Storage
Content
RAW MATERIAL STORE DEPARTMENT
PLANT LAYOUT & FACILITY DESIGN
BY, Akta Gupta Chetan Tajane Farheen Ansari GnanaShree Vullanki
INTRODUCTION
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.
Fabric Storage:
The
fabric as received from the processing is kept in the quarantine area
before storing in heavy duty fabric storage racks.
It
is the responsibility of fabric stores in-charge to store the fabric safely
& correctly.
The
fabric stores in charge records every day fabric stock in Fabric Stock
Register.
MATERIAL STORAGE
Proper housekeeping is an important compliance feature and improves the overall working environment of the company as well. Work in progress (WIP) generated at different stages of operations should be identified along with the quantity of the material to be stored. The storage medium should be selected as per the nature of the material, process and also the subsequent operations to have ease of working and to reduce the wastages that occur due to improper storage.
RAW MATERIAL STORAGE DEPARTMENT
CALCULATION: Rack size=10m * 1.8m * 4m No. of roll size in 1 rack=360 rolls Roll weight=30 kg Roll diameter=10 = 0.25m Total no. of racks=3 racks Total roll storage=360*3 = 1080 rolls Total fabric capacity=1080*30 =32400 kg (ASSUMPTION 1000pcs ) Consumption per garment = 220gm WIP for 30 days = 1000*30 = 30000 Total fabric req in kg s = 30000 * .220 = 6600 Total no of rolls = 6600/30 =220
RAW MATERIAL STORAGE DEPARTMENT
Button : 1 rack : 42 cartons, 10 days inventory
o
Rack Dimension: 7 x 2 x 6.5 (2.1 x 0.6 x 1.9 mtr.) 1 x 1 x 1 (0.3 x 0.3 x 0.3 mtr.)
oCarton Dimension:
Labels: (for 10 days inventory)
oApprox 20 oFor oFor
styles at any point of time.
4 types of labels, approx 80 cartons reqd. 80 cartons: (each of 1 x 1 x 0.5 ). in one cubicle, so 3 cubicles are reqd.
o28 cartons oOne rack
of dimension: 7 x 2 x 6.5 reqd.
RAW MATERIAL STORAGE DEPARTMENT
Threads
Thread consumption (incl. wastage) 150 meters Production per day =10,000 garments. y Daily reqt: 150 x 10000 = 1500000meters y For 10 days inventory = 15000000 meters y Considering 5000 meters spool, spools reqd: 3000 Carton dimention: 10 x 10 x 6 (10 spools) No of cartons reqd: 300 y Rack dimension: 7 x 2 x 6.5 One cubicle contains: 8 x 2 x 3 = 48 cartons So cubicles reqd: 6 Cubicles in one rack: 3 Racks reqd: 2
RACKS FOR ACCESSORIES
All
the accessories will be kept in a box. Here we have assumed the dimension of the box and approximately the no. of pcs that can be accommodated in the box.
RACKS FOR ACCESSORIES
Accessori Required Dimensio No. of pcs Volume es Amount n of box that can of box(in for 15 (inches) be cubic days l*b*h inch) accommo dated Button Thread(Tk No. 25) Thread(Tk No. 50) Thread(Tk No. 100) Printed Paper Tag
52550 4*3*2 100 24 12612 10237500 8*8*2.5 30000 160 54600 1995000 8*8*2.5 30000 160 10640 840000 1837500 3*2.5*2 8*8*2.5 2000 30000 15 160
Required volume (in cubic inch)
6360 9800
RACKS FOR ACCESSORIES
Accessori Required Dimensio No. of pcs Volume es Amount n of box that can of box(in for 15 (inches) be cubic days l*b*h inch) accommo dated Printed Paper Main Label Wash Label
205276 52550 5 Dia*2 5 Dia*2 375 375 157 157 22000 22000 52550 16*16*1 200 256
Required volume (in cubic inch)
67264
Care 52550
Therefore total required volume (in cubic inch)
COMPANY LOCATION & SITE
THANDYA INDUSTRIAL AREA
Its developed in Thandavapura Nanjangud Town, Mysore District.
Village
near
The Industrial Area is located about 160 kms from Bangalore & 20 Kms. from Mysore. The Industrial Area is well connected by road, rail & airport is situated at a distance of about 5 kms. River Kabini & Hullahalli Cannal Distributary runs very near to the Industrial Area.
