Professional Documents
Culture Documents
(PROJECT FEASIBILITY)
KARINYOSA APPAREL, INC
FACTORY LAYOUT
1. GROUND FLOOR
a. Raw material storage department
b. Cutting department
c. Sampling department
d. Warehouse
e. Operator Canteen
f. Maintenance department
g. Boiler room
h. Training department, utility room, medical room, executive parking, labour parking
2. FIRST FLOOR
a. Director Cabin
b. Administrative department & H.R department
c. Production floor
d. Conference Room
e. I.E. Department
f. Q.A. Department
g. Compliance department
h. Display Room
i. Finishing department
j. Staff Canteen
WORKING IN AN INDUSTRY
BUYER
2
PRODUCT DEVELOPER
MERCHANT
SAMPLING
FABRIC
TESTING
MARKER PLANNING
SPREADING
CUTTING
PRODUCT DEVEVELOPEMENT
3
SALESMAN SAMPLE
GRADING
ORDER CONFIRMATION
EXTERNAL DESIGNING
4
APPROVAL/COMMENTS
APPROVAL/COMMENTS
APPROVAL
ORDER CONFIRMATION
MERCHANDISING
PROCESS FLOW OF MERCHANDISING DEPARTMENT
5
Start
Obtain tech pack from buyer
Costing
Analyze fabric
consumption from
CAD
Sampling
Analyze cost of
trims and fabric
Obtain general
sewing data from
IED
Develop sample as
per the tech pack
Develop proto
sample
Confirmation
of order
Yes
No
Approv
al
Cost sheet
reworked
Obtain GSD
from IED
Execute
bulk order
Yes
Follow up with
production
departments &
update the buyer
Approv
al
Submit required
documents to
documentation
dept
No
Follow up
on the
payments
for goods
En
d
SAMPLING
STEPS OF SAMPLING:
PP SAMPLE MADE
8
SHIPPMENT
TOP
SIZE
SAMPLE
SET
SAMPLE
MADE
MADE
MADE
FABRIC SOURCING
Fabric requisition from merchandiser
Order placed
After comments reentry in the system with final comments if rejected or accepted
If accepted
Relocation in store
RECEIVE PO FROM
MERCHANDISER
PREPARE A FABRIC
REQUISITION
10
YES
LAB TESTING
RE
OR
DE
R
APPROV
ED
YES
LAB DIPS PREPARED AT DYEING
UNIT IN NEAREST SHADE
FABRIC STORE
SOLID/YARN
GRIEGE FABRIC
11
DYED/PRINT
ED
SEND IT FOR
PROCESSING
BACK TO INHOUSE AFTER DYEING
OR PRINTING
KEPT IN STORE
FABRIC INSPECTION
12
Sta
rt
Receive
fabrics
Conduct
shrinkage test on
minimum 2
bits/bale or
minimum 10 bits
of consignment
If No
Verify whether
quantity received
match with quantity
ordered
If No
If Yes
Forward one
meter of each
consignment for
lab test
Inspection based on
four points system.
Match bulk with
approved dye lot,
width of fabric etc.
If Yes
If No
If
approved
If Yes
Forward to
cutting
dept.
Reject lot
End
13
TESTING LAB
14
Star
t
Fabric
Sourcing
Accessory stores
Merchandising
Test
Test
Carry on
test on
fabric and
garment as
per buyer
requirement
Count
Buttons
Construction
Color
fastness to
washing
Color
fastness to
crocking
Lining
fabrics
On meeting
buyer
requirement
, samples to
be sent to
external lab
to get
approval
Dimensional
stability to
washing
Fabric
Strength
Fabric
Weight
En
d
AC
CES
SORIES STORE
WORK FLOW OF ACCESSORIES STORE
Merchandiser prepares swatch card
15
TYPES OF ACCESSORIES
LABELS AND TAGS: Main label, size label, wash care label, price tag & hand tag
THREADS: Sewing threads.
BUTTON
INTERLINING AND FUSING MATERIAL: Shoulder pads paper foams etc.
NEEDLES
STATIONARY: Record books, role paper, pens etc.
construction enquiry
16
Calculate SMV
dept.
merchandising dept.
