architechtural brief

PLANT LAYOUT ARCHITECHTURAL BRIEF FOR FASHION SHIRT MANUFATURING PLANT Submitted By: Akriti Sharma (03) Amit Kumar (04) 1

Ashish Kumar (07) Vaibhav (28)

PART 1 INTRODUCTION

2

Introduction About The Project •

It is proposed to setup an apparel manufacturing facility for manufacture of fashion shirts.

• The proposed facility is to be setup within an area of 15,000sft. •

The facility shall perform composite functions of fabricating the product right from the raw material to its finished state.

• The facility shall cater and be oriented towards domestic as well as export oriented markets. •

The processes in the manufacturing would be in house with the exception of the processing of raw material like fabrics which shall be procured in processed forms.

• The nature of the product is not staple thus variations are possible in machine requirement as well as the production work flow. •

Type of manufacturing system is proposed to be a combination of product for assembly line and process type for small parts construction.

•

The required production rate of finished product is to be 3000 pieces/day.

3

Product Analysis Product Overview

Fig: fashion shirt

Name of the Product

Fashion shirt

Category(Men’s/Women’s/Children)

Men’s, Women’s and Childrens

Type of Product(Casual/Formal)

Casual

Staple/fashion Product

Fashion

Major rawmaterials

Fabric (woven),trims like button, fusible interlining, zipper and sewing threads

4

PRODUCT DESCRIPTION •

The casual or fashion shirt is an apparel for casual/daily wear purpose.

•

It must have desirable fashion features such as darts, panels, embroidery, etc for providing an attractive look to the wearer.

•

A standard fashion shirt has around 11 components.

•

Variations among these components are done to develop various designs.

•

The major raw materials consumed in the manufacturing are fabrics.

•

Variety of woven fabrics can be used as raw material for the product.

•

The construction of the product can vary from easy to complex depending on the style variation.

•

Small parts like collar and cuffs are separately prepared before being assemble into the main garment.

•

The collar and cuff require fusing machines for attaching the fusible interlinings to the respective parts.

5

PARTS LIST A standard fashion shirt consists of the following parts: Part number

Part name

Quantity per final assembly

Make/buy

1.

Front

2

Make

2.

Back.

1

Make

3

Yoke (Back).

2

Make

4

Sleeve.

2

Make

5.

Collar.

1

Make

6

Collar band.

1

Make

7

Cuff.

2

Make

8.

Sleeve placket.

2

Make

9

Pockets.

1 or 2

Make

10

Front placket (Button/Button hole).

1

Make

11

Buttons

7-8

Buy

1+1+1+1

Buy

Other auxiliary parts are: Labels o Brand 12 .

o Size o Fit o Wash care

6

Sewing Operation Breakdown The following operations are for sewing a men’s casual (fashion) shirt. These are general operation irrespective of any variation. MACHINE

Operation Number Operation name

REQUIRED

A01

Serge front

5Th O/L

A02

Fuse fusible interlining on

Fusing m/c

A03

Serge front placket

5Th O/L

A04

Sew front buttonhole placket to front.

SNLS

A05

Sew button placket

SNLS

A06

Top stitch button hole placket

SNCS/SNLS

A07

Serge back

5 TH O/L

B01

Sew shoulder

SNLS

B02

Attach pocket

SNLS

B02

Sew under sleeve placket to sleeve

SNLS

B03

Fold upper sleeve placket

IRONINGTABLE

B04

Sew upper sleeve placket

SNLS

B05

Sew tack to sleeve mouth

SNLS

B06

Sew sleeve

SNLS

B07

Counter stitch sleeve

SNLS/DNLS

B08

Sew side and under sleeve

Feed of the arm

B09

Fold bottom and slit

Manual

B10

Sew top of slit

SNLS

B11

Top stitch bottom and slit

SNLS

B12

Crease label

Ironing Table

B13

Sew size label to brand label

SNLS

B14

Baste brand label to neck

SNLS

Fuse fusible interlining on upper

Fusing m/c

B15

collar 7

B16

Run stitch collar

SNLS

B17

Cut collar point ,turn & fold collar

B18

Sew collar bottom

SNLS

B19

Sew collar

SNLS

B20

Counter stitch collar

SNLS/DNLS

B21

Fuse Fusible interlining on cuff

Fusing m/c

B22

Sew edge of cuff

SNLS

B23

Turn and form cuff

Cuff turning m/c

B24

Topstitch cuff

SNLS

B25

Sew cuff

SNLS

B26

Turn body and mark button position

Manual

B27

Sew button to point

B28

Sew button hole to cuff

Collar turning m/c

Button attach m/c Button Holing m/c Button stitch machine

B29

Sew button to front and cuff

C01

Trim thread

C02

Inspect

Manual

C03

Press body

Vacuum Press

C04

Finishing iron

Iron

Thread trimming machine

8

PRODUCT/PART VARIATIONS Part name

Possible Variations 1. Kimono sleeve 2. Pleated shirt

Front and back body

3. Shirt with yokes(front and back) 4. Multi-Panel shirt 5. Gather shirt 1. Sailor collar 2. Shirt collar 3. Peter Pan collar 4. Stand collar

Collar 5. Roll collar 6. Madrin collar 7. Turtle neck

1. Cap sleeve 2. Dart less sleeve 3. Petal sleeves Sleeve

4. Circular hemline sleeves 5. Lantern sleeves 6. Cowl sleeves 7. Leg-o-mutton sleeves

Sleeve cuffs

1. Basic shirt cuff 9

2. Self-faced cuff 3. French cuff 4. Contoured cuff 5. Roll-up- cuff 1. Epaulets 2. Zippers 3. Buttons(metallic /plastic) Decorative trims/parts 4. Patch work 5. Paupers or rivets 6. Hood

10

Part 2 Production process and Related Activities

11

PROCESS INVOLVED / OPERATING ACTIVITIES

Proto type sample development

Pp sample development

Pp sample approval

SEWING

Sample approval

Order Conformation

Size sample approval

Size set samples

Production Planning and raw material procurement (SCM)

Cutting

Receive raw material and inspection

Stores

Marker from CAD

Pressing and Finishing

Quality checking and audit

Packaging

Dispatch

Standard Production Operations/activities

12

Processes involving specialized operations Specialized operation required for meeting the requirements of the product variations are as follows: •

Embroidery

•

Printing

•

Washing

Embroidery:-Embroidery can be done on any part/component. It is usually done before sewing/assembly operations. The parts requiring the embroidery are transported from the cutting to the embroidery section. After embroidery the parts are transported back to cutting and re bundled with original pieces. Printing: Printing also can be done on any individual part or component before the sewing/assembly operations. The parts requiring the embroidery are transported from the cutting to the embroidery section. After embroidery the parts are transported back to cutting and re bundled with original pieces and sent for sewing. Washing: To provide a variety of effects the garments may be given washes or for providing shrinkage. These operations are usually done after the production operations are completed and just before the packaging. The garments which are produced out from the sewing lines are sent directly for washing from where after washing they are sent to the finishing department for finishing and packaging.

13

Process flow with specialized operations

Proto type sample development

Pp sample development

Pp sample approval

PRINTING

Sample approval

Order Conformation

Size sample approval

Size set samples

Production Planning and raw material procurement (SCM)

EMBROIDERY

Sewing

Cutting

WASHING

Quality checking and audit

Pressing and Finishing

Receive raw material and inspection

Marker from CAD

Stores

Packaging

Dispatch

14

OPERATION BREAK DOWN FOR MAJOR DEPARTMENTS FABRIC STORE

Invoice received from the merchandiser

Identification of supplier

Negotiation with supplier

Issue of purchase order

Follow up with the supplier

Receiving of fabric

Storage of fabric

Fabric check

Issuing of the fabric

15

CUTTING DEPARTMENT

Fabric received from the fabric stores

Spreading

Marker Making

Lay Checking

Cutting Re- cutting (for embroidery and sometimes checks)

Ticketing Component checking

Fusing (when required)

Bundling

Issued to sewing batch

16

FINISHING DEPARTMENT

Button Holing/stitching

Washing

Thread cutting

Pressing

Checking

Re- pressing

Measurement check Thread sucking

Folding

Tagging

Packing Dispatch

17

Computer Aided Design (CAD)

1

18

RFD

19

SAMPLING

Receive the tech peck from the merchandiser

Develop the patterns

Developing the fit sample and sending for approval

Developing the size set

Developing the PP samples

Sealing the patterns and send for production

20

PART 3 PRODUCTION SYSTEM: PROGRESSIVE BUNDLE SYSTEM

21

Production System: Progressive Bundle System The production system proposed for the facility is “Progressive Bundle System” with the material flow being “zigzag” motion. PBS system is exactly what its name implies, a system whereby the garments are gradually assembled as they move through successive sub-assembly and main assembly operations in bundle form. The principles of this system are: •

The various sections are positioned according to the main operation sequence, with each section having a layout according to the sequence of operations required to produce a particular component.

•

A work store is positioned at the start and the end of every section of these buffers is used to store work received from a preceding operation and to hold work complete by that section.

•

Due to these work stores or buffers, each section is not directly dependent on the preceding section, but can absorb slight variation in output via the stocks held within the section.

The reasons for using PBS system are highlighted below: •

Labors of all levels, that is skilled, unskilled, semi-skilled labors are involved in this system where the operations are broken into small simple operation. Hence the cost of labor is cheap.

•

The quantity and quality of each component is checked during the individual operation itself, so the quality is good.

•

The component are moved in bundles from one operation to the next operation, so there is less chance for confusion like, lot mix-up, shade variation, size variation etc.

•

Specialization and rhythm of operations in PBS increase the overall productivity

22

•

Bundle tracking is possible, so identifying and solving problems becomes easy.

The material flow is zigzag movement of material. In case of the zig zag movement the straight line is divided into two lines such that if the first operation is on the right side of the centre table, the subsequent operation is done on the opposite side of the table. The completed parts are placed on the table and the next operator picks up the same. •

The system is very useful in terms of ergonomics as it requires minimum operator’s motion.

•

The workflow is also improved and the chances of the bundles breaking in the middle of the line are minimized.

The pattern is well explained by the following illustration. For example if there are 6 operation in manufacturing a part. Let ,the operations be Op1, Op2, Op3, Op4, Op5 and Op6, and the operators be 1,2 ,3 4, 5 and 6 respectively, the material flow would be

6

OP6

4

OP4

2

OP2

Material Flow

OP5

OP3

Operators for the operation

5

3

1

OP1

Centre table

Machines for operations

Illustration of the zig zag movement of the material

23

PART 4 MAN MACHINE AND MATERIAL CALCULATIONS

24

Man Machine and Material Calculations • The calculations for the man, machine and material have to be done department wise depending. • The type and quantity of equipment desired is to be determined by deriving information from the process breakdown compiled. • The desired Production capacity is of 3000 garments per day. • Thus it is necessary to plan the capacity of the various production related departments such that they have a capacity of 3000 garments at 100% efficiency. • This is required in order to synchronize the material flow among departments and avoid excess WIP.

DEPARTMENT WISE CALCULATION

FABRIC STORE Equipments Required Storage pallets • The main raw material fabric is to be stored on plastic pallets in the fabric store by piling up rolls or arranging bales. • The pallets have to be of moulded 4-way type. • It has been preferably proposed to procure Sintex pallet (model-9PNR4-1012-

02). • Dimension of each pallet- 1000mm X 1200mm X 200 mm (L X B XH). 25

• Fabric required for one day (3150gmts)=3150*2=6300 mts • Storage policy for fabric store= 7 days inventory. Therefore, •

The required fabric meter age to be stored= 7*6300= 44100 mts.

•

Average meter age available per roll= 100 mts

•

There for the number of rolls required for storage= 441 (approx)

•

Capacity of each plastic pallet=300-400 kgs.

•

Average weight of fabric rolls of 150mts = 30 kgs.

•

Thus, per pallet quantity to be stocked= 10 rolls • Thus , Quantity of pallets required= 44 • Area covered in sft= 567.072 sft (approx). • Benefits of plastic pallets for storage:

•

Cost effective

•

Compatible with all existing lifting systems

•

Easy to clean & wash

•

Excellent resistance to most chemicals

•

Maintenance-free

•

Rot proof

•

Extensive testing to ensures quality standards

•

Secure

•

Robust design to render long service

•

Meets all GMP requirements

•

Hygienic

•

Water proof

•

High impact strength and rigidity

26

Fabric Checking Machine •

A fabric inspection machine would be required for the purpose of inspecting the received fabric in order to certify the quality of the fabric and help in making the batches of fabric as per shades.

•

The fabric inspection machine that is to be procured is of Paramount (ModelCheckMate Basic™).

• Dimension of each inspection machine- 2100 mm X 1475 mm X 1800 mm. (L X

B XH). • The area covered by inspection machine=2.1*1.47= 3.087mt2 • Quantity of inspection machines=2 • Area covered in sft= 70 sft (approx).

Inspection tables • Dimension of each inspection table- 12’x6’ • The area covered by inspection table=.72’ • Quantity of inspection machines=2 • Area covered in sft= 144 sft (approx).

Manpower (Personnel and labour) •

Quality Inspection- 3

•

Quality assuarance-1

•

Department in charge -1

•

Office Clerks-3

•

Helpers-5 27

•

Total manpower - 13

Material • The raw material that is stored in the fabric store is only fabric for production.

• The material is available in rolls and bale form.

Accessory Store Storage cabinet • A storage cabinet is required for storing the required trims for production. • A storage cabinet with multi level rack is apt for its compactness and less space consumption. • Preferably storage cabinets would be procured from Kompact systems. • The dimension of 11 rack storage cabinet = 70”x30”(5.8’x2.5’)

• Total Area covered= 14.5 sft

Inspection tables • Dimension of each inspection table- 12’x6’ • The area covered by inspection table=.72’

• Quantity of inspection tables =4 • Area covered in sft= 288 sft (approx).

28

Man(Personnel and labour) •

Quality Inspection- 4

•

Quality assuarance-2

•

Department in charge -1

•

Office Clerks-3

•

Helpers-5

•

Total manpower - 15

Material • The raw material that is stored in the accessory store is only the trims and accessory required for production. • The material is available in small sizes and large quantities thus storage must be done in racks /cabinet.

29

Thread Store Storage cabinet • A storage cabinet is required for storing the required threads and thread boxes for production. • A storage cabinet with multi level rack is apt for its compactness and less space consumption. • Preferably storage cabinets would be procured from Kompact systems. • The dimension of 11 rack storage cabinet = 70”x30”(5.8’x2.5’) • Total Area covered= 14.5 sft

Inspection tables • Dimension of each inspection table- 12’x6’ • The area covered by inspection table=.72’

• Quantity of inspection tables=4 • Area covered in sft= 288 sft (approx).

30

Man power(Personnel and labour) •

Quality Inspection- 2

•

Quality assuarance-1

•

Colour matching assistant-2

•

Department in charge -1

•

Office Clerks-2

•

Helpers-5

•

Total manpower - 13

Material • The raw material that is stored in the accessory store is only the trims and accessory required for production. • The material is available in small sizes and large quantities thus storage must be done in racks /cabinet.

31

Spreading and Cutting Spreading and cutting tables • Spreading and cutting will be done on the same table only • The required capacity for 8 hrs shift is 3000 pieces.

• The average consumption for a shirt= 2mts. • The length of the marker for a 4-way marker= 8mts. • Preferable Number of plies per lay=100 • Number of garment required per hour= 3000*60/480= 375 gmts/hr.

Now,by Time standards • Time for spreading 1 lay manually= 1.1 mins • Time for spreading 100 lays = 110 mins. Similarly • Time for cutting 1 mts of lay= 0.041 mins. • Time for cutting 800 mts(100 lays) of a lay= 800*0.041=32.8 mins There fore • For spreading and cutting 400 garments time required= 32.8+110=142.8mins. • For spreading and cutting 1 garment time required= 142.8/400=0.35mins

Hence • Number of garments spread and cut in an hour=60/0.35=171 • Thus,

the

required

number

of

tables

for

spreading

cutting=375/171=3( approx). • The length of the table (assuming 4 way marker with allowances)=12 mts. 32

and

• The width of the table (assuming max width of 60”) =162.5 cm=1.6mts. • Area of spreading tables= 12*1.6mts= 19.2*3mts2= 57.6mts2=618.62sft

• The tables are to be of ceramic surface for smooth operations.

Cutting Equipments • Each table has single straight knife cutting machine. • Straight Knife cutting machine can be stored under the table and don’t need

separate storage. • 2 band knife machines for recutting purpose. • Area covered by band knife= 2.10mts*1.6mts= 3.36 *2mt2 =6.72mt2 =72.17sft • 2 continuous Fusing machine required for fusing the fusible interlining on collar,

cuffs and placket. • Area covered by fusing machines = 3.26mts*1.58mts= 4.84*2= 9.68mt2

=103.96sft

Storage racks • 2 End bit racks of dimension = 1.17mts*0.61 mts=0.7137 sq mts= 15.33 sft (2

racks). • 1 rack for remnant fabric pieces=1.17mts *0.61 mts= 0.7137 sq mts=7.62sft

Quality checking Tables • 1 table = 2.45*1mts.58mts=3.871 sq mts=41.57 sft.

Bundling and ticketing tables • 2 Bundling tables of dimensions= 2.45mt*1.58 mts • Thus area for bundling tables= 7.742 sq mts= 83.14 sft. • 1 Ticketing tables of dimensions= 2.45mt*1.58 mts= 3.871 sq mts= 41.57 sft 33

Man power (Personnel and labour) •

Master spreader - 3(1 per each table).

•

Cutting master – 3 (1 per each table).

•

Spreading helper-3(1 per each table).

•

Cutting helper-3 (1 per each table).

•

Department in charge -1.

•

Office Clerks-3.

•

Fusing machine operators-4.

•

Recutting operator- 1.

•

Total Manpower - 21

Material • The raw material that is stored in the cutting room is only fabric for production.

• The material is available in small sizes and large quantities thus storage must be done in racks /cabinet.

34

SEWING Equipment Required Sewing Machines The following list provides the amount and type of machines required for production /sewing of a single garment based on the sewing operation breakdown (refer Product analysis). The list is also representative of the machines required in setting a single sewing line

Sno

Type of machine

Quantity

1

SNLS

21

2

DNLS

4

3

SNCS

1

4

Feed of the Arm

1

5

Button attach

2

6

Button hole

2

7

5TH O/L

3

Total sewing machines

35

34

Specialized machines Machines required for catering to special purposes such as collar turning , cuff turning and ironing .

Sno

Type of machine

Quantity

1

Collar turning

1

2

Cuff turning

1

3

Ironing

2

Total specialized machines

4

Inspection tables • 2 inspection tables of mid line and end line inspection of dimension ( ).

Manual operation Tables • 2 tables for performing manual operation per sewing line.

Sewing lines • Required production rate = 3000 garments /day

• Working hours per day= 8hrs (480 mins). • Standard allowed Minute for Production of single garment= 20 mins. • Minutes required for production of 3000 garments= 3000*20= 60,000 mins. • Number of sewing machines/operators required to perform production in single sewing line= 34. • Efficiency desired for production= 60%

Therefore, 36

• Total labour required for producing 3000 gmts in 480 mins using the efficiency formula= Minutes required/Minutes available • Hence total sewing operators= 3000*20/480*0.6=208 operators. • Since, 34 operators are required per sewing line, the number of sewing lines

required for desired production level =208/34= 6 sewing lines (appox).

Sewing Work station • In line with the production system proposed (PBS –zigzag motion), considering the machines are arranged in two rows separated by a centre table. • For calculation purpose, a single unit of a sewing line consists of two machines on either side of the centre table inclusive of the centre table measurement and operator workspace allowance.

5

OP5

6

OP6

Centre table Operators for the operation Machines for operations

Illustration of a single unit of a sewing line

37

• Measurement of the single unit of sewing line :

•

Width- 1.20 mts(machine width -0.60mts+ operator allowance=0.60mts)

•

Length-2.04mts (2* Machine length(2mts)+ centre table width-0.40 mts).

• Area of a single unit= 1.20mts*2.04mts= 2.88 sq mt-30.93 sft.

• There are such 17 units in a single sewing line • Thus area of a single line= 525.83 sft. • Since, there are 6 sewing line, working area= 3154.98sft.

Manpower • Sewing Operators- 208 • Operator for specialized machines-30 • Helpers -30 • Quality checkers-12 • Supervisors- 1 per line=6 • Production manager-1 • Assistant Production manager-1 • Quality Assurance personnel – 3 • Total sewing department manpower = 291

38

FINISHING Finishing machinery list Machine

Model number

quantity

Washing machine

WS 35 fabcare

2

Hydro extractor

HDS 25 fabcare

2

Tumble dryer

DTS-60 fabcare

1

Pressing machine

RAMSONS VEIT 4255-

5

65

Boiler

RAMSONS diesel

1

steam generator

Machine requirementsDifferent machines required are washing machine, hydro extractor, tumble dryer, pressing machine, boiler. • The washing machine which will be utilized is of fabcare, model number- WS 35. Area of the washing machine = 1050 mm * 1200 mm=1260000 mm2 39

Number of washing machine used = 2 Therefore, area used = 2520000 mm2 = 27.11520 sq ft. • The hydro extractor which will be utilized is of fabcare, model number- HDS 25. Area of the machine = 1200 mm * 1350 mm=1620000 mm2 Number of machine used = 2 Therefore, area used = 3240000 mm2 = 34.86240 sq ft. • The tumble dryer which will be utilized is of fabcare, model number- DTS-60. Area of the machine = 1350 mm * 1690 mm= 2281500 mm2 Number of machine used = 1 Therefore, area used = 2281500 mm2 = 24.54894 sq ft. • The pressing machine which will be utilized is of ramsons, model number- VEIT 4255-65. Area of the machine = 110 cm * 32 cm =3520 cm2 Number of machine used = 5 Therefore, area used = 17600 cm2 = 18.93760 sq ft. • The boiler which will be utilized is of ramsons diesel steam generator. Area of the machine = 1150 mm * 1350 mm = 1552500 mm2 Number of machine used = 1 Therefore, area used = 1552500 mm2 = 16.70490 sq ft. • Inspection Tables are required for different purposes which are initial checking,

thread trimming and final inspection.

40

Number of tables required = 12 (4 for 1st inspection+ 4 for thread cutting +4 for final inspection) Area of the table = 2.1 mts* 1.47 mts = 3.087 mt2 = 33.21612 sq ft. • Sewing machines are also required for reworking if any. Number of machine required = 5 Area required = 5* 1*0.60mts=3 sq mt= 32.22sft

Packaging • 1 Metal detector for detecting metal parts within garments before packaging

• Dimensions of metal detector= 0.6mts *0.9 mts=0.54 sft=5.77 sft. • 8 packaging tables of dimension 2.1mts * 1.47 mts • Dimension of Packaging tables= 8*2.1*1.47=24.696mt2 = 265.23 sft

Total area required for the finishing machinery = 27.11 sq ft. +34.86 sq ft. + 24.54sq ft. +18.93 sq ft. + 16.70 sq ft. + 33.21 sq ft. + 32.22 sft +265.23 sft = 452.80 sft.

MANPOWER • Washers – 7 • Pressers-5 • Helpers -20 • Quality checkers- 10 • Quality assurance-5 • Finishing incharge =1 • Packers- 20 • Total manpower= 68 41

PRINTING Machinery details Printing machines • M&R challenger II –(16 colour) automatic Curing machines • Transwift mini curing machine • M&R sprint 2000 – automatic continuous curing machine Fusing /Heat Transfer Machines • Cheran fusing machines-2 • HIX fusing machine Screen development machinery • Nu-Arc tri-light exposing machine • M&R Digikote’T’ automatic coating machine • 1 chamber heater. • 4 Inspection tables Total Area for Printing department= 1870 sft

42

Manpower •

Printers-5

•

Colour developer-2

•

Screen developers-5

•

Curing machine operators-5

•

Heat transfer operators=5

•

Helpers -8

•

Total manpower- 30

43

Embroidery Machine details Embroidery machines • Barudan (18 head 9 thread)-2 • Barudan (6 head 9 thread)-1 • Amaya XT (16 colour)-2 Patch cutting machine • Golden laser cutting machine-1 Needle detector machine • Hashima metal detector Total Area for embroidery department= 1200 sft

Manpower •

Embroiders-5

•

Patch cutters-2

•

Laser cutting operator-2

•

Helpers-6

•

Total manpower- 15

44

SAMPLING Machinery Details S.no

Machine

Quantity

1.

Flat locks

8

2.

Over lock

10

3.

Feed of the arm

3

4.

SNLS

17

5.

Riveting machine

1

6.

Straight knife

1

7.

Ramsons veit iron table

1

8.

Picotting m/c

1

9.

buttonhole

1

10.

buttoning m/c

1

Total machines

44

Storage Racks • 2 storage racks Table • 2 pattern making tables Area • Total area of sampling department = 3700 sft

45

Manpower planning • Cutting master – 2 • Pattern maker – 5 • Stitching master – 50 • Helpers – 10 • Sampling head – 1 • Total manpower – 68

46

CAD DEPARTMENT Machinery •

Gerber digitizer (16 button cursor)

•

Gerber Plotter (Infinity series)

•

4 Desktops

Area covered by Cad department – 96 sft Manpower Details •

CAD operators- 4

•

Helper – 2

•

Total operators - 6

47

AMENITIES REQUIREMENT Different amenities requirements are as follows: •

2 water cooler per floor

•

4 toilets per floor •

2 for operators (men and women)

•

2 for supervisors and officers (Men and women)

•

Worker’s canteen on the top floor, area of 1000 sft

•

Parking space at the basement

Total Setbacks of entire building is proposed to be 2000 sft with an estimate of 44 ft at each side. This set back is for transport parking and loading/unloading of the trucks.

48

PART 5 Area allocation

49

Store department– Fabric store Area covered by pallets

567.072 sq ft

Area covered by fabric checking

70 sq ft

machine Area covered by Inspection table

144 sq ft

Accessory store Area covered by storage cabinet

14.5 sq ft

Area covered by inspection tables

288 sq ft.

Thread store Area covered by storage cabinets

14.5 sq ft

Area covered by inspection tables

288 sq ft.

Office area

200 sq ft

Total area

1586.072 sq ft

Total area with 20% allowance for

1903.286 sq ft

walking and storing auxiliary items

50

Spreading and cutting departmentArea covered by the tables

618.62 sq ft

Area covered by the fusing machine

103.96 sq ft

Area covered by the band knife

72.17 sq ft

machine Area covered by the end bit racks

15.33 sq ft

Area covered by the remnant racks

7.62 sq ft

Area covered by the quality checking

41.57 sq ft

tables Area covered by the bundling and

83.14 sq ft

ticketing tables Office area

200 sq ft

Total area

1142.41 sq ft

Total area with 20 % allowance for

1370.892 sq ft

walking and storing auxiliary items

51

Sewing department – Area covered by the sewing floor

3154.98 sq ft

Office area

200 sq ft

Total area

3354.98 sq ft

Total area with 20 % allowance for

4025.976 sq ft

walking and storing auxiliary items Finishing department – Area covered by the washing

27.115 sq ft

machine Area covered by the hydro extractor

34.86 sq ft

Area covered by the tumble dryer

24.548 sq ft

Area covered by the pressing

18.937 sq ft

machine Area covered by the boiler

16.70 sq ft

Area covered by the inspection tables

33.21 sq ft

Area covered by the sewing machine

32.22 sq ft

Area of metal detector

5.77 sq ft

Area of packaging tables

265.23 sq ft

Office area

200 sq ft

Total area

658.585 sq ft

Total area with 20 % allowance for

790.21 sq ft

walking and storing auxiliary items

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Printing and embroidery department Printing department area

1870 sq ft

Embroidery department area

1200 sq ft

Total area

3070 sq ft

Total area with 20% allowance for

3684 sq ft

walking and storing auxiliary items

Sampling and cad departmentArea of sampling department

3700 sq ft

Area of CAD department

96 sq ft

Total area

3796 sq ft

Total area with 20% allowance for

4555.2 sq ft

walking and storing auxiliary items

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Auxiliary departmentsReception area

100 sq ft

Merchandizing and marketing

200 sq ft

HR

150 sq ft

Finance and accounts

200 sq ft

IE

200 sq ft

Quality assurance

100 sq ft

Design

200 sq ft

Administrative

300 sq ft

PPC

200 sq ft

Canteen

50 sq ft

Total area

1700 sq ft

Total area with 20 % allowance for

2040 sq ft

walking etc.

AuxiliaryThe auxiliary block consists of various departments such as merchandizing, marketing, PPC ,HR ,financial accounts,IE,Production,Design,Reception area and etc.these consist of the offices where the various personnel perform their job. The offices only consist of working desks and desktops for performing the job. Each workspace is separate by a cabin wall. Preferably each cabin space must be ergonomically of 2 cu meters.

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