Plant Jury

LAYOUT Women's Top(casual) manufacturing Industry By: Ankur (03) Dayal (05) Kunal (09)

INTRODUCTION • VARIANT:

Casual of woven fabric (twill -cotton and polyster blend.) Casual on knit fabric TH E PLANT PLA NT:: • CAPACITY OF THE Daily production: 3000 pcs • BUSINESS TYPE:

For Domestic Market. AREA : 20000 sq. ft. • PLOT AREA

INTRODUCTION • VARIANT:

Casual of woven fabric (twill -cotton and polyster blend.) Casual on knit fabric TH E PLANT PLA NT:: • CAPACITY OF THE Daily production: 3000 pcs • BUSINESS TYPE:

For Domestic Market. AREA : 20000 sq. ft. • PLOT AREA

DEPARTMENT H.R. Department  Accounts Merchandising Sampling I.T Department

CAD/ CAM Spreading & cutting Sewing Quality and Audit Finishing Warehouse Stores

FACILITY: Estimates assumed: Product - Garment- Casual Shirts Style details: Casual top with epaulette and pocket flap. Casual top with epaulette. Casual top with front yoke. Full sleeve and half sleeve top.

Plant efficiency: 60% Target per day-=3,000 pieces Type of production system : Progressive Bundle system Total no of machines in one line = 15(Approx.) Total no of machines in sewing section= 160(Approx.) So, total no. of lines required = 140/15 = 11 Total production per day= 3,000 No of shifts per day=1 Working hours per shift= 8 hours

LAYOUT (Ground floor ) The plant has 3 floors. The ground floor has the security near the entrance. The generator is on the back side of the security. There is a pathway for the container form main gate to warehouse. There is parking on the both side, one is opposite to security room and another is near to the generator. Building is surrounded by the fence and has two entrance one which leads to the sampling and another to the office area.

LAYOUT The building has the lift and stares too. The adjoining room is a meeting and show room and near to that G. M. Operations cabin. Opposite to that there is merchandising office which has passage in between. Every floor has toilets.  And the boiler is on the terrace.

FIRST AND SECOND FLOOR first floor has cutting room , fabric and trim store. Fabric store contains fabric checking m/c.  Also there is electric panel room and fusing m/c. Second floor is completely for sewing and finishing. On the floor there is cabin for production manager and floor manager.

AREA CALCULATION, MANPOWER REQUIREMENT, FURNITURE AND EQUIPMENT DETAILS FOR VARIOUS DEPARTMENTS

DEPT.

TOTAL AREA

MANPOWER

COMPUTE R TABLE

CHAIR

RACKS

H. R.

300 sq. ft.

06

06

08

03

 ACCOUNT 300 sq. ft. S

08

08

05

---

MERCHAN 400 sq. ft. DISING

05

05

12

10

SAMPLIN G

600 sq. ft.

12

--

04

---

I. E.

200 sq. ft.

04

04

10

---

CUTTING SPREADING DEPT. AREA

500 + 140 + 74sq. ft.

TICKETING TABLE

(dimensions of table= 5’x3’) x4

BAND KNIFE

(5’’ x 4’’) x2

RACK

(10’’x3’’) x2

FUSING M/C

(4’’ x 3’’) x2

BUNDLE TABLE

(5’’x 5’’) x2

SRAIGHT KNIFE

4

FABRIC STORE AREA

738 sq. ft.

RACK

(20’’ x 4’’ x 3.5’’) x12

Fabric inspection

(6’’ X 5’’ X 2’’) X2

INSPECTION TABLE

(8’’ x 6’’) x4

TRIMS STORE AREA

360 sq. ft.

RACK

(10’’ x 8’’ ) x6

CUTTING DEPARTMENT AREA AND MANPOWER CALCULATION Daily production: 3000 garments Daily working hours: 8 Let 1 lay consist of 100 plies with 4 way marker  Thus, no. of garments = 100x4 = 400 SPREADING:

Spreading time of 1 lay= 120 min So, SAM = 120/400 = 0.3 Now, total SAM req. per day= 3000x0.3 = 900 min Thus, total no. of tables req.= 900/480 = 1.85 = 2 Manpower req. per lay (spreading) = 3 (2 operator + 1 helper) Thus, total manpower req. = 2*3 = 6 (4 operator + 2 helper)

Cutting: Cutting time of 1 garment= 22.5 min (approx.) So, Cutting time for 4-way marker = 22.5x4 = 90mins SAM = 90/400 = 0.225 Now, total SAM req. per day= 3000x0.225 = 675 min Thus, total no. of tables req.= 675/480 = 1.40 = 2 Straight knife -4 Manpower req. per lay (cutting) = 3 (2 operator + 1 helper) Thus, total manpower req. = 2*3 = 6(4opr + 2 helper) Band knife – Manpower req. = 2 (1 operator + 1 helper) Machine requirement = 4 straight knife + 1 band knife m/c

Fusing It is found that 1 m/pcs are capable of handling fusing required per day  Assuming 3 persons per m/c, Manpower required for fusing = 3 1 supervisor  1 cutting head 4 helpers

Ticketing Ticketing time per garment = 10s Time required per day = 3000x0.16 = 480mins Machine requirement = 480/480 = 1 Manpower requirement = 1 No. of tables required = 1

TOTAL MANPOWER IN CUTTING = 6+6+2+1+3+2+4=24

Now, the cutting room should have the capacity to store inventory of three days. Inventory to be stored= 3000 x 3 = 9000  A rack of (5’ x 3’) can store 1000 garment pieces.

Hence 9 racks required to keep the inventory. Total area covered by the racks= (5’ x 3’) x 9=135 sq.fts

 Area Calculation for Store Room Total yardage = 120 m Roll diameter = 7 inches Roll height = 60 inches So, Total number of rolls =36,000 /120

= 300 rolls

Rack:

Length = 6m approx 20 ft Breadth = 1m approx 3.5 ft Height = 1 m approx 3.5 ft  Area of rack: 70 sq ft 1 rack can store 25 rolls Therefore for 300 rolls aprox 12 racks (keeping one rack on another) So we need 6 colums for keeping 12 racks

Other equipment's in a store are:

Fabric inspection m/c = 2 (6 feet x 5 feet x 2) =60sq ft Fabric inspection table = 4 (8 feet x 6 feet) = 192 sq ft Office = 1 (100 sq ft) Main gangway = 13 ft Gangway between racks = 10 ft So, space requirement for racks and machines = 738 sq

f t 

Accessories Storage Area (Thread Storage, Button Storage etc.)

No. of Racks: 6 Length: 10 ft Width: 8 ft  Area: (10*8)*6=480 ft Free space: 40 sq ft Total area for trims:

SEWING FLOOR SNLS JUKI MACHINE:

Length: 42 in Width: 21 in.  Area: approx 6 sq feet 120 m/c: 120*6= 720 sq ft

DNLS Machine:

Length: 42 in Width: 21 in.  Area: approx 6 sq feet

Over lock machine:

Length: 41 in Width: 21 in  Area: approx 6 sq ft

Iron table:

Button hole:

Length: 51 in Width: 32 in  Area: approx 11 sq ft

Length: 47 in Width: 23in  Area: approx 8 sq ft

SEWING FLOOR Number of machines = 160 Total area required for machinery = 1500 square feet Total number of ironing tables in sewing floor = 8  Area required for each = 12 square feet Total area for ironing tables = 12 X 8 =96 approx 100 square feet Total number of inspection tables/bundle table= 12  Area required for each = 8 square feet Total area for inspection tables = 12 X 8 = 96 approx 100 square feet Total chairs =180  Area required for each chair: 3 sq ft Total area for chair: 540 sq ft Total area for machines: 2250 sq ft

SEWING FLOOR Production Manager Cabin: 100 sq ft Free space between m/c lines: 600 sq ft Total Area for Sewing Floor (excluding the aisle space) =approx 3390 square feet Free space required: 800 sq ft TOTAL AREA REQUIRED FOR SEWING DEPARTMENT: 4200 sq ft

WAREHOUSE AREA CALCULATION Dimension of a carton = 60 cm x 40 cm x 30 cm Peak Total Inventory = 30 days Total production per day = 600 So, Total number of Casual top in a day = 3000 casual top In the carton considered, 10 casual tops can be stored. So, Number of cartons in warehouse at a time = 18,000 /10 = 1800 cartons. Cartons will be stored on racks.

WAREHOUSE AREA CALCULATION Racks dimension:

Length = 6m approx 20 ft Breadth = 1m approx 3.5 ft Height = 1 m So, In this way, Total of 300 cartons can be stored on a single rack. Stacking one rack on another we can store 600 cartons on two racks, so we need 1800/ 600 = 3such racks In a single column, 2 such racks would be there with a storage capacity of  600 cartons. We will have 3 such columns. Total rack area: 20*3.5= 70 sq ft 3 racks: 70*3=210 sq ft Free space required: 190 sq ft

FINISHING AREA CALCULATION No. of m/c

Dim

Area per unit

Total Area

Checking table

10

6ft*4ft

24

240

Iron table

10

5ft*3ft

15

150

Stain removal

5

5ft*3ft

15

75

Thread sucker 

2

4ft*3ft

12

48

Needle detector 

2

2.5ftx4ft

10

20

Table (packing)

4

15ft*5ft

75

300

total

833

 Area required for machines = 833Sq. feet Free space required: 867 sq ft Total space required: 1700 sq ft

CRÈCHE The place where the worker’s children are properly taken care , when there parents are in shift for productio’s a small play center 

 Area required for one child = 1 square metre = 10 square feet Therefore, area required for 30 children = 30 X 10 = 300 square feet CANTEEN:

Its is the place for having lunch during the lunch time Kitchen area = 300 square feet Dining area = 700 square feet Seating capacity = 150 TOTAL AREA: 1000 sq ft

DEPT.

LIGHT

FAN

POWER SOCKET

H. R.

300 lux x1

08

 ACCOUNTS

300 lux x1

1 fan per 50 sq ft (total 6 fans) 1 fan per 50 sq ft (total 6 fans)

MERCHANDISI NG

300 lux x4

1 fan per 50 sq ft (total 8 fans)

08

SAMPLING

400 lux x12

1 fan per 50 sq ft (total 5 fans)

04

I. E.

300 lux x4

1 fan per 50 sq ft (total 4

06

10

STITCHING MAN POWER STATUS S. NO.

WORK TYPE

REQUIRED

1

MANAGER

1

2

EXECUTIVE

2

3

OPERATOR

160

4

HAND OPERATOR

35

5

IN – LINE CHECKER

10

6

FINAL CHECKER

12

7

S.P.I. CHECKER

2

8

Q.C.

5

9

DESPATCHER

4

10

PRODUCTION WRITER

2

STITCHING MAN POWER STATUS (I.E.)

