PLANT LAYOUT
Assignment 2
Neha, Nandini, Fidha
PRODUCT AND
BUILDING TYPE
Product and Building type
● Product- Men’s POLO T Shirts
● SAM- 15 minutes
● Fabric Consumption- 0.85 meters
● Machines- 400
● Total area- 70000 sq. ft
● Building type- Multi storey(administration) and single storey(production)
Machine No. of machines Required
SNLS 16
O/L 12
F/L 2
Button hole M/C 1
Button M/C 1
Trimmer 1
Helper 9
Inline Checking table 1
Machine No. of machines Required
SNLS 11
O/L 8
F/L 2
Button hole M/C 1
Button M/C 1
Trimmer 1
Helper 9
Inline Checking table 1
1. Total No of operators = 391
2. Working time in a day( 8 hrs shift - 50 min break) = 470 minutes
3. Total man minutes available in a day = 470*380 = 183770 min
4. SAM = 15 min
5. Line Efficiency = 100%
6. Targeted Daily production = Total man minutes available in a day/SAM X average
line efficiency.
• = 183770/15 * 100%
• = 12251 pieces per day
PLANT LAYOUT AREA
Area([Link]) Area(sq.m)
Area required for one machine 175 0.092903
Area required for 400 machine 70000 6503.2128
Product Polo T shirt Sq. ft Sq.m
Total no. of Machines 400 1 0
Area required for Sq. ft. Sq. m
one machine Ratio
Total area 70000 6503.21 Cutting Sewing Finishing
Cutting 145259.25926 1324.727963 1.1 3 1.3
Sewing 38888.888889 3612.894444 0.21 0.5 0.24
Finishing 16851.85185 1565.587593
site 14000 1300.642 Site 20% extra
Administration 7000 650.321 Administration 5-10% extra
WAREHOUSE/
FABRIC STORAGE
Process Flow
Issuing Product
Product Shade to Cutting &
Inventory Inspection Testing
Receive Segregation Sewing
Department
Inform
merchandiser or
supplier
Fabric Storage Area
Quantity Unit Quantity Unit
Daily Production 11059 Pc Fabric roll Weight calculation
Fabric Consumption 0.85 m Fabric length 100 M
Fabric Width 1.83 M
Total Fabric Required Per Day 9400 mts GSM 210 Gsm
No. of Days of Inventory 20 Days Fabric roll weight 38.43 Kg
Total Fabric in store 188003 mts
Storage capacity of racks 4000 Kg
Roll Diameter 0.3048 m No. of roll per rack 104
Roll Radius 0.1524 m Length 3.6 M
Roll Length 1.83 m Width 1 M
Meters of Fabric on roll 100 m 2 Rack can be placed to accommodate rolls in width
Total rolls required per day 94 Such arrangements can accomodate
For 20 days 1880 No. of rolls(104*2) 208
Volume available on truck 960 Cu. mts Length of the arrangement 3.6 M
Truck Required 14 Width of the arrangement 2 M
Fabric Inspection 10%
Area of the arrangement 7.2 [Link]
Fabric storage area
Space for unloading area Space for checking Area
Main Storage Area
20% of fabric Required 1880 mts Total Fabric 9400 M
For Racks
per day 10% of total Fabric 940 M
90% of fabric required 8460 m
per day
Speed of checking 0.6 m/min
Rolls per day 19 Rolls machine Rolls per day 84.6
20 days stock to be 376 Rolls 20 days stock to be 1692 Rolls
1567 Min kept
kept
Total available 420 Min Rack arrangement 8.0
Rack arrangement 2
minutes required
required
So checking machines required Total 57.6 Sq.m
Total area 14.4 Sq.m
No. of checking 4
machines
Weighting machines 1 Stock lot area
Length 2.6 M
Length 0.6096 Width 1.55 m Lot area 200 Sq.m
Width 0.6096 Area 4.03 Sq.m. Total area 288.49 Sq.m
Area 0.37 Sq.m
Total Area required 16.12 Sq.m.
for checking
Total 14.77 Sq.m machines
Fabric Storage Area
Minimum required area: 342 sq. m
Provided Area : 400 sq. m
SPREADING AND
CUTTING
DEPARTMENT
Process Flow
Received the
Decide the
cutting ratio from Make the cutting
Lay planning Marker making Make marker ratio quantity of fabric
apparel quantity
spreading
manufacturing
Fix the number of Take the fabric Marker setting on Fabric cutting
Check the Fabric Fabric spreading
lay per cutting from store lay (straight knife)
Fabric cutting Bundling and
Taking to sorting Taken to loading
(band knife for checking of Ticketing
table racks
smaller parts ) panels
Spreading and Cutting Department
Garments to be produced 110059 Space for cutting table Space for Band Knife
No. of cutting tables 5
No. of band knife 5
Extra 5% to cut 5530
Length 10 m
Length 2.85 m
Pieces to be cut 16589
Width 2 m
Fabric Consumption 0.85 m Width 1.5 m
Area 20 Sq.m
Fabric required to cut 14100 m Area 4.275 Sq.m
Total area 100 Sq.m
Length of table 8 m
Marker type 10 Straight knife cutting 10
machine
Total garments to be cut in one ply 10 Total area 21.375 Sq.m
Spreaders 5
No. of plies 150
Total garments to be cut in one lay 1500 Space for Dye Cutting Machines
Total 127.375 Sq.m
Time taken to spread 2 hr Dye cutting Machines 2
Time taken to cut with 2 Cutters 2 Hr Length 2 m Allowance 200%
No. of lays 11.059 Width 1.5 m
254.75 Sq.m
Area 3 Sq.m
11 lays has to be spread and cut to produce 16589 pc
per day. Within a shift of 8 hour 2 lays can be cut on
same table. Hence 5 tables would be required and
incase required then one table can be put on over
Total area 6 Sq.m
time of 2 hrs per day
Cutting and Spreading Department
Minimum required area: 254.75 sq. m
Provided Area: 536 sq. m
SEWING
DEPARTMENT
Process flow
Finish
Sewing
Loading Line
racks
Sewing Arrangement of a line Machine Dimensions Area Required Area Required (m2)
JUKI UBT 8700 121.9*91.4 11141.66 1.11
Length 31 m JUKI 4T O/L 121.9*91.4 11141.66 1.11
Width 3 m JUKI F/L 121.9*91.4 11141.66 1.11
Area 93 Sq.m Button Stitch Machine 130*85 11050 1.11
Total no. of machine 400 Button hole 130*86 11050 1.11
ABC thread trimming 130*85 11050 1.11
No. of operators 33
machine
No. of sewing Line 12.1212121212 Inline Checking Table 120*70 8400 0.84
[Link] Process Flow/ Activity Materi Qu Space Machinery Quantity Space Tools/ Quantity Space Remark
Description al ant Required required equipments Required
Handli ity / Furniture
ng Required
1 SNLS JUKI UBT 192 213.92
2 OVERLOCK JUKI 4T O/L 144 160.44
3 FLATLOCK JUKI 24 26.74
4 BUTTON STITCH JUKI LK 12 13.26
1903B
5 BUTTON HOLE JUKI LBH 12 13.26
1790
6 THREAD TRIMING ABC thread 12 13.26
trimmer
7 INLINE CHECKING Inline 12 10.08
Checking
table
Total 450.96
Sewing department
Total Area : 2101.93 sq. m
FINISHING
Process Flow
100% Label & Key
100% Garments point
First Checking Thread sucking Pressing Measurement
Final QC check
check
Metal Detector 100% Garments
Folding Tagging Shade Check
Check Getup Check
Packing Assortment Cartooning Final Inspection
FINISHING & PACKAGING SECTION
Daily production= 11060pcs/day No. of sec required for Inspection & Trimming = 40
SAM = 40/60mins=0.66 min
SAM –
Total time required per day = 11060 x 40/60 =
No. of sec required for Inspection & Trimming = 40 7373mins
SAM = 40/60mins=0.66 min
Manpower requirement = 7373/480 = 15
Total time required per day = 11060 x 40/60
= 7373mins Assuming 2-3 persons per table,
Manpower requirement = 7373/480 = 15 No. of tables required = 5
Assuming 2-3 persons per table, No. of sec required for final Ironing = 60
No. of tables required = 5 SAM= 60/60mins
No. of sec required for Thread sucking = 10 Total time required per day = 11060 x 60/60 =
SAM= 10/60 mins=0.166 min 11060mins Workstation requirement = 11060/480 = 23
Total time required per day = 11060 x 10/60 Manpower requirement = 23
= 1843.3mins Machine requirement = 1843.3/480 = 4
approx
Manpower requirement =4
FINISHING & PACKAGING SECTION
No. of sec required for Folding & Tagging = 60
SAM = 60/60 = 1 min
Total time required per day = 11060 x 1 = 4858mins
Manpower requirement = 11060/480 = 23
Assuming 1 person per table,
No. of tables required = 23
No. of sec required for Final Packaging =60
SAM = 60/60 =1 min
Total time required per day = 11060 x 1 = 4858mins Manpower requirement = 11060/480 = 23
Assuming 2 persons per table,
No. of tables required = 11
Manpower Required
[Link]. Designation No. of Manpower
1 Finishing Supervisor 1
2 Ironing/Pressing 23
3 Tag attachment 23
4 Thread sucking 4
5 Inspection & Trimming 15
6 Packing 23
Total Manpower 89
ADMINISTRATION
CONFERENCE ROOM QUALITY ASSURANCE
MAINTENANCE SKILL DEVELOPMENT
DEPARTMENT
WASHING AREA CAD DEPARTMENT
LAYOUT