COMPANY LOCATION & SITE
Particulars
Land acquired 144.00
Area
Acres Acres Acres
Net Area available for 104.00 allotment Total area allotted 104.00
Land reserved for CA & 10 + 2.75 Sump No. Of units allotted 44
COMPANY LOCATION & SITE
At present the tentative cost at Thandya Industrial Area is Rs. 15.00 lakhs per acre.
The following infrastructure has been developed in the Industrial Area: Formation of Roads GLR Constructed Electrical Infrastructure Open Drainage System Telecommunication System Area has been reserved for commercial infrastructure line Canteen, Bank, Post Office, etc.,
COMPANY LOCATION & SITE
1. Roads: - 18.00 Mts. Road 1.20 Kms. - 12.00 Mts. Road 0.80 Kms. 2. Water supply works: The existing borewells & 5 MGD water is being drained from Kabini at the cost of Rs. 9.45 crores & 2 pumps of 125 HP each is used. 3. Electricity: The entire Industrial Area is covered by one substation erected by KPTCL located near Nanjangud Industrial Area. 4. Open Drainage System: The KIADB has taken up open drainage system. 5. Telecommunication System: Telephone Exchange is in Nanjangud Town which is nearby & the telephone cable is drawn in the existing Industrial Area.
COMPANY LOCATION & SITE
6. Post Office: The nearest Post Office is in Nanjangud Town & an area has been reserved for Post Office in the Industrial Area. 7. Commercial Infrastructure: For canteen, bank, local shopping, etc., 10.00 Acres of land has been reserved in the existing Industrial Area. 8. Transportation: Industrial Area is located very adjacent to Bangalore ² Niligiri State Highway. 9. Railways: Thandavapura Railway Station is situated at a distance of 2.5 Kms. from Industrial Area.
COMPANY LOCATION & SITE
LOCATION OF THE COMPANY
PLANT LAYOUT ARCHITECTURAL BRIEF
Product category: shirt Product: Formal men full sleeve shirt & formal ladies top Nature of Business: Domestic Rate of Production: 10000pieces/day Dimension and area: 600*400 sqft
PRODUCT & ITS VARIATION
COLLAR
CUFF
Removable Collar (Bone) Inserted Collar (Bone) Button Down Collar Button Down Collar(Loop) Piped Band Collar Chinese Collar V- Hem Straight Hem Rolling Placket (Single Placket) Double Placket ² 1µ and ¾µ Double Placket- 1µ and ½µ
Round Cuff Square Cuff Double Cuff Double Button Cuff Single Button Cuff Chisel Cuff & Fancy Cuff Round Pocket Square Pocket V- Pocket Chisel Pocket Without Gusset With Gusset (FOA) With Gusset (Patch)
HEM
POCKET
SLEEVE
ASSEMBLY
PRODUCTION SCHEDULE
Number of shifts: 1 per day Timings: 8 hrs per day Quantity to be produced: 10000units per day WIP between departments: 3days Inventory policy: Store has 12 days inventory.
NUMBER OF MACHINES
Machines used SNLS O/L B/H (TANDEM WITH FEEDER) DNLS Turning machine Trimming machine Cutting machine Pressing machine Number 292 4 16 48 10 4 4 9
SAM DISTRIBUTION FOR EACH ACTIVITY
ACTIVITY RELATIONSHIP CHART
DEPARTMENTS
Design Department Marketing & Merchandising Department Store Department Pre Production Department CAD Department Cutting Department Sewing Department Finishing Department Quality assurance Department
Industrial Engineering Department Information Technology Department Maintenance Department Administrative Department Human Resource Department Safety Department Security Department Warehouse department
DEPARTMENTS
Design Department Area = 20*10(sq. Ft) This department functions for the design of the products. It requires a team of designers. The basic space requirements are in the form of workstations & design tables only.
Following are the main activity required in the department. - The garments are designed here, & - Sample designing is done here.
DEPARTMENTS
Marketing & Merchandising Department Marketing area = 20*10(sq. Ft) Merchandising area = 20*10(sq. Ft) It caters to the marketing & sourcing of product & its components. It requires a list of workstations & cabins for officers & managers.
Following are the list of activities that are carried out in this department. - Material Planning - Initial Costing - Purchase Orders - Sample development - Approval/Rejection
DEPARTMENTS
Human Resource Department Area = 20*20(sq. Ft) This department requires a team of HR executives leaded by a HR manager. The department need not have very big area.