11

COMPUTER OPERATOR

12

3 Jr. I.E.

2

13

SUPERVISOR

11

14

LINE INCHARGE

11

15

FLOOR INCHARGE

2

16

WRITER

1

17

FEEDSWRRRRRRR

7

18

NEEDLE STOCK

1

19

MECHANIC

2

20

ELECTRICIAN

2

COSTING DIRECT LABOUR

No. of workers

Category of Workers

Salary per 

Total salary in

worker 

Rupees

SNLS m/c operator 

70

5200

364000

4th O/L m/c operator 

40

5200

208000

5th O/L m/c operator 

20

5200

104000

3th F/L m/c operator 

30

5600

168000

Button hole/Button m/c operator 

4

5600

22400

Fusing m/c operators

2

5500

11000

Cutting m/c operators

10

5500

55000

Ironers

30

5000

150000

Packers

30

5500

165000

Garment checkers

50

5900

295000

Fabric checkers – skilled

5

5800

29000

Fabric checker  – semi-skilled

4

5500

22000

Helpers

80

4900

392000

Store keepers

2

8000

16000

Mechanics

2

9000

18000

Electrician

17000

2

8500

Office boys

2

4800

9600

Watch and Ward

12

7500

90000

Sweepers

12

4800

57600

2193600

Total Direct Labour cost per month

Additional Benefits @ 15%

329040

Total Direct Labour cost per month including Benefits

2522640

Total Direct Labour cost per Annum including Benefits

Total Direct Labour cost per Annum including Benefits =302.716

lakhs

30271680

FACTORY SUPERVISION Category of Staffs

No. of staffs

Salary

Total in Rs.

per staff  Senior ppc manager 

55000

55000

45000

45000

Production Manager 

1 1

Floor incharge

2

28000

56000

I.E

1

25000

25000

Cutting Manager 

1

25000

25000

Quality Manager 

1

32000

32000

Supervisor  Factory Supervision cost per month Additional Benefits @15%

16

9000

144000

382000

Total cost of Factory Supervision per month

57300 439300

Total cost of Factory Supervision per Annum

52,71,600

Total cost of Factory Supervision per Annum = 52.71 lakhs

OFFICE /ADMINISTRATION Category of Staffs

No. of

Salary

staffs

per staff 

Total in Rs.

1

23,000.00

23000

2

23,000.00

46000

Export/Import Manager 

1

28,000.00

28000

Office Assistants

2

15,000.00

30000

Fabric Merchandisers

2

30,000.00

60000

Garment Merchandisers

2

22,000.00

44000

Accounts/Admn Manager  Assistants

231000 34650

Additional Benefits @ 15% Total Salaries per month including Benefits

265650

Total Salaries per Annum including Benefits

31,87,800

Total Salaries

Annum including Benefits

31.878lakhs

Machinery Estimation of Machinery Required and Cost Estimate Details of Machine

Single Needle Lock Stitching m/c

Quantity

Cost per

Total Cost

M/c in US$

In US$

50

320

16000

20

1850.00

37000

50

900.00

45000

[Juki DDL-5530N] Double Needle Lock Stitching m/c [Juki LH-3168SF] Overlock Machine [Juki Mo-3316E DE4-40H] flat lock Machine

15

1,450

21750

15

2270

34050

2700.00

5400

cover seam flat lock Machine bottom seam Button Holing Machine

2

Button Sewing Machine

2

3850.00

7700

[Juki LK-1903SS/304/MC-590-3K]

2

Fusing Machine

16365

32730

[Hashima HP-400CS] Edge Cutter [Eastman EC-3]

2

450.00

900

Straight Knife Cutter 

4

1000

4000

[Eastman 629 X 8”BS-11]

3

Banned Knife Cutter [Wastema]

12000.00

36000

Total value in us dollars

240530

Total Value in Indian Rupees @ Rs.55 per dollar 

13229150

Details of Machine

Needle detector Equipments

Quantity

1 set

cost per m/c in Rs.

Total in Rs

450000

450000

Ironing Table Set-ups [Ramsons]

10 sets

25900.00

259000.00

Fabric CAD with Scanner/printer 

1 set

75000.00

75000.00

Hand Scissors

Total Cost for Machinery in Indian Rupees = [7.90] lakhs]

20 Nos

300.00

6000.00

790000

Cutting Table/Assorting Table/Checking Tables

48000.00

Other Furniture

50000.00

Total Cost for Furniture etc in Indian Rupees = Rs 98000

Needle cost per month = 30 X 160 X 6 = Rs 28800 Needle cost per annum = 12 X 28800 =Rs 345600 Total Raw Materials Costs per Annum = Debtors - Direct Labours - Factory Supervision - Admn Salary

= = =

302.716 52.71 31.878

-----------------

lakhs lakhs lakhs

Expenses

Machinery

= 140.19 lakhs

Furniture

= Rs 98000

Needle Total expenses =

= Rs345600 144.26 lakhs