PL

PLANT LAYOUT
ARCHITECTURAL
BRIEF
ASSIGNMENT NO. 3
Submitted by:-
Devesh Kumar (09)
Himanshu Kumar (11)
Mohd. Nawaz Khan
(16)
Rajani kant Gautam
(24)
COMPANY PROFILE
Type Of Garments:- Men’s Formal shirt
Type of company:- Export oriented and domestic as well
Daily Production capacity:- 3000 garments/day
Factors Considered for plant layout & Construction

 Man
 Machinery and equipment
 Material handling and movement
 Product type
 Inventory
 Service
 Building
Operation Breakdown of the garment

S.NO. OPERATION SEAM TYPES MACHINE
PREPARATORY PROCESS
FRONT LEFT
1. Sew front fly on left front Superimposed SNLS
2. Fold right front edge Superimposed SNLS
Button hole
3. Sew button & button hole m/c
4. Fold pocket mouth Folding m/c
5. Top stitch pocket mouth Superimposed SNLS
6. Sew pocket on left front Superimposed SNLS
YOKE & BACK
7. Fold upper yoke
8. Crease brand label
9. Sew size label to brand label Superimposed SNLS
10. Sew brand label to under yoke Superimposed SNLS
11. Sew yoke to back Superimposed DNLS
12. Counter stitch yoke lapped SNLS
SLEEVE & PLACKET
Superimposed SNLS
13. Sew under sleeve placket to sleeve
SNLS
14. Fold upper sleeve placket
Superimposed SNLS
15. Sew upper sleeve placket to sleeve
17. Top stitch to placket Lapped SNLS
COLLAR
Fusing
18. Fuse fusible interlining Machine
Superimposed SNLS
19. Sew keeper to fusible increase interlining
Fuse fusible increase interlining on Fusing

20. fusible interlining Machine
Fusing
21. Fuse fusible interlining on upper collar machine
SNLS
Production system followed : PROGRESSIVE BUNDLE SYSTEM
In PBS production, sewing operations are broken down by

management into a number of distinct Progressive bundling and
separate operations depending on the complexity of the garment.
Management assigns an expected sewing time or “standard” (in
minutes) for each operation such that the amount of effort
required to sew a standard minute is equivalent across tasks.
Workers are paid based on individual piece rates according to the
standard set for the operation they undertake. In addition to the
piece rate standard, workers also receive an hourly wage, or
variance pay, when work is interrupted.
The advantages of the PBU system can be listed as under:

1. Helps to cope up with frequent style changes
2. Helpful for small lot sizes also
3. Allows the garment manufacturer to meet short delivery
deadlines
DEPARTMENTS
Merchandising Department
The Merchandising department is directly reporting to the Marketing department. As
already stated earlier, the merchandising department, controls and coordinates the
activities of the Sampling department as well.
Area Required: 25’x25’
Man Power Required:-
• Head Merchandiser – 1
• Merchandiser – 3
• Asst. Merchandiser – 3
• Helpers - 2
Machines Required:-
• Computer – 4 (For every merchandiser & one for the head)
 Processor above 2.0 ghz
 1 GB RAM minimum
 Server Connection and internet connection
• Printer – 2 (Connected to Every Computer)
SAMPLING DEPARTMENT
The Sampling Department works out to make the required samples with the given
specifications supplied by the buyer. As already discussed previously, the
merchandising team for the particular buyer coordinates the sample development
process.
Total Area Required:- 20’ x 20’
• Pattern Master – 2
• CAD (Software) Engineer – 1
• CAD Master – 2
• CAD Helper – 1
• Cutting Master – 2
• Sewing Operators – 40
• Helpers - 10
Machines Required:-
• Single needle lock stitch - 28

 Model: SunStar KM-250AU-7S
 Usage: For thin materials (for general use)
 Speed: Max. 5500spm (Standard: 5000spm)
 Stitch length: Max. 4mm
 Needle: Dpx5
 Needle bar stroke: 30.7mm
 Pressure foot height: Manual: 5.5mm
 Knee: 14mm
 Motor: Servo motor
• OverLock machine - 4
 Model: Juki MO-6900S
 Sewing Machine: Max.8500 spm
 Needle: DCx27 #11
 Number of Needles: 2
 Overedging Width: 4.8 mm
• Button attaching m/c - 1

 Model: SunStar SPS/D-B1202
 Sewing speed: Max. 2500spm (Standard: 2200spm)
 Needle: DPx17#14
 Needle bar stroke: 35 mm
 Button clamp lift: Max. 13mm
 No of patterns: Max. 99 patterns (Standard: 33 patterns)
 No of stitches: Max. 10000 stitches
 Motor: Direct drive AC Servo Motor
 Voltages: 1-phase: 100-240V,
 3-phase: 200-415V, 50/60 Hz
• Multi needle chain stitch machine - 4

 Model: Kansai DFB-1404 PS
 No of needles: 2-4
 No of threads: 4 needle threads & 4 looper threads
 Needle:
 Stitch length: 2-5mm
 Tension set: Mounted type
 Puller width: 55mm
 Gauge width: Min. 4.76mm (3/16 inch)
 38.1mm (1-1/2 inch)
 Motor: 3-phase, 2-pole, 400W clutch motor
• Button hole sewing m/c - 1
 Model: SunStar SPS/B-BH3000-G
 Stitch Type: Drop feed
 Usage: General fabrics such as shirt, blouse,
 working dress, lady's dress, etc
 Sewing speed: Max. 4000spm
 Button hole area: Width: Max. 6mm
 Length: Max. 40mm
 Length of cutter: 6.4-31.8mm
 Needle: DPx5#14
 Needle bar stroke: 35mm
 Pressure foot lift: Max. 13mm
 No of stitches: 768(stitches)/1 pattern
 Motor: Direct drive AC Servo Motor: 1
 Pulse Motor: 3
 Temperature: 5º C-40ºC
 Relative humidity: 20%-80%
 3-phase: 200-415V, 50/60 Hz
 Oil supply: Automatic
• Gerber plotter (Cartridge plotter): Black and White plotter - 3
 Maximum media width – 1010 mm
 Maximum cutting area – 920 x 1720 mm
 Floor space Requirement – 2068mm x 1285 mm
 Weight – 80 kgs
 Power Consumption – 160 VA
• Computer – 1
 2.0 Ghz processor (minimum)
 1 GB RAM (minimum)
FABRIC STORES
Assumptions for Fabric Stores:
 The fabric is received in form of rolls hence the entrance should be at least 8 feet
wide and 12 feet high.
 The movement of rolls is done with trolleys and fork lift or with the aid of helpers.
 The aisle space for the movement of trolleys and fork lift – 1.5 meters.
 Fabric rolls are stored in Racks.
Inventory calculation:
 Fabric consumption per day for 2000 gmnt – 2000 x 1.6 mts
 Dimension of a roll - approx - 60” x 12”
 Dimension of racks - 6’ x 6’ x maximum height possible.
 With divisions after every 3 feet.
Total Area Required:- 50’x66’
• Store Manager – 1
• Assistants – 3
Machine Required:-
• Computer – 1
• Inspection table – 1
ACCESSORIES AND TRIMS STORE

Assumptions for the Trims & Accessories Store:
 Trims are received in cartons and are inspected for quality issues and counts.
 Trims are already lab tested and only physical verification is done in the stores
 Along with the trims /accessories / packaging materials the stores also keeps
stationery required for the unit.
The list of trims and accessories which are stored is as listed:

• Thread (sewing)
• Buttons
• Shirt folding pieces
• Back support
• Paper collar
• Collar traveler
• Tag pin
• Fusing (of Different width)
• Poly-bag
• Tissue paper
• Label
• Cartons
• Stickers (Bar code, size etc.)
Total area Required:- 10’ x 16’
• Store Manager – 1
• Assistants – 2
Machine Required:-
• Computer – 1
SOURCING & PURCHASE DEPARTMENT
The fabric sourcing department sources the fabric and other raw material required.
These are responsible for the sourcing of:-
• Fabric
• Threads
• Trims
• Accessories
• Packing materials
• New sewing, cutting, finishing, embroidery machines and workstations
• Non production related equipments like-
• Stationery
• Other equipments
• Manager – 1
• Asst. Manager -1
Machine Required:-
• Computer – 2
CENTRAL IE DEPARTMENT
The Central IE department is responsible for the preparation of the
• Operation Breakdown
• GSD analysis
• Thread Consumption
of the styles provided to them by the Merchandising.
Each new style requires to be timed so that the cost to the company can be calculated
as well as the capacity can be allotted to the various floors. It also maintains the
production details for the floor.
Total Area Required: - 20’ x 20’
• IE Head – 1
• IE Manager -2
• Asst. Manager – 2
• Helper – 2
Machine Required:-
• Computer – 2

 Machine Specifications:
 Needle: Dpx5
 Knee: 14mm

 3-phase: 200-415V, 50/60 Hz

 Needle:
 38.1mm (1-1/2 inch)

 Needle: DPx5#14
 Pulse Motor: 3
 3-phase: 200-415V, 50/60 Hz
• OverLock machine – 3
TOTAL QUALITY ASSURANCE DEPARTMENT

The TQA department is responsible for the quality assurance at each stage of the
product. The stages are that of raw material, Work In Progress and the Finished
Materials.
Room Dimensions: 14ft x 18ft
Man power Requirement:-
• TQA Dept. head – 1
• TQA Incharge – 4
• Quality Checker – 4
• Helpers – 4
SREADING AND CUTTING SECTION

Assumptions for the Spreading & Cutting Section:
 Aisle space for the movement should be 5 feet.
 Aisle space around the computerized cutting machine is 5 feet.
 Band knife should be at the corner with the operator facing the wall.
 While working on the table (numbering /sorting), every worker is given an area of
25 sq. feet for easy movement and working
 Bundled cut parts are stored in bins.
 The cut pieces in bins are issued to the sewing department on a trolley.
 There are racks present in the section for the storage of cut pieces.
Total Area Required:- 2787 sq.feet
• Floor Incharge -1
• Spreading Master – 4
• Cutting Master – 4
• Helpers - 4
Tables Required:-
• Spreading and cutting table – 2
 432” x 34.75” x 72”
• Pin table – 2
 96” x 48” x 36”
Machine Required:-
• Band Knife Cutter – 2
 Model: Eastman EC-900N
 Cutting Capacity : 180 mm
 Table size: 1500 x 2100 mm

 Table height: 720 -790 mm
 Arm length: 900 mm
 Variable speed: 570-1440 m/min
 Motor: AC 220V 750W 1-phase
 Knife Dimension: 0.45 x 10 x 3960 mm
• Straight knife cutter – 6
 Model: Eastman Blue streak II
 Cutting Capacity: 4.5 inch
 Motor: AC 220V 60Hz 1-Phase
 Weight: 15.4 kg
 Stroke: 1.25 inch
 RPM: 17,000
 Blade type: Straight
• Fusing Machine – 2
 Model: Hashima HP-600LSC
 Power supply: Single or 3-phase
 Rated output: heater-7400W
Motor – 90W
 Fusing Width: 600 mm
 Pressure: max. 5.0 kg/cm2
 Dimensions: 1325x1180x1090mm
 Net weight: 296 kgs
• Computer – 1

• Ticketing guns – 6
SEWING SECTION
Assumptions for the Sewing Section:
 Unit production system is in place.
 There are 7 lines for 90% efficiency the daily production of 3,000 shirts. SAM for
the garment: 21.8
 Total working min in an 8 hour shift: 480
 Total number of sewing machines required: 260
 Aisle space is 5 feet
 Each lines has a sub assembly and an assembly section
 Each SNLS is equipped with UBT (Under Bed Trimmer)
Total Area Required:- 3500 sq. feet
• Production head – 1
• Asst. Production Manager – 1
• Pre-Production manager – 1
• Asst. Pre-Production manager -1
• Helpers – 50
Machine Required:-

 Needle: Dpx5
 Knee: 14mm
• OverLock machine - 4

 3-phase: 200-415V, 50/60 Hz

 Needle:
 38.1mm (1-1/2 inch)

 Needle: DPx5#14
 Pulse Motor: 3
 3-phase: 200-415V, 50/60 Hz
• Collar Turning Machine - 7
 Model: Ngai Shing NS 81
 Power: 2600 W
 Weight – 10Kg
 Machine Dimension: 100x110x120cm
• Pressing Machine with table – 14

 Model: Braithwaite M28
 Heating element – 1KW
 Length of cable – 2.5 metre
 Dimensions of table – 25” x 50”
FINISHING DEPARTMENT
Assumptions for the Finishing Section:
 The washing of the garments is outsourced.
 Finished garment can be stored in the finishing section.
 Folding of the garment is done manually.
 Aisle space is 5 feet.
 Material handling of cartons takes place through trolleys
Inspection/ Trimming:
 Manual Operation
 Table dimensions: 5 and half feet by 4 feet
 Area/ table: 6 sq feet (approx)
Total Area Required: - 1502 sq. ft.
• Finishing Head – 1
• Operators – 28
• Helpers – 10
Machine Required:-
• Thread sucking Machine - 14
 Model: WenZhou LG-X530

• Shirt Folding Machine-14
 Model: Ngai Shing NS -50
 Production Rate:- 300 pieces/shift
• Spot cleaning gun - 14
 Model: Albatross EX-4000
 Power: 110-120 V
• Pressing Machine with table – 7
 Model: Braithwaite M28
 Heating element – 1KW
 Length of cable – 2.5 metre
 Dimensions of table – 25” x 50”
OTHER DEPARTMENTS
Assumptions for other departments:
 Effective arrangements have been made in factory for the treatment of wastes
and effluents due to the manufacturing process carried on therein, so as to
render them innocuous, and for their disposal.
 There is 1 water point for every 25 workers.
 Crèche is present for children up to 6 years.
 Fire extinguishers are present in each section.
 Separate urinals are present for the male and female workers with walls glazed
with tiles up to the height of 3 feet.
 Boilers /compressor/transformers are situated outside the factory premise and

should be managed as per boilers act.
 Main security point is at the main door situated at the distance of 12 feet from the
factory building.
 Parking facility is present inside the main building.
CRECHE:
Man Power Required:- 1
MEDICAL:
SECURITY:
Machine Required:-
• Metal Detectors – 6
CONFERENCE ROOM:
Machine Required:-
• LCD Projector – 1
• Computer -1
RECEPTION:
Machine Required:-
• Computer - 1
MD CABIN:
Machine Required:-
• Computer – 1
GENERATOR ROOM:
Machine Required:-
• High Electric Power Generator
 Model:- Bliss Kirloskar
BOILER ROOM:
BIBLIOGRAPHY
• http://www.hashima.co.jp/english/products.html
• http://www.sewingmachinery.com/pressing/pressing.ht
ml
• http://www.ngaishinghk.com/english/products.htm
• http://www.gerbertechnology.com/default.asp?
contentID=8
• http://www.juki.co.jp/industrial_e/products_e/all.html

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PLANT LAYOUT

Type Of Garments:- Men’s Formal shirt

Type of company:- Export oriented and domestic as well

Daily Production capacity:- 3000 garments/day

Factors Considered for plant layout & Construction

 Machinery and equipment

 Material handling and movement

Operation Breakdown of the garment

1. Sew front fly on left front Superimposed SNLS

2. Fold right front edge Superimposed SNLS

4. Fold pocket mouth Folding m/c

5. Top stitch pocket mouth Superimposed SNLS

6. Sew pocket on left front Superimposed SNLS

YOKE & BACK

7. Fold upper yoke

8. Crease brand label

9. Sew size label to brand label Superimposed SNLS

10. Sew brand label to under yoke Superimposed SNLS

11. Sew yoke to back Superimposed DNLS

12. Counter stitch yoke lapped SNLS

SLEEVE & PLACKET

17. Top stitch to placket Lapped SNLS

Fuse fusible increase interlining on Fusing

In PBS production, sewing operations are broken down by

The advantages of the PBU system can be listed as under:

Area Required: 25’x25’

Man Power Required:-

• Computer – 4 (For every merchandiser & one for the head)

 Processor above 2.0 ghz

 Server Connection and internet connection

• Printer – 2 (Connected to Every Computer)

Total Area Required:- 20’ x 20’

Man Power Required:-

• CAD (Software) Engineer – 1

• Single needle lock stitch - 28

• Button attaching m/c - 1

• Multi needle chain stitch machine - 4

• Gerber plotter (Cartridge plotter): Black and White plotter - 3

 Maximum media width – 1010 mm

 Maximum cutting area – 920 x 1720 mm

 Floor space Requirement – 2068mm x 1285 mm

 Power Consumption – 160 VA

 2.0 Ghz processor (minimum)

 Fabric rolls are stored in Racks.

 Dimension of a roll - approx - 60” x 12”

 Dimension of racks - 6’ x 6’ x maximum height possible.

 With divisions after every 3 feet.

Total Area Required:- 50’x66’

Man Power Required:-

 2.0 Ghz processor (minimum)

ACCESSORIES AND TRIMS STORE

The list of trims and accessories which are stored is as listed:

• Shirt folding pieces

• Fusing (of Different width)

• Stickers (Bar code, size etc.)

Total area Required:- 10’ x 16’

Man Power Required:-

 2.0 Ghz processor (minimum)

Total Area Required:- 10’ x 10’

Man Power Required:-

 2.0 Ghz processor (minimum)

Total Area Required: - 20’ x 20’