Following are the activities carried out here: Employee Benefits Recruitment Training and development Employee guidance Personnel documents
DEPARTMENTS
Conference Room Area = 20*20(sq. Ft) All the official meetings within company heads, buyers & contractors take place here. Crèche Room Area = 20*20(sq. Ft) This room is for providing service like playing rest & care centre for children·s of workers. Activities like: - Taking care of the kids of the workers. - Feeding the children. - Involve them in some kind of playful activities. All safety measures like fire safety devices, first aid are also required.
DEPARTMENTS
Reception Area = 10*10 (sq. Ft) Reception is where all the people, buyers, contractors etc will be received when they visit. Medical Room Area = 20*20 (sq. Ft) Provides medical facility to the workers & employees of organization. Keeping & upgrading the first aid boxes in all the departments regularly. In case of any accident or emergency taking immediate action. Maintain Ambulance for any emergency.
DEPARTMENTS
Library Area = 10*10 (sq. Ft) Library is used for reference purpose and for the knowledge access purpose. Administrative Department Area = 200*100 (sq. Ft) The administrative department caters to documentation regarding to the following documented activities. Purchase department Documentation Finance Accounts Bank documents Letter of Credit Bills Placing Purchase Orders Raw material Procurement Affirmation of Purchase order by Supplier
DEPARTMENTS
Information Technology Department Area = 20*10(sq. Ft) It serves the purpose of IT specialists that solves the software·s problems in the organization. It requires a server room for storing important data & managing the internet connection. Following are the activities: Computer Room/IT room Conference halls Software and Hardware Storage Maintenance Server
DEPARTMENTS
Training & development department Area = 75*35*10(sq. Ft) Training for the employees & workers are carried out here in order to improve their skills. Sampling department Area = 50*35*10(sq. Ft) The samples to be approved by the buyer is prepared in this department by highly skilled operators. The required machines for sampling is provided in this department
DEPARTMENTS
Raw material storage department Area = 150*125(sq. Ft) This department is required for the storage of trims & raw materials received. The department also keeps a record of trims received & issued to the production. Following are the activities:
Raw Material (fabric & trim receipt) Quality checking Issue material for production Packaging material storage Weighing machines Spring balance
DEPARTMENTS
FABRIC REQUIREMENTS: No. of garments = 10,000 Width of the fabric = 48 inch Fabric for one garment = 2.15mts(avg.) Fabric per day requirement= 10000X2.15 = 21500m Fabric per 12days requirement= 21500X12 = 258000m Now, assuming that 1 roll has 200 m fabric. Total rolls to be stored for 12 days= 1295 rolls.
10
DEPARTMENTS
Rack structure will accommodate = 27 rolls at a time. Therefore number of such racks required: 1295/27 = 47.2 approx 49 racks. The extra one will be used for storage of end bits and extra fabric after order completion. 7 extra racks for storing fabric during inspection.
DEPARTMENTS
CAD Department Area = 35*35 (sq. Ft ) The purpose is to generate pattern for the garment & produce the production marker for the same. The CAD department also requires to produce costing markers for the merchandisers. Following are the activities and assets required in the department. Plotter Digitizer Marker making Marker Preparation Costing marker Bundle preparation report
DEPARTMENTS
Cutting Department Area = 50*150(sq. Ft ) Length of the cutting table is a critical factor in deciding the area of the cutting room. The process of numbering & bundling is also carried out here.
Following are the requirements for this department.
Spreading Tables Cutting tables Numbering tables Bundling tables Checking tables Cutters required Fusing is required Cut part storage rack Inspection tables Temporary roll storage
DEPARTMENTS
Production /day = 10000pcs
Total fabric required per day =10000*2.15 =21500mts. Assumed 1 lay = 110 plies
So, no. of lays = 10000/110 = 909 lays
DEPARTMENTS
Sewing Department Area = 150*150 (sq ft) Following are the various activities carried out in sewing department:
Approval of operation breakdown Special machines & attachments approval Line balancing No. of machines required Deciding or approval of manufacturing system Sewing Checking
DEPARTMENTS
Finishing Department Area = 35*150 (sq ft) The finishing department is meant for ironing, folding & packing of the garment. The department will require tables for checking, folding & packaging. Following are the activities: Ironing Tags attached Checking Folding & Packaging
DEPARTMENTS
Since the production is 10,000 garments from sewing dept. Reducing 2% for rejection, calculated amount taken is 9800. Time taken for finishing for each garment = approx 8mins. Therefore, total time taken is 9800 * 8 = 78400 But Time available is 480 mins. Therefore, no. of operators required are = 78400/480 = 162
DEPARTMENTS
Packaging & storage of finished goods Area = 75*150 (sq ft) Here the orders are stored till they are shipped. Following are the various processes: Cartons are brought in from finishing department Cartons are stored Cartons are moved to parking be shipped Quality control department Area = 35*35 (sq ft) Performs the action of controlling & maintaining the quality.
DEPARTMENTS
Maintenance Department Area = 40*35(sq. Ft ) The department stores basic tools for the maintenance of the machines. It also requires space for the maintenance job. Following are the activities: Tools & machinery storage for maintenance of sewing & finishing machines Spare parts storage Building maintenance parts storage Machine maintenance UPS or power backup maintenance Air conditioning maintenance Electric supply decisions.
DEPARTMENTS
Canteen Area = 100*100 (sq ft) Canteen is common for all but there will be different timings for operators & officials. Operators will be offered snacks and tea at subsidized cost. Parking Area = 100*100(sq ft) Here all the vehicles of both operators &officials will be parked. Also parking is the place where the trucks & other vehicles for transport will be received. The security guard will see to it that rules are abided by the people. Assembly area
Area = 100*100(sq ft)
DEPARTMENTS
Toilets Area = 35*35 (sq ft) Total no of employees in production department = 720 Man : Woman ratio = 45:55 Total no of men employees = 300 Total no of women employees = 420 Toilet for gents: For 100 men no. of toilets = 4 and no. of urinals = 8 (data taken by UK standards) For 300 men no. of toilets =12 Wash basins - 16 Toilet for ladies: For 100 women number of toilets = 5 (data taken by UK standards) For 420 women number of toilets = 22 Wash basins - 16
ELECTRICITY CONSUMPTION
Particulars Fans Exhaust fans Tube lights Air conditioner Desktop computer Brand Khetan Khetan Surya Samsung Apple/ibm Power consumption 60 watts/hr 40 watts/hr 40 watts/hr 10000 watts/hr 400 watts/hr
ELECTRICITY CONSUMPTION
Departments Fans Tube lights Other machines (computer/ ac/exhaust fan) Total power consumed per hr
i. Store department i. Cutting department i. Sewing department i. Finishing department i. Quality assurance department i. Industrial engineering
20 32 126 90 17
250 224 1000 177 60 Comp-1 Ac-2 Comp-3
11200 10880 407560 12480 23820
12
60
4320
ELECTRICITY CONSUMPTION
Departments Fans Tube lights Other machines Total power (computer/ consumed per ac/exhaust fan) hr in (watts)
i. Maintenance department i. Administrative department i. Control department i. Security department
8 85 2
66 396 24 16 Comp-20 Ac-10
3120 128940 1080 880 5520 9620 1920
4 i. Toilet i. Canteen i. Cloak room 87 138 110 48
ELECTRICITY CONSUMPTION
Machine name Number Power consumed Total power consumed (watts) 29200 1600 2000 4800 2000 1000 40000 35190 8952
SNLS O/L B/H (tandem with feeder) DNLS Turning machine Trimming machine Cutting machine Pressing machine Water tank
292 4 16 48 10 4 4 9 2 tanks (2motors)
100 watts/hr 400watts/hr 125 watts/hr 100 watts/hr 200 watts/hr 250 watts/hr 10000watts/hr 3910 watts/hr 3HP power each motor consumes
ELECTRICITY CONSUMPTION
Total power consumed in all departments = 621340 watts/hr Total power consumed in 1 shift ie 8 hrs: 9941440watts= 9941 k watts
Power consumed by all machines in 1 hr= 115790 watts Power consumed by all machines in 1 shift ie. 8 hrs= 926320 watts = 926 k watts
Power consumed for filling water into the tank for 2 hrs a day = 8952 watts Total power consumed by all machines & water tank = 926320 + 8952 = 935272 watts. i.e. = 935 k watts. Therefore, total power consumed by the whole plant for a day = 9941 k watt + 935 k watt = 10,876 k watts. The capacity of the generator is 50% of the total power consumption of a day = 5438 k watts.
WATER CONSUMPTION
1 person consumes = 45 liters of water per day Total no. of employees = 1500 Total water required =45*1500 = 67,500 liters/day Size of tank =12*10*10 cubic feet Height of tank from ground level = 15 feet Number of tanks = 2 Number of motors = 2 each (3 HP each)
OTHER UTILITY AREAS
PARTICULARS Generator room Compressor Boiler Water tank (2) Assembly area Atm Future extension AREA 25*30(sq. Ft) 25*30(sq. Ft) 30*50(sq. Ft) 12*10*10(sq. Ft) 40*100(sq. Ft) 8*6(sq. Ft) (100*235+150*100) (sq. Ft)
CONCLUSION
The design of a process plant is a complex activity that usually involves many different disciplines over a considerable period of time. The design may go through many stages from the original research & development phases, conceptual design, detailed process design & onto detailed engineering design & equipment selection. Factors including safety, health, environment, economic & technical issues have to be considered before the design is finalized. ´APPAREL SOLUTIONSµ is one company which has considered all the above points before setting up its industry. It has efficiently utilizatized its resources & production techniques. Moreover, ´Apparel Solutionsµ is a plant which is very feasible & its plant layout can be adopted by any new industry to be successful.
PLANT LAYOUT & FACILITY DESIGN
BY, Akta Gupta Chetan Tajane Farheen Ansari GnanaShree Vullanki
INTRODUCTION
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.
Fabric Storage:
The
fabric as received from the processing is kept in the quarantine area
before storing in heavy duty fabric storage racks.
It
is the responsibility of fabric stores in-charge to store the fabric safely
& correctly.
The
fabric stores in charge records every day fabric stock in Fabric Stock
Register.
MATERIAL STORAGE
Proper housekeeping is an important compliance feature and improves the overall working environment of the company as well. Work in progress (WIP) generated at different stages of operations should be identified along with the quantity of the material to be stored. The storage medium should be selected as per the nature of the material, process and also the subsequent operations to have ease of working and to reduce the wastages that occur due to improper storage.
RAW MATERIAL STORAGE DEPARTMENT
CALCULATION: Rack size=10m * 1.8m * 4m No. of roll size in 1 rack=360 rolls Roll weight=30 kg Roll diameter=10 = 0.25m Total no. of racks=3 racks Total roll storage=360*3 = 1080 rolls Total fabric capacity=1080*30 =32400 kg (ASSUMPTION 1000pcs ) Consumption per garment = 220gm WIP for 30 days = 1000*30 = 30000 Total fabric req in kg s = 30000 * .220 = 6600 Total no of rolls = 6600/30 =220
RAW MATERIAL STORAGE DEPARTMENT
Button : 1 rack : 42 cartons, 10 days inventory
o
Rack Dimension: 7 x 2 x 6.5 (2.1 x 0.6 x 1.9 mtr.) 1 x 1 x 1 (0.3 x 0.3 x 0.3 mtr.)
oCarton Dimension:
Labels: (for 10 days inventory)
oApprox 20 oFor oFor
styles at any point of time.
4 types of labels, approx 80 cartons reqd. 80 cartons: (each of 1 x 1 x 0.5 ). in one cubicle, so 3 cubicles are reqd.
o28 cartons oOne rack
of dimension: 7 x 2 x 6.5 reqd.
RAW MATERIAL STORAGE DEPARTMENT
Threads
Thread consumption (incl. wastage) 150 meters Production per day =10,000 garments. y Daily reqt: 150 x 10000 = 1500000meters y For 10 days inventory = 15000000 meters y Considering 5000 meters spool, spools reqd: 3000 Carton dimention: 10 x 10 x 6 (10 spools) No of cartons reqd: 300 y Rack dimension: 7 x 2 x 6.5 One cubicle contains: 8 x 2 x 3 = 48 cartons So cubicles reqd: 6 Cubicles in one rack: 3 Racks reqd: 2
RACKS FOR ACCESSORIES
All
the accessories will be kept in a box. Here we have assumed the dimension of the box and approximately the no. of pcs that can be accommodated in the box.
RACKS FOR ACCESSORIES
Accessori Required Dimensio No. of pcs Volume es Amount n of box that can of box(in for 15 (inches) be cubic days l*b*h inch) accommo dated Button Thread(Tk No. 25) Thread(Tk No. 50) Thread(Tk No. 100) Printed Paper Tag
52550 4*3*2 100 24 12612 10237500 8*8*2.5 30000 160 54600 1995000 8*8*2.5 30000 160 10640 840000 1837500 3*2.5*2 8*8*2.5 2000 30000 15 160
Required volume (in cubic inch)
6360 9800
RACKS FOR ACCESSORIES
Accessori Required Dimensio No. of pcs Volume es Amount n of box that can of box(in for 15 (inches) be cubic days l*b*h inch) accommo dated Printed Paper Main Label Wash Label
205276 52550 5 Dia*2 5 Dia*2 375 375 157 157 22000 22000 52550 16*16*1 200 256
Required volume (in cubic inch)
67264
Care 52550
Therefore total required volume (in cubic inch)
COMPANY LOCATION & SITE
THANDYA INDUSTRIAL AREA
Its developed in Thandavapura Nanjangud Town, Mysore District.
Village
near
The Industrial Area is located about 160 kms from Bangalore & 20 Kms. from Mysore. The Industrial Area is well connected by road, rail & airport is situated at a distance of about 5 kms. River Kabini & Hullahalli Cannal Distributary runs very near to the Industrial Area.
COMPANY LOCATION & SITE
Particulars
Land acquired 144.00
Area
Acres Acres Acres
Net Area available for 104.00 allotment Total area allotted 104.00
Land reserved for CA & 10 + 2.75 Sump No. Of units allotted 44
COMPANY LOCATION & SITE
At present the tentative cost at Thandya Industrial Area is Rs. 15.00 lakhs per acre.
The following infrastructure has been developed in the Industrial Area: Formation of Roads GLR Constructed Electrical Infrastructure Open Drainage System Telecommunication System Area has been reserved for commercial infrastructure line Canteen, Bank, Post Office, etc.,
COMPANY LOCATION & SITE
1. Roads: - 18.00 Mts. Road 1.20 Kms. - 12.00 Mts. Road 0.80 Kms. 2. Water supply works: The existing borewells & 5 MGD water is being drained from Kabini at the cost of Rs. 9.45 crores & 2 pumps of 125 HP each is used. 3. Electricity: The entire Industrial Area is covered by one substation erected by KPTCL located near Nanjangud Industrial Area. 4. Open Drainage System: The KIADB has taken up open drainage system. 5. Telecommunication System: Telephone Exchange is in Nanjangud Town which is nearby & the telephone cable is drawn in the existing Industrial Area.
COMPANY LOCATION & SITE
6. Post Office: The nearest Post Office is in Nanjangud Town & an area has been reserved for Post Office in the Industrial Area. 7. Commercial Infrastructure: For canteen, bank, local shopping, etc., 10.00 Acres of land has been reserved in the existing Industrial Area. 8. Transportation: Industrial Area is located very adjacent to Bangalore ² Niligiri State Highway. 9. Railways: Thandavapura Railway Station is situated at a distance of 2.5 Kms. from Industrial Area.
COMPANY LOCATION & SITE
LOCATION OF THE COMPANY
PLANT LAYOUT ARCHITECTURAL BRIEF
Product category: shirt Product: Formal men full sleeve shirt & formal ladies top Nature of Business: Domestic Rate of Production: 10000pieces/day Dimension and area: 600*400 sqft
PRODUCT & ITS VARIATION
COLLAR
CUFF
Removable Collar (Bone) Inserted Collar (Bone) Button Down Collar Button Down Collar(Loop) Piped Band Collar Chinese Collar V- Hem Straight Hem Rolling Placket (Single Placket) Double Placket ² 1µ and ¾µ Double Placket- 1µ and ½µ
Round Cuff Square Cuff Double Cuff Double Button Cuff Single Button Cuff Chisel Cuff & Fancy Cuff Round Pocket Square Pocket V- Pocket Chisel Pocket Without Gusset With Gusset (FOA) With Gusset (Patch)
HEM
SLEEVE
ASSEMBLY
PRODUCTION SCHEDULE
Number of shifts: 1 per day Timings: 8 hrs per day Quantity to be produced: 10000units per day WIP between departments: 3days Inventory policy: Store has 12 days inventory.
NUMBER OF MACHINES
Machines used SNLS O/L B/H (TANDEM WITH FEEDER) DNLS Turning machine Trimming machine Cutting machine Pressing machine Number 292 4 16 48 10 4 4 9
SAM DISTRIBUTION FOR EACH ACTIVITY
ACTIVITY RELATIONSHIP CHART
DEPARTMENTS
Design Department Marketing & Merchandising Department Store Department Pre Production Department CAD Department Cutting Department Sewing Department Finishing Department Quality assurance Department
Industrial Engineering Department Information Technology Department Maintenance Department Administrative Department Human Resource Department Safety Department Security Department Warehouse department
DEPARTMENTS
Design Department Area = 20*10(sq. Ft) This department functions for the design of the products. It requires a team of designers. The basic space requirements are in the form of workstations & design tables only.
Following are the main activity required in the department. - The garments are designed here, & - Sample designing is done here.
DEPARTMENTS
Marketing & Merchandising Department Marketing area = 20*10(sq. Ft) Merchandising area = 20*10(sq. Ft) It caters to the marketing & sourcing of product & its components. It requires a list of workstations & cabins for officers & managers.
Following are the list of activities that are carried out in this department. - Material Planning - Initial Costing - Purchase Orders - Sample development - Approval/Rejection
DEPARTMENTS
Human Resource Department Area = 20*20(sq. Ft) This department requires a team of HR executives leaded by a HR manager. The department need not have very big area.
Following are the activities carried out here: Employee Benefits Recruitment Training and development Employee guidance Personnel documents
DEPARTMENTS
Conference Room Area = 20*20(sq. Ft) All the official meetings within company heads, buyers & contractors take place here. Crèche Room Area = 20*20(sq. Ft) This room is for providing service like playing rest & care centre for children·s of workers. Activities like: - Taking care of the kids of the workers. - Feeding the children. - Involve them in some kind of playful activities. All safety measures like fire safety devices, first aid are also required.
DEPARTMENTS
Reception Area = 10*10 (sq. Ft) Reception is where all the people, buyers, contractors etc will be received when they visit. Medical Room Area = 20*20 (sq. Ft) Provides medical facility to the workers & employees of organization. Keeping & upgrading the first aid boxes in all the departments regularly. In case of any accident or emergency taking immediate action. Maintain Ambulance for any emergency.
DEPARTMENTS
Library Area = 10*10 (sq. Ft) Library is used for reference purpose and for the knowledge access purpose. Administrative Department Area = 200*100 (sq. Ft) The administrative department caters to documentation regarding to the following documented activities. Purchase department Documentation Finance Accounts Bank documents Letter of Credit Bills Placing Purchase Orders Raw material Procurement Affirmation of Purchase order by Supplier
DEPARTMENTS
Information Technology Department Area = 20*10(sq. Ft) It serves the purpose of IT specialists that solves the software·s problems in the organization. It requires a server room for storing important data & managing the internet connection. Following are the activities: Computer Room/IT room Conference halls Software and Hardware Storage Maintenance Server
DEPARTMENTS
Training & development department Area = 75*35*10(sq. Ft) Training for the employees & workers are carried out here in order to improve their skills. Sampling department Area = 50*35*10(sq. Ft) The samples to be approved by the buyer is prepared in this department by highly skilled operators. The required machines for sampling is provided in this department
DEPARTMENTS
Raw material storage department Area = 150*125(sq. Ft) This department is required for the storage of trims & raw materials received. The department also keeps a record of trims received & issued to the production. Following are the activities:
Raw Material (fabric & trim receipt) Quality checking Issue material for production Packaging material storage Weighing machines Spring balance
DEPARTMENTS
FABRIC REQUIREMENTS: No. of garments = 10,000 Width of the fabric = 48 inch Fabric for one garment = 2.15mts(avg.) Fabric per day requirement= 10000X2.15 = 21500m Fabric per 12days requirement= 21500X12 = 258000m Now, assuming that 1 roll has 200 m fabric. Total rolls to be stored for 12 days= 1295 rolls.
10
DEPARTMENTS
Rack structure will accommodate = 27 rolls at a time. Therefore number of such racks required: 1295/27 = 47.2 approx 49 racks. The extra one will be used for storage of end bits and extra fabric after order completion. 7 extra racks for storing fabric during inspection.
DEPARTMENTS
CAD Department Area = 35*35 (sq. Ft ) The purpose is to generate pattern for the garment & produce the production marker for the same. The CAD department also requires to produce costing markers for the merchandisers. Following are the activities and assets required in the department. Plotter Digitizer Marker making Marker Preparation Costing marker Bundle preparation report
DEPARTMENTS
Cutting Department Area = 50*150(sq. Ft ) Length of the cutting table is a critical factor in deciding the area of the cutting room. The process of numbering & bundling is also carried out here.
Following are the requirements for this department.
Spreading Tables Cutting tables Numbering tables Bundling tables Checking tables Cutters required Fusing is required Cut part storage rack Inspection tables Temporary roll storage
DEPARTMENTS
Production /day = 10000pcs
Total fabric required per day =10000*2.15 =21500mts. Assumed 1 lay = 110 plies
So, no. of lays = 10000/110 = 909 lays
DEPARTMENTS
Sewing Department Area = 150*150 (sq ft) Following are the various activities carried out in sewing department:
Approval of operation breakdown Special machines & attachments approval Line balancing No. of machines required Deciding or approval of manufacturing system Sewing Checking
DEPARTMENTS
Finishing Department Area = 35*150 (sq ft) The finishing department is meant for ironing, folding & packing of the garment. The department will require tables for checking, folding & packaging. Following are the activities: Ironing Tags attached Checking Folding & Packaging
DEPARTMENTS
Since the production is 10,000 garments from sewing dept. Reducing 2% for rejection, calculated amount taken is 9800. Time taken for finishing for each garment = approx 8mins. Therefore, total time taken is 9800 * 8 = 78400 But Time available is 480 mins. Therefore, no. of operators required are = 78400/480 = 162
DEPARTMENTS
Packaging & storage of finished goods Area = 75*150 (sq ft) Here the orders are stored till they are shipped. Following are the various processes: Cartons are brought in from finishing department Cartons are stored Cartons are moved to parking be shipped Quality control department Area = 35*35 (sq ft) Performs the action of controlling & maintaining the quality.
DEPARTMENTS
Maintenance Department Area = 40*35(sq. Ft ) The department stores basic tools for the maintenance of the machines. It also requires space for the maintenance job. Following are the activities: Tools & machinery storage for maintenance of sewing & finishing machines Spare parts storage Building maintenance parts storage Machine maintenance UPS or power backup maintenance Air conditioning maintenance Electric supply decisions.
DEPARTMENTS
Canteen Area = 100*100 (sq ft) Canteen is common for all but there will be different timings for operators & officials. Operators will be offered snacks and tea at subsidized cost. Parking Area = 100*100(sq ft) Here all the vehicles of both operators &officials will be parked. Also parking is the place where the trucks & other vehicles for transport will be received. The security guard will see to it that rules are abided by the people. Assembly area
Area = 100*100(sq ft)
DEPARTMENTS
Toilets Area = 35*35 (sq ft) Total no of employees in production department = 720 Man : Woman ratio = 45:55 Total no of men employees = 300 Total no of women employees = 420 Toilet for gents: For 100 men no. of toilets = 4 and no. of urinals = 8 (data taken by UK standards) For 300 men no. of toilets =12 Wash basins - 16 Toilet for ladies: For 100 women number of toilets = 5 (data taken by UK standards) For 420 women number of toilets = 22 Wash basins - 16
ELECTRICITY CONSUMPTION
Particulars Fans Exhaust fans Tube lights Air conditioner Desktop computer Brand Khetan Khetan Surya Samsung Apple/ibm Power consumption 60 watts/hr 40 watts/hr 40 watts/hr 10000 watts/hr 400 watts/hr
ELECTRICITY CONSUMPTION
Departments Fans Tube lights Other machines (computer/ ac/exhaust fan) Total power consumed per hr
i. Store department i. Cutting department i. Sewing department i. Finishing department i. Quality assurance department i. Industrial engineering
20 32 126 90 17
250 224 1000 177 60 Comp-1 Ac-2 Comp-3
11200 10880 407560 12480 23820
12
60
4320
ELECTRICITY CONSUMPTION
Departments Fans Tube lights Other machines Total power (computer/ consumed per ac/exhaust fan) hr in (watts)
i. Maintenance department i. Administrative department i. Control department i. Security department
8 85 2
66 396 24 16 Comp-20 Ac-10
3120 128940 1080 880 5520 9620 1920
4 i. Toilet i. Canteen i. Cloak room 87 138 110 48
ELECTRICITY CONSUMPTION
Machine name Number Power consumed Total power consumed (watts) 29200 1600 2000 4800 2000 1000 40000 35190 8952
SNLS O/L B/H (tandem with feeder) DNLS Turning machine Trimming machine Cutting machine Pressing machine Water tank
292 4 16 48 10 4 4 9 2 tanks (2motors)
100 watts/hr 400watts/hr 125 watts/hr 100 watts/hr 200 watts/hr 250 watts/hr 10000watts/hr 3910 watts/hr 3HP power each motor consumes
ELECTRICITY CONSUