is an official form of communication from the owner to the architect of a
construction site which entails the facility design, requirements and floor space area
distribution to guide the architect to construct the site as well as fulfil the requirementsspecified by the owner. Usually, the architects brief contains the following details-
Project brief
Topographical survey
Plot details
Manpower requirements
Product development
Nature and type of business
Domain of various departments
Capacity to be met
Approx. sizes of different workspaces required
Compliance and safety requirements
Machine variety and distribution
Nature of machinery used
Process flow
Rough layout
Safety guidelines
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PROJECT BRIEF
Mens formal trouser is a garment with a standard process which allows the machinery andequipment required to be fixed permanently. This type of garment requires very basic
sewing machines as well some sophisticated finishing equipment in order to achieve the
professional look as desired by the garment. The garments construction methods remain
standard with just a few minor changes with different styles. Also, the kind of raw materials
that the production requires are similar amongst all styles. Hence, the site to be designed
can totally eliminate the fact that the machinery needs to be moved at frequent intervals
and can focus on more permanent fixtures.
Here under are the primary details concerned with the industry:
Product category Trouser
Product Mens Formal Trouser
Nature of business Export
Rate of production 2000 pieces/day
Daily working hours 8 hours/day
6 days/week
Location Apparel Park, Gundlapochampally
TOPOGRAPHICAL SURVEY
The designated plot is situated in the Apparel Expo Park, Gundlapochampally along
with other apparel export industries like Chermas and Pochampally. The park is
designed to provide all the necessities of an apparel industry.
The apparel park is well connected to the NH-7 and just at a distance of 580 kms
from the nearest port.
The park is designed with well-planned roads which facilitate the easy movement of
trucks and other heavy machinery. Also, there is a sufficient allowance between two
consecutive factories.
The park is also equipped with latest security and surveillance systems.
The park is located on medium black soil and contains sufficient green belts around.
The plot is located on the south-west side of the park and faces east.
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The distance from the main gate to the plot is around 600m, which is quite feasible
to cover in a short time
PLOT DETAILS
The plot is 25,000 sq. ft in area.
It is L-shaped
FSI is 1.1
Ground coverage should be 40%-60%
Front margin should be 30 feet
Side margin should be 26 feet
FIGURE. ROUGH STRUCTURE AND LAYOUT OF THE PLOT
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PRODUCT DEVELOPMENT
The mens formal trouser has the following variations depending upon a little change in the
components:
1. Double-Pleated
2. Single-Pleated
3. Flat-Front
4. With lining
5.
Without lining
6. With Bottom Cuff
7. With normal bottom hem
8. With Waistband Extension
NATURE AND TYPE OF BUSINESS
The industry mentioned in the project has high man force requirements and is a worker
oriented industry out of which the 60% of the workers are women. So, the industry needs to
be designed on the basis of high numbers of worker movement and facilities. The industry
is focused towards producing high quality goods for exports and hence, should maintain all
the ISO standards for garment production. The industry is supposed to entail all the safety
provisions and instructions as to guide the workers amongst various departments. Also, the
industry is suggested to be developed to support shorter life cycles and frequent style
adaptations. The industry is supposed to follow the Progressive bundle system i.e. the
production continues in bundles. Hence, there occurs a requirement to store the products
at each stage of production.
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DOMAIN OF VARIOUS DEPARTMENTS
Marketing:
The marketing department plays a key role in getting orders from buyers across the world.
This department usually publicizes its products across the world in Order to get orders.
Merchandising:
Once the buyer confirms the order, the job of the merchandising department starts. Before
taking any order the marketing department will also check with merchandising department
for open capacity. The merchandising department checks with PPC for open capacity. Once
an order is finalized, the merchandiser is the Middle man between the buyer and his
factory.
Sampling:
The sampling department is responsible for making the above samples as & when asked for
by the merchandiser. These samples have to be carefully stitched & finished by the sampling
department as they are the final samples the buyer will approve for bulk production.
Store: stores are the department where the trims , fabrics, needles , packing materials are
kept in bulk. whenever any departments like sewing , finishing , packing needs the required
elements the stores provide them.
Cutting:
This departments objective is to separate fabric parts as replica of pattern pieces in
marker plan.
Sewing:
The basic duties of the sewing department is to stitch the cut parts provided by the cutting
department & to provide the required quality of stitching & mend the Reparable mistakes
when pointed out by the QA team .
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Finishing:
The function of this department is to finish and present the garments as per the buyers
specifications.
Packaging:
the garments are packed either in poly bags , hangers , etc and then these
are in turn packed in cartons as per buyers requirements.
Quality Control:
Ensuring the production of the garment with reference to the
standard specification is known as quality control. Quality of the garment is inspected
in various stages from fabric to finished garment.
Maintenance:
The machineries used in the garment production are to be maintained Periodically for
continuous working.The main objective of it is:
Solving problems in machineries
Preventive measurements
Monitoring at regular intervals
Accounts:
it looks after all the financial aspects of the industry.
Human Resource:
The human resource department deals with following:
1. Factory human resources.
2. Salary as per Grade and Designation
3. Health and Safety Policy
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Training:In this department the new joiners are given training for 30-45 days at Technical
Training Division. The trainees are evaluated for production team during training and are
graded A, B, C and D. If required, training is extended for further 15 days.
Sourcing :helps in finding out as to where the fabric , trims etc. can be obtained.
Fabric warehouse:
The warehouse has be designed to keep the sourced material that is ready to be cut and fed
into the production system. The section consists of huge racks that are enabled to keep the
bales and rolls of different fabrics separate and segregated.
Fabric inspection:
This section is equipped with checking tables that check the fabric which is supposed to
enter the fabric lines.
Goods Warehouse:
This warehouse keeps the finished goods ready for delivery after packaging
Ticketing/Bundling:
This section divides the cut pieces into bundles that are to be fed in the sewing lines.
Trims and accessories:
These departments keep all the trims and accessories required per order. These may
contain Buttons, Zipper etc.
CAD/ Pattern making:
This department is responsible for making patterns and markers to enable cutting.
Testing Lab:
The testing lab is a very sophisticatedly maintained workspace with temperature, humidity
and lighting maintained. The testing lab is supposed to be designed as per the ASTM
standards for testing.
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Boiler:
The boiler is centralized and is responsible for providing steam to all the departments of
production
Maintenance:
This department is responsible for maintaining the physical and electrical issues occurring
with the industry. It also keeps the track for faulty facilities and replacement parts
AHU:
The AHU room is designed to provide central air-conditioning to all the offices as well as the
production floors. The AHU is to be designed to provide proper ventilation within the
industry.
Vacuum Room:
This department is responsible for provide pneumatic vacuum pressure in the pressing
machines in the finishing department
Gate:
The main gate should be a sliding metal gate , so it would be easy to open & close it.& also
it should be wider so any truck or heavy vehicle easily can pass through of it.
Security cabin:
An entrance gate should have security check cabin to check the entry of incoming & out
coming transport vehicle and also of visitor . it should have the layed pipe lines to avoid the
entrance of cattles & security personnel will come to know if any vehicle passes through
the gate.
A main entrance should have following facilities:
1- CCTV camera
2- Security personnel
3- Biometric /manual enter/ exit record system.
4- Land line phone with Intercom facility.
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Reception:
A reception lounge should have reception desk with sitting facilities like sofa, chairs, table
& feedback book for customers & visitors.
Reception should have daily newspaper, magazine etc.
Parking:
Parking should be available for employees, worker & for visitors or customer. The parking
may be divided by the type of vehicle like two wheelers; four wheelers .parking should have
also a security CCTV camera.
Crche:
A garment industry should have crche because of the most of the employees or workers
are female. so a garment industry should run a crche & should appoint a caretaker.
Medical dispensary:
A garment industry should have a small medical dispensary for providing the first aid
treatment to employees & workers .
1- Doctor should be appointed by the organization.
2- Ambulance facility
3- One assistant should be appointed.
Fire extinguisher:
for security purpose fire extinguisher should be installed in all the departments.
Emergency exit:
Every dept. should have emergency exit. (10*4feet)
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PROCESS FLOW
Hereunder is a rough process flow in order to provide a relationship amongst the
departments as how the departments should be arranged in order to enhance the
continuous movement of products:
GENERAL STRUCTURAL REQUIREMENTS
The building structure required should be a steady permanent construction, using
cement, concrete and iron bars.
The roof of each floor should be strong enough to hold the weight of machinery and
workers designated.
The floor for each unit should be properly levelled.
The walls, the floor and the roof should contain proper plumbing, electrification and
proper insulation in order to prevent fire hazard.
Depending
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AREA REQUIREMENTS BASED ON DIFFERENT DEPARTMENTS
BasementCutting 3000 Sq. Ft
Fabric Warehouse 800 Sq. Ft
Inspection 600 Sq. Ft
Quality 800 Sq. Ft
Sourcing 400 Sq. Ft
Ticketing / Bundling 600 Sq. Ft
Trims/Acc 400 Sq. Ft
Toilets 300 Sq. Ft
CAD/ Marker /PM 200 Sq. Ft
Sampling 300 Sq. Ft
Testing 500 Sq. Ft
Training Centre 400 Sq. Ft
Ground FloorFinishing 1500 Sq. Ft
Packaging 1500 Sq. Ft
Boiler 600 Sq. Ft
Electricity and maintenance 400 Sq. Ft
AHU 200 Sq. Ft
Vacuum Room 200 Sq. FtCrche 300 Sq. Ft
Clinic 200 Sq. Ft
HR/IT/Admin/Fin/Log 200 Sq. Ft
Toilets 800 Sq. Ft
Conference Room 300 Sq. Ft
Meeting Rooms 240 Sq. Ft
First FloorSewing 1500 Sq. Ft
Mark/Mirch 540 Sq. Ft
I.E. 60 Sq. FtCanteen Executive 500 Sq. Ft
Canteen Workers 400 Sq. Ft
Toilets 500 Sq. Ft
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(2.7 X1.5 X2.7)
AREA DISTRIBUTION IN VARIOUS DEPARTMENTS
1. STORES
2. FABRIC & TRIM WAREHOUSE
Rolls to be stored in palletized form
Inventory of 15 days
FABRIC STORAGE REQUIREMENT
Fabric required for 2000 trousers for 15 days inventory
Fabric required per top =1.4 m
So, total fabric for 15 days sewing=1.4X2000X15mts.+5%wastage (5760)=44100
mtrs.
Since, 1 roll contains 100 mtrs. Fabric
Total roll=44100/100 = 441rolls
RACKS requirement:
Now, 1 roll dimension=0.45 (dia)
Racks dimension= (2.7 X1.5 X2.7)
Rolls kept in 1 racks=36 rolls
Racks required=441/36= 13 racks
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3. DISPENSARY
Equipments Quantity Area sq. ft.
Beds 3 63= 54
Checking table 1 63=18
Doctor cabin -Equipment storage -
Total area 200
4. SEWING/ FINISHING/CUTTING
Machine No. of
machines
Power
Standardized(Watt)
Dimensions Weight
Weishi fabric
inspection
machine
4 1100 watt 2600*1850*2100 600 kg
SpectraLUX Jr
i2 Colour
matching
cabinet
(Paramount)
1 1100 Length 406mm
Depth355mm
Height482mm
15 kg
Morgan FOX
100
Automatic
spreadingmachine
1 10392 Width available 180 - 230 cm 400 kg
Gerber
Automatic
spreader
XLs125
2
11500 Total Height over Table Top with
Full Size Roll 90 cm /35 in
Table Width Machine width + 20
cm
Heavy
machine,wt not
mentioned
Cnc cutter
gerber GTXL
2 9872 L-4.19 m,breadth-2.74m Heavy
machine,wt not
mentioned
Gerber
vaccum table
3 6600 2.34 x 4.37 m (92 x 172 in) Heavy
machine,wt not
mentioned
Veith pintable
2 1280 170cm x 404 cm
Eastman band
knife ec-900 n
2 750 1500* 1800 mm 300 kg
Eastman
straight knife
blue streak 2
2 1100 34 lbs. (15.4kg)
Eastman
round knife
Plastic Master
2 5715 9.52 kg
Kannegiessar
Fusing
Machine
MultiStar DXT1400L
2 10392 Working width 1400 mm 1440 kg
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WEISHI YTP-
W20 Stepper
Vacuum Table
12 9872 1300*700*870mm 125 kg
Weishi
YTPW28B Up
steam table
12 9872 1400*750*1650mm 125 kg
Macpi formfinisher
8 1700
Macpi legger
machine
12 9872 2670mmx1560mmx1680mm 750kg
Macpi 820
Topper
machine
8 2450 4100*2100 mm
Macoi q58c
Buck flap
turning &
pressing
8 2000 1200X1150X1400 mm 270 kg
WeishiQ51F
Buck bottom
press
12 1900 1200*650*1650/1400*750*1650
mm
125 kg
DURKOP ADLER
220-5300 NRNLS( needle feed)
With UBT
30 5.8 amps, 110 VAC
at
60 Hz; single phase
100*70*80cm 38.5 kg
Snls edge
cutterDURKOPP
ADLER 272-740-
642
20 39 kg
SNLS( drop feed)
With UBTPFAFF-1483
35 100*70*80cm
SncsPFAFF-3801
10 100*70*80cm 40 kg
5 thread o/lJUKI MO-6716S
5 100*70*80cm 39 kg
BartackBROTHER BF-
438D
20 100*70*105cm 53 kg
Button sewBROTHER BE-
438C
10 100*70*105cm 61 kg
Button holeDURKOPP
ADLER 580
PREMIUM
10 100*70*105cm 68 kg
Button
warpingLOIVA ST-10
5 400 VA 600mm x 600 mm x 400 mm 65 kg
Auto sergingDURKOP ADLER
1465-4
5 590VA 1,800mm (W) 790mm (D)
880mm (H)
Long-table type
(L): 160kg (with
stacker)
Blind hem
strobel
5 100*70*890cm 45 kg
SNLS(
differential feed)With UBTDURKOPP
5 50 cm x 35 cm x 25 cm 25 kg
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ADLER 275-140-
342
COMPLIANCE AND SAFETY REQUIREMENTS
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 3 feet.
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.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
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Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
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
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
Manpower
Manpower Department wise Male/Female Strength Report
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Attendance Report
Late Report
Absenteeism 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 month-wise
Minimum Wages
Basic
D.A.
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
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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)
FACILITY REQUIREMENTS
ARTIFICIAL LIGHTING FOR DIFF. DEPT.
SEWING:
For checking lux level-900-1000,twin tube light of 24 watt each
For pressing lux level-500-600,single tube light of 30 watt each
For loading lux level-500-600,single tube light of 30 watt each
For loading lux level-500-600,single tube light of 30 watt each
For normal sewing Lux level- 500-600, single tube light of 30 watt each
For trimming lux level-500-600,single tube light of 30 watt each.
CUTTING:
For panel check and re-cutting lux level-1000-1200,twin tube light of 24 watt each
For spreading and cutting lux level-700-800,single tube light of 36 watt each
For fusing and ticketing Lux level- 400-500, single tube light of 30 watt each
FABRIC STORE AND TRIM STORE:
For trims storage lux level-500,single tube light of 36 watt each
For checking trims lux level-700-800,twin tube light of 30 watt each
Storage of fabric Lux level- 200-250, single tube light of 30 watt each
FINISHING:
For pressing and finishing Lux level- 400-500, single tube light of 30 watt each.
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WATER CONSUMPTION
Total Man power =600
Total Drinking Water requirement/day= 1550 ltrs
Water requirement required for basic necessities =3840 ltrs(6.4 ltr/man power)
MANPOWER DETAILS
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