Prod. Cost
Tech analysis before fit stage-suggest amendments(stamp)
incorporate in sampling
PPC
prod. planning
merchandising dept.
merchandising. dept
thread order
develop customized
(innovate)
17
tool
IE
Improve methods
rebalance
line
Achieve target
MACHINE MAINTENANCE
Adjusting settings
Oil changing
Graph maintenance
Outward/inward reports
History card
CAD DEPARTMENT
Receive spec
sheet form
Receive
patterns from
pattern
Digitize
pattern to
feed in
Pattern
correction
Output to
Graphtec
plotter
Pattern
grading
Cut ratio
planning
Pattern sent
to
merchandiser
for sampling
Market
planning
according to
the cut plan
Output
marker to
plotter
WORK FLOW
IN CAD
DEPARTMENT
Send to
cutting room
for cutting
Output mini
marker to
printer
Send to
merchandiser
for costing
20
SPREADING
RELAXATION FOR
8 HR.
CUTTING
MANUAL/AUTOMA
TIC
TICKETING
FUSING
CHECKING
BUNDLING
TRANSFER TO
PRODUCTION
SPREADING
PROCESS FLOW OF SPREADING:
FABRIC IS LOADED ON SPREADING MACHINE
21
Cutting
package from
production
manager
Acquire fabric
from fabric
store
22
Cut sample to
check
Requir
e
Checki
ng
Yes
Send to CAD
for Change
No
Receive
changed
pattern from
Assemble and
check
Requir
e NO
chang
esNo
Yes
Issue job
order
Cut plan
Bulk cutting
Sortin
g
23
Bundlin
g
Issue
Start
On receiving the orders, allocate the same
to units based on line openings and
buyers ratings
Provide details to the respective units on
PCD, order quantity & sample
End
24
Confirm in
consultation with
embroidery, washing
departments
SEWING DEPARTMENT
Production floor follows Assembly Line system. Following are steps to start a production line:
To study the production file.
To study operation bulletin and set line accordingly.
Manpower tailors and helpers.
Load and feeding lines.
To arrange buffer or work-in-progress.
Manufacturing.
To make daily production and to achieve targets accordingly.
To understand bottlenecks stage of production.
Working steps of production dept:
Shrinkage production pattern is issued to production floor from CAD dept.
Ready patterns are made as per the requirement of production room.
Cutting receives from cutting dept.
Cross checking of cut panels with patterns.
Bundling of cut panels is done.
Operation wise feeding of cut panel into the line.
Inline checkpoints.
Output of line.
Final checkpoints.
Auditing of checked pieces.
25
Washing
26
En
d
WASHING
PROCESS FLOW:
Start
Drying
Inspection
(Random)
Accounting &
despatch to
different units
End
27
FINISHING
PROCESS FLOW OF FINISHING
WASHING
THREAD CUTTING
ALTERATION
REIRONING
FINAL CHECKING
PRESENTATION/FINAL IRONING
MEASUREMENT
28
PACKAGING
PROCESS FLOW OF PACKAGING
GARMENTS COMES FROM
INSPECTION
IT IS THEN FOLDED
1 OR 2 ARE PACKED TOGETHER
ALL PIECES PUT IN TO CARTONS
PACKING NORMS
Packages are sent under licensing rules for shipment. The rules are also specified by the individual buyer
and are universal for their respective order. Some of such norms include:
All garments packed in individual poly bags.
Poly bag sticker on poly bags, which may be printed by the factory.
Order must be completed (packed, ready for shipment) prior to bulk orders.
Order must be inspected and audited by the factory 100%.
Order must be of first quality, no repair or ungraded garments should be in license shipments.
Order must be shipped 100% complete otherwise notified.
The packed goods are now ready to be passed through the
29
Given Parameter:
FSI =1.2
G.C = 40%
Front margin = 5 mt
Side margin = 5 mt
Total space = 120*100 = 12000 sq. mt
FSI = 1.2*12000 = 00 sq. mt (Maximum available floor space)
Ground coverage = .65*3600 = 2340 sq. mt
Available floor space = (60-12) * (60-21)
= 48*39 sq. mt
= 1872 sq. mt
DEPARTMENTS
AREA (in sq
mts)
TOTAL NO.
OF LIGHTS
31
TOTAL NO.
OF FANS
AIR
CONDITION
EXCUTIVE PARKING
353.5 sq mts.
1 halogen
TIME OFFICE
13.77 sq mts.
MAIN ENTRY
15 mts.
UNLOADING AREA
91.8 sq mts.
STORE MANAGER
13.77 sq mts.
TRIMS AREA
12.39 sq mts.
REJECTED ROLLS
16.06 sq mts
TESTING LABS
23.87 sq mts.
LABOURWASH ROOMS
6.88 sq mts.
UTILITY ROOM
17.90 sq mts.
CRECHE
17.9 sq mts.
LOCKERS
35.8 sq mts.
SUPERVISOR
3.67 sq mts.
WASTE ROOM
18.36 sq mts.
REMENENT
18.36 sq mts.
CAD
28.4 sq mts.
112.02 sq mts.
PATTERN MAKING
48.2 sq mts
MANAGER
28.12 sq mts.
MEDICAL
28.12 sq mts.
EXECUTIVE WASH
ROOM
4.59 sq mts.
EXECUTIVE CANTEEN
22.95 sq mts.
CONFERENCE
27.54 sq mts.
RECEPTION
20.66 sq mts.
PPC
27.54 sq mts
GM
20.66 sq mts
MD
21.34 sq mts
STUDIO
27.54 sq mts
PURCHASE
20.66 sq mts
EXPORT
20.66 sq mts
ACCOUNTS
20.66 sq mts
32
MIS
20.66 sq mts
HR
30.99 sq mts
LOGISTICS
13.77 sq mts
MERCHANDISER
27.54 sq mts
SENIOR
MERCHANDISER
13.77 sq mts
WORKER PARKING
91.5 sq mts
FIRST FLOOR:
DEPARTMENTS
AREA (in sq
mts)
TOTAL NO.
OF LIGHTS
TOATAL
NO. OF
FANS
AIR
CONDITION
SAMPLING
530.3 sq mts.
14
MAINTAINENCE
123.9 sq mts.
IE
19.2 sq mts.
QUALITY ASSURANCE
1.83 sq mts
SEWING AREA
2107.2 sq mts
1065
59
COMPLIANCE
36.7 sq mts.
TRAINING
31.22 sq mts.
MANAGER ROOM
13.77 sq mts.
STORE
31.22 sq mts.
BOILER
18.36 sq mts.
EXECUTIVE WASH
ROOMS
11.01 sq mts
--
WASTE ROOM
18.36 sq mts
DRINKING WATER
4.59 sq mts.
WASH ROOMS
4.59 sq mts.
33
RACKS
27.5 sq mts.
SECOND FLOOR :
DEPARTMENTS
AREA
(in sq mts.)
AIR
CONDITI
ON
WASH ROOMS
9.18 sq mts.
LABOUR CANTEEN
385.6 sq mts.
11
MEASUREMENT &
INSPECTION
128.5 sq mts.
65
AUDIT AREA
80.34 sq mts.
40
PACKAGING
144.6 sq mts.
50
DISPATCH AND
LOADING
96.4 sq mts.
CARTON STORAGE
18.36 sq mts.
WASHING AREA
146.9 sq mts.
10
WASHROOMS
4.59 sq mts.
DRINKING WATER
4.59 sq mts.
SUPERVISOR
2.52 sq mts.
WASHING MANAGER
27.5 sq mts.
FINISHING MANAGER
27.5 sq mts.
FINISHING ZONE
156.1 sq mts.
78
34
DEPARTMENT
NO. OF EMPLOYEES
Executive
Human resources
Purchase
MIS
Logistics
Merchandising
PPC
IE
CAD
Maintenance
TOTAL
42
SAMPLING DEPARTMENT:
Cutting master
Sampling manager
Sampling in charge
Pattern master
Supervisor
Tailors
35
35
Helpers
Ironer
checker
TOTAL
51
Store manager
Assistant manager
Checker
Workers/helpers
20
TOTAL
26
Store manager
Assistant manager
Workers/helpers
10
TOTAL
14
Trim store
CUTTING DEPARTMENT:
Production manager
Pattern master
Cutting master
3
36
Workers/helpers
50
TOTAL
58
SEWING DEPARTMENT:
Production manager
Supervisor
Quality checker
Workers/helpers
268
Male:female(ratio)
70:30
TOTAL
277
Quality manager
Workers/helpers
TOTAL
FINISHING DEPARTMENT:
OPERATION
WORKER
HELPER
Button holing
Button attaching
Thread cutting
25
37
Pressing
20
Initial checking
15
Final checking
Re final checking
Spot removal
PACKAGING DEPARTMENT
Assistant manager
Quality checker
Workers/helpers
38
39
Range
Resolution
Elongation
Range
Motor Speed
Clamps
Averaging
Supply
Size
40
41
Model: YG502B
Standard: GB/T4802.1-1997
Dimensions 520x280x360
Weight 45kg
Power AC220V
Magnification 10, 20
Dimensions 975335mm
42
Weight 20kg
43
Manual
Model Y571M
Rubbing Pressure 9N
44
Brand: JAG
Model: JAG60
Weight: 25Kg
45
Testing breaking strength; break elongation rate, fixed elongation, etc. of fibers, or thin metal
wires.
Resolution 0.01cN
Weight: 85KG
WASHING MACHINE
FABCARE WASHING MACHINE
specifications:
Fabcare 'Washing Machines' are designed for all types of Laundry Jobs, Technical and Enzyme
Washings.
Machines are available with different types and size to cater the need of different Fabrics such as
Available in 20, 35, 70, 140 Kg. Dry weight per charge capacity.
47
DRYING TUMBLER
MODEL CAPACITY
CAPACITY DRY WTPEPCHARGE
BASKET SIZE
MOTOR DRIVE BLOWER
STEAM CONN.
CONSUMPTION
ELECTRIC
OVERALL DIMENSIONS
NET WEIGHT
:SDS 30
: 30 KG 1:24
: 950 X850
: 0.75 KW
: 15 (0.5" BSP)50KG/HR
: 18/24 KW
: 1150 X 1460 X 1980
: 560 KG
48
2. END CUTTER
MODE EC-3
LF EC-00900
220 V,50HZ,1 PH,0.5AMP
EASTMAN M/C CO.
NEW YORK,US
3. STRAIGHT KNIFE
49
Motors
110v, 1ph:
Weight
34 lbs. (15.4kg)
Horsepower
.65hp
Blade Size
(inches): 5"
(cm): 12.7cm
Cutting Capacity
(inches):3.5"
(cm):8.89cm
Stroke Size
(inches):1.125"
(cm): 2.86cm
Specifications :
Bed dimensions:
Length: 18 3/4" (477 mm) Width: 7" (178 mm) Space to right of needle: 10 5/16" (262 mm)
Outside diameter of machine pulley: 2 61/64 (75 mm) effective diameter for V-belt
Regular machine: Singer clutch motor high speed 1/2 H.P.
Under bed thread trimmer (U.T.T): Singer AC servo motor/EC (N.P.) motor
Including the operation panel C-30
Needle bar Stroke: For 200A: 1 3/16 " (30 mm) For 300A: 1 3/18" (35 mm)
Clearance under presser foot: By hand 7/32 " (5.5 mm) By knee 1/2" (13 mm)
2.DOUBLE NEEDLE LOCKSTITCH :
50
SPECIFICATIONS ;
5 THREAD OVERLOCK
SPECIFICATIONS :
Brand: Juki
Application: For light-weight materials
Lubrication: Automatic
SPECIFICATIONS :
AE-300
MODEL
SINGLE PHASE
POWER SUPPLY
HEATER
3 KW
MOTOR
0.40 KW
CURRENT
17 A
TEMPERATURE
200 C
PRESSURE
1 KG/CM2
BELT SPEED
8.7 M/MIN
FUSING WIDTH
300 MM
53
2. PRESSING
MODEL
NX-2429
NO. OF
MOTORS
POWER
DIMENSIONS(L*W*H
) INCHES
WEIGHT KG.
50*30*36
80
54
CALCULATION:Total area=390 sq mt
Rack size=7*6
Fabric Gsm=220
Fabric weight-100 kg
Fabric width =56
Capacity of 1 rack=1800 kg.
Fabric diameter=2.5
Total no. of racks=28racks
Total capacity of racks=28*1800
= 50400 kg.
CUTTING DEPARTMENT
CALCULATION
Total area=694 sq mt
No of pieces cut per day=2000
3% extra=2000*3*2060/100 pcs/day
Avg consumption/t-shirt=0.9 mtr
Avg consumption /t-shirt=220*100/.9*56*2.5=1.4 kg
Marker way=10 way
55
56
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 112 cm.
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.
Drinking Water Signage in English and Tamil
Locate from 20 feet away from toilet
Locate maximum 50 meteres distance from work spot
Drinking Water vessale cleaned at least once in a day
Water Reservoir or Tank Cleaned at least once in a week
Water centre cleaning condition
Water Vessal Cleaning log sheet
Water Centre Incharge person with cleanliness
Suggessation Box Register
58
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 Accomodation Min. 61 cm for every 50 employees upto first 500
Urnial Accomodation Min. 61 cm for every 100 employees for above 500
Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
Dust Bins
Buckets with mug at toilets
Toilet White Washed once in every four month
Tiles/Mosaic floors washed with Detergent or disinfectant once in four month
Daily Cleaning Log sheet provided
Adeaquate Water Tabs
No smoking Sign in Gents Toilet
Awareness Quotes in Toilets
Ladies / Gents Toilet Name Sign in Dual Language and Picture
Spittoons
Adequate Spittoons
Sipittoons filled by Sand or Suitable disinfectant
Spittoons covered by bleaching powder layer
Spittoons scrapped or cleaned at least once in every day
Others
500 Cubic feet for every employees
Disposal of Wastes and effluents
Room Temperature
Lighting facility
Trees on factory campus
59
Safety Guards
Metal Glows on good Condition
Rubber Mat to ironers
Rubber Glows to ironers
Ironers wearing slipper
Motar Guard
Needle Guard
Eye Guard
Sharp Tools
Paddle Mat
Scissors and trimmers are tied
Sharp Boxes
Mask
Needle disposal once in six month
Broken Needle Register
Human resources
Dining Hall
Dining Hall with sufficient Space
Dining Hall with Sufficient Chair/Table
Water Facility
Ambulance Room
Doctor Visit
Nurse
Medicines
Medicines Issueing Record
Creach
Sufficient Space
Creach Attender
Creach Children Detail
Daily Register
Cradle
Toys
Postures
Wash Room Facility
Toilet
Milk
Eatables Available
Drinking Water
60
Ventilation
Chairs for mothers
Shady plaground for older children
First Aid
First Aid Boxes with All medicines
First Aid Boxes Location List
First Aid Box Daily Checklist
First Aid Training employees (20 %)
First Aid Trainer Name & Photo List
First Box once for 150 employees
First Aid Stations
Fire
Sufficient Fire Extinguisher
Fire Extinguisher all in good Condition
Fire Extinguisher Location List
Fire Extinguisher Service Checklist
Access area without hindarance
Fire Extinguisher kept in 3 feet
Fire Signage in Tamil & English
Usage Guide in dual language
Fire Extinguisher Colour Background Marking
Space beneath marked
Space beneath kept empty
Refilling Service Done
Fire Certified persons photo
Evacuation Drill (External) Every Six Month
Evacuation Drill (External) File
Evacuation Drill (Internal) Every Three Month
Evacuation Drill (Internal) File
Sufficient Fire Safety trained employees
Fire safety trained employees name & Photo List
Fire Buckets to Diesel Storage Area with Water and Sand
Fire Buckets to Boiler Room with Water and Sand
Fire Buckets to Genset room with Water and Sand
Fire Buckets to E.B. Panal Board with Water and Sand
Fire Buckets to Motor Room with Water and Sand
Fire Buckets to Appropriate place.
Fire Tray with sand
Diesel Storage area floor filled by sand
Evacuation Plan in all Floor / Area
Emergency Exit
Emergency Exit on Open
Emergency Exit Signage
Emergency Exit with outside open facility
Emergency Exit Board Light with UPS Connection
Emergency Light to All room / Area Adequate
Emergency Light to All staircase
61
PF Nomination Form 2
Gratuity Nomination Form F
Factory Act Nomination Form 34
Track Record
Appointment Order
Insurance
NDA with Signature
Employee Manual
I.d. Card to All
Adequate Swiping machine
Punching Card to All
ESI Card to All
PF Slip to All
Awareness Programme
Stress Relieve Counselling
Meetings
Performance appraisal
Leave Card
Full & Final Settlement
Exit Interview
Gratuity
Bonus
Salary Breakup
Salary on Date
Induction Programme
Induction Register
Manpower
Manpower Departmentwise Male/Female Strength Report
Presentism Report
Late Report
Absentism Report
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.
Other Salary Breakups
Over Time
Double Salary to Over Time
63
66