GROUP G

MEMBERS NAME:
Prem Khachar – 500208481
Simran jaswal – 500209159
Sameer pasha - 500200137
 Sample factory layout of an apparel factory.

RAW MATERIAL STORAGE AREA

STAFF FACILITIES
MANUFACTURING
AREA:

 Clothes
production ADMINISTRATIVE/
assembly MANAGEMENT OFFICE

 Cutting
area

R&D DEPARTMENT:  Sewing/

stitching
area

 Finishing/
quality
control

WAREHOUSING/ FINISHED GOODS STORAGE AREA

  APPAREL MANUFACTURING FACILITY
 CAPACITY: 10,000 UNITS PER 3 HOURS
 LOCATION: DHAKA, BANGLADESH
 SQUARE FOOTAGE: 100,000 sq ft.
 COST TO BUILD: 3,000,000.00

This factory will be located in Dhaka because we feel this status offers the company
reduced tariffs on numerous developing and developed countries. With over 52
countries around the globe offering Bangladesh duty-free market access, you can rest
assured that its products are highly likely to be competitive even on a global scale.
In addition, Bangladeshi businesses enjoy preferential treatment following the signing of
several trade deals.

 Administration area and Management office-

The management office or administrative area is vital for managing numerous elements
of business operations in the apparel sector. In a clothing unit, the administrative
section is in charge of managing daily management duties and offering services to
multiple departments.
This department typically includes some sub-functional sections such as legal and
compliance section, office administration,human resource and finance department,
accounting and procurement whereas The management office of a clothing unit is
responsible for manufacturing corporate coordination, strategic planning, and decision-
making. The management office and administrative area engage closely on ensuring
the successful functioning of the attire unit. To support the objectives of the
organizational structure, they work simultaneously on strategic initiatives, resource
allocation, financial planning, and the enforcement of policies and procedures.

 Research and development department-

Certainly! An apparel unit's research and development (R&D) department is essential
for developing innovation, inventing new items, developing current designs, and
maintaining a competitive edge.
[Link] research - To determine upcoming fashion trends, consumer preferences,
and market demands, the R&D department undertakes a great deal of research on its
products. To create a thorough awareness of the target market and spot chances for
product development, they examine fashion predictions, customer reviews, and industry
information.

[Link] and Concept Development: The R&D section works to conceptualize and
create new apparel goods or enhance current ones in light of research findings. To
make the concepts a reality, this entails making drawings, mock-ups, and prototypes.
They take into account details like fabric choice, colour schemes, patterns, and
aesthetics to make sure the designs complement the brand's mission and appeal to the
target market.
[Link] and Material Exploration: To improve the quality, performance, and utility of
clothing, the R&D department investigates various fabrics, materials, and textiles. To
make sure the finished items live up to client expectations, they test and assess
different materials for toughness, comfort, breathability, moisture-wicking, and other
desired qualities.
[Link] Integration: The R&D division stays current on developments in
technology that are pertinent to the apparel sector. They investigate methods to
incorporate technology into clothing, such as using wearable sensors, smart materials,
or sustainable production techniques. Utilizing cutting-edge technology requires
partnering with outside partners, suppliers, or research organizations.
[Link] assessment and feasibility studies are carried out by the R&D department to
see whether new goods will be commercially viable. To establish if the items can be
manufactured and marketed successfully, they evaluate issues such production costs,
materials sourcing, manufacturing procedures, and anticipated market demand.
The R&D division at a clothing unit helps to produce distinctive and compelling clothing
items. Through their efforts, the apparel unit is able to develop, become more
competitive, and keep up with changing consumer tastes and market trends.

 Raw material storage Area:

The various materials used in garment manufacture are kept in the raw material storage
area, a dedicated location within manufacturing facilities or warehouses. These
materials frequently consist of the fabrics, trimmings, notions, and other elements
required to make clothes.
• Fabric - it is the main basic material used to make garments. In the raw material
storage room, many fabric kinds, including cotton, polyester, silk, and blends, are
kept. Fabrics are frequently arranged according to their kind, colour, pattern, and
weight after being received in rolls or bolts. To guarantee the quality of the
textiles, proper storage conditions, such as temperature and humidity control,
may be maintained
• Notions and Trims - Button, zipper, elastic, ribbon, thread, label, and other minor
parts used in garment creation are examples of trims and notions. These
materials are kept apart from the textiles and frequently categorised by kind, size,
and colour in bins, drawers, or shelves. The accessible amount of trimmings and
notions may be kept under control with the use of accurate labelling and
inventory management systems.
• Security and Safety - Security and safety preventative measures may be in place
to guard priceless goods from theft and damage in the raw material storage area.
Restricted access, security measures, and inventory management practises
might all fall under this category. To guarantee the wellbeing of employees and
merchandise, safety precautions like fire prevention measures or correct
handling guidelines may also be established.

Assuming an average fabric width of 150 centimeters (59 inches), a fabric weight of 10
ounces per square yard (340 GSM), and a fabric utilization efficiency of 80%, we can
calculate the fabric requirement as follows:

• Determine the fabric area per unit: Fabric area per unit = (Fabric width / 100) x
(Length of jeans + Seam allowance) square meters.
• Calculate the total fabric area required: Total fabric area = Fabric area per unit x
Number of units.
• Convert the fabric area into fabric yardage: Total fabric yardage = Total fabric
area / (Fabric weight in ounces per square yard).
Now, let's calculate the fabric requirement for 10,000 units produced in 3 hours, working
7 days a week:

First, we need to determine the production rate in units per hour: Production rate = Total
units / Total production hours Production rate = 10,000 units / (3 hours x 7 days x 24
hours per day)

Next, we calculate the fabric requirement for one unit using the fabric area per unit and
fabric yardage formulas mentioned above.

Finally, we multiply the fabric requirement per unit by the total number of units produced
in the given time frame:

Fabric requirement = Fabric requirement per unit x Total units

 SEWING AND ASSEMBLY AREA

An essential part of the clothing business is the sewing and assembly room, where
clothes are sewn together and put together to create final goods. Sewing operations are
carried out in a dedicated workplace by professional employees known as
seamstresses or sewers to create clothing using the specified designs and patterns.
To produce 10,000 units every 3 hours in a sewing and assembly area that operates
24/7, we need to consider the production rate and the time it takes to complete each
unit. Let's break it down:
1. Production rate:
 The production rate is 10,000 units per 3 hours.
2. Time per unit:
 To determine the time, it takes to complete each unit, we divide the
production time (3 hours) by the number of units produced in that time
(10,000 units).
 Time per unit = Production time / Number of units
 Time per unit = 3 hours / 10,000 units
 Time per unit = 0.0003 hours (or 0.018 minutes, or 1.08 seconds)
3. Total production time:
 To produce 10,000 units every 3 hours, we need to calculate the total
production time required for 10,000 units.
  Total production time = 3 hours
4. Number of production cycles per day:
 To determine how many production cycles can be completed in a day, we
divide the total number of hours in a day (24) by the production time (3
hours).
 Number of production cycles per day = Total number of hours / Production
time
 Number of production cycles per day = 24 hours / 3 hours
 Number of production cycles per day = 8 cycles
5. Number of workers required:
 The number of workers required depends on the cycle time and the time
per unit.
 Assuming each worker works for 8 hours per day, we can calculate the
number of workers needed.
 Number of workers required = (Total production time / Time per unit) /
Number of production cycles per day
 Number of workers required = (3 hours / 0.0003 hours) / 8 cycles
 Number of workers required = 10,000 workers
Therefore, to produce 10,000 units every 3 hours in a sewing and assembly area
operating 24/7, approximately 10,000 workers would be required. Each worker would
work for 8 hours per day, completing one cycle in 3 hours.

 Quality Control
The apparel business depends heavily on quality control to make sure that products are
of the requisite quality, fit, and durability. To find and fix any flaws or inconsistencies, it
entails several procedures and inspections carried out at various stages of the
manufacturing cycle.
The apparel business may guarantee that products fulfill desired standards, legal
requirements, and consumer expectations by putting in place effective quality control
procedures. This will boost customer satisfaction and brand reputation.
 Warehousing and finished goods:
Prior to being supplied to retailers or customers, finished items are managed and stored
in the apparel industry through the use of warehousing. In the apparel sector,
warehousing is essential for handling completed items, keeping inventory accurate, and
assuring prompt and effective delivery. It makes it possible to store, organize, and
distribute clothes efficiently, which helps the supply chain run smoothly and increases
consumer satisfaction.

INVENTORY:

Threads
Trims
Fabrics Embellishmen Sewing
Accessories
t Threads

Zippers
Cotton Elastic
Buttons Embroidery
Silk Brands
Threads
Ribbons Drawstrings
Polyester

The inventory section will occupy approximately 4000 sq ft and will hold safety
stock to support 2 weeks of production, because according to us this much stock
is enough to handle minor disruption.