Architectural Brief

 NATIONAL INSTITUTE TECHNOLOGY, New Delhi

OF

FASHION

PLANT LAYOUT & FACILITY DESIGN

ARCHITECTURAL BRIEF OF TANK TOP MANUFACTURING UNIT

SUBMITTED TO: Ms. Bhavna Verma

SUBMITTED BY: Aadarsh Kadambi Akhila Menon Arun Kumar Rajat Sharma Somya Tank M.F.T. (SEM. 2)

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CONTENT

TOPIC

PAGE No.

BRIEF

5

DEPARTMENTS LIST

7

SPECIFICATION

9

STORE

10

CUTTING DEPT.

10

SEWING DEPT.

11

FINISHING

11

Q.A.DEPT.

12

WAREHOUSE

13

TRAINING

14

MAINTENANCE

14

SAMPLING

15

CANTEEN

16

MAN POWER

17

COMPLIANCE

20

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Plant layout Architectural Brief

Product category: Tank top Product: ladies Tank top Variations:

1- Ruffle collar top 2- Lace top 3- Cotton cull top 4- Crop top 5- V tank top 6- Pull over top 7- Racer tank top 8- Bustier top 9- Kela top 10- Stella top 11- Yoke tank top Nature of Business: Export Rate of Production: 7680 pieces/day No. of lines: 7 lines with 80% efficiency.

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Variation

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BRIEF 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 cattle’s & security personnel will come to know if an y 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.

Reception: 5

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.

Crèche: A garment industry should have crèche because of the most of the employees or workers are female. so a garment industry should run a crèche & 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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Various departments in the organization 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 depa rtment 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 department’s 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 .

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 buyer’s requirements.

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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 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.

Purchase: The purchasing department deals with purchase of every single thing

required in the industry. Sourcing : helps in finding out as to where the fabric , trims etc can be obtained.

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Top Tank Plant Layout Specification: Plot Area: 310 × 150 feet = 46500 sqft. FSI: 1.1 Ground Coverage: 40% Front Margin: 30feet Side margin: 26 feet Daily Production Capacity: 7680 pieces/day Daily working hours = 8 hrs. Working days = 6day/week

1. ADMINISTRATION DEPARTMENT DEPARTMENTS

Reception/ Waiting Room

SIZE( IN FEET)

20×10

CEO’s Cabin  

20×10

Conference Room

20×30

Buyers Room

30×10

PPC Cabin

20×10

Staff Canteen

20 ×10

HR Cabin

20×10

Canteen

20×35

Merchandising

20×10

Purchase account & finance

20×10

Department

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STORE DEPARTMENT

DEPARTMENTS

SIZE( IN MTR)

Trim & Accessories Cabin

15×10 feet

Rack size

(2.7 X1.5 X2.7)

 Number of roll in one rack

36

Roll length

100

Roll dia

0.45

Total no. of racks

27

Total number of roll storage

945

CUTTING ROOM DEPARTMENTS

SIZE( IN FEET)

CAD

40×25

Spreading & Cutting table

22×5

Ticketing & bundling

4×4( for each table)

Managers cabin

10×10

Water closet

3×3

 No of pieces cut/day

1440

Average consumption per garment

0.8 meter

Marker

8 way

Expected marker length

8× 0.8mtr =6.4 mtr

Total no of layers per cut

90

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SEWING ROOM Total sewing m/c = 180 Total Area for 180 m/c =1134 sqft Total chairs area : 296 sqft For future expansion: 2lines of 360 sqft Total no. of inspection table = 7 Area of table: 30sqft/table Total area = 210 sqft TOTAL AREA OF SEWING FLOOR = 11625sq.ft. TOTAL SMV = 9 TOTAL NO. of M/C = 24 / LINE (Note:- Area of the floor= Total Area + 150% o f Total Area)

Finishing

Finishing department being the final process of garment manufacturing endures value addition to the product, thus providing it with aesthetic and attractiveness for packaging. Each and every  process in garment finishing adds value in which pressing and packaging contributes the most. Following are the activities. 

Ironing



Tags attached



Checking

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Finishing department No. of work force Designation

Number

Area (sq.ft.)

finishing Head Finishing executives finishing operator Pressing Folding & packing Area required for equipments Inspection Tables Stain removing station Total area

1 4 16 2 3

100 100 7×3 = 21 7×4= 28 each

1 1

3×3 =9 8×8 = 64 278

Q&A Department: The quality assurance department is meant for setting the quality standards

for the product and then checking their sustainability in the production process. The department requires one quality manager and quality supervisors. QA department No. of work force Designation QA Head QA executives

Computer Seam slippage testing m/c Tear strength testing Wash fastness testing m/c Rubbing fastness m/c Light fastness Pilling testing Chair Total area

Number 1 4

Area (sq.ft.) 10 × 10 = 100 -

3 1 1 1 1 1 1 5

2×4 = 8 1×1= 1 109

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Warehouse Fabric & Trim warehouse

Rolls to be stored in palletized form Inventory of 15 days FABRIC STORAGE REQUIREMENT



Fabric required for 7680 top tank for 15 days inventory



Fabric required per top =0.8-1mt



So,

total

fabric

for

15

days

sewing=1X7680X15=115200

mts.+5%wastage

(5760)=120960 mtrs. 

Since, 1 roll contains 100 mtrs. Fabric



Total roll=120960/100=1209.6 rolls = 1210rolls (rounded off)

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=1210 /36= 34 racks

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Training Dept.:

This department carries the responsibilities of training the

newly recruited workers for

 production activities. This department consists of all m/c in the sewing department . Training Department No. of work force Designation Number Training head 1

Supervisor Machine Machine Computer Chair Sewing m/c

Description

Area (sqft)

Description

Dimension (ft) 2×4 1×1 2×3 =6

2 Number 3 5 15

Maintenance dept. :

The department is responsible for the maintenance of the machines. It also requires space for the maintenance job. Following are the activities of the department. 

Maintenance of sewing and finishing machines



Tools and machinery storage for special machines



Spare parts storage



Air conditioning maintenance



Electric supply & power backups

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Product development Cycle (PDC) Dept. Sampling Room

In sampling room one line of product development is there thus designated machine is required which are there in sewing room. Design development

 Number of Employees = 1 designer Helper = 2 Area is around is 800 sq. ft.

Utility Boiler Room = 2000 Sq ft Air compressor = 300 sq. ft Power house = 1000 sq ft

Security Main security room: 10×10=100 sq.feet Workers entry security room : 10*10= 100 sq. ft. (Note:- Area of the floor= Total Area + 150% o f Toatal Area) Crèche: 20× 20 = 400 sq. feet Dispensary: Equipments Beds Checking table Doctor cabin Equipment storage Total area

Quantity 3 1

Area sq. ft. 6×3= 54 6×3=18 100

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CANTEEN

Man power for 1 line =10 Table sizes = 10×3  No. Of table = 10 Canteen Area= 60 × 35 = 2100sqft. Executive canteen area = 35× 20 = 700 sqft.

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 tub e 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

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FABRIC STORE AND TRIM STORE: 

For trims storage lux level-500,single tube light of 36 watt ea ch



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, sin gle tube light of 30 watt each.

MAN POWER REQUIREMENT Administration:

Reception =1 CEO = 1 Canteen = 4 Marketing merchandising = 4 Production merchandising = 4 Compliance = 2+4 Purchase department = 6 HR department = 8 Fire and Security department = 15 Office boy =3 Medical room = 2 Store room:

Store manager = 1 Loading/unloading boy = 5 Inspection = 4 Issuing in-charge (fabric and trims) = 2 Data operator = 1 Sweeper = 2 17

Warehouse:

In-charge = 1 Data operator =1 Helper = 4 CAD Room:

Marker planner = 2 Drawing master/designer = 1

Pattern making Room:

Pattern master =1 Asst. Pattern master =1 Sampling Room:

In-charge = 1 Operator = 4 Helper = 1 Cutting Room:

Cutting in-charge =1 Supervisor = 1 Spreading operator = 3 Cutting operator = 3 Data operator = 1 Helper = 3 Ticketing/bundling = 4 Straight knife operator = 2 Sweeper = 1 Sewing Room:

Production manager = 1 Line in-charge = 1 Supervisor = 2 18

Operator = 24 × 7lines Helper = 20 Data operator = 1 Sweeper = 2 Finishing Room:

In-charge = 1 Supervisor = 1 Ironing operator = 10 Spot cleaner operator = 2 Thread sucker operator = 2 Hang tag operator = 4 Inspection operator = 6 Helper = 2 Data operator = 1 Sweeper = 2 Maintenance Room:

In-charge = 1 Technician = 4 Electrician = 3 Quality department:

Head = 1 Supervisor = 2 Cutting quality checker = 4 Sewing quality checker = 4 IE department:

Head = 1 Staff = 2 Data operator = 1 Total Man power =350 19

Total Drinking Water requirement/day= 1550 ltrs Water requirement required for basic necessities = 2200 ltrs(6.4 ltr/man power) COMPLIANCE REQUIREMENT: 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 Effective water Sewage system 20

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 Attendance Report Late Report Absenteeism Report 21

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 monthwise 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 Securities Uniform/Cap/Shoe/Belt etc. Securities Knowledge about Fire Evacuation & Fire Safety Security Agreement file (If outsourced) 22

Security Salary register file (If outsourced) Security ESI, PF Challan (If Outsourced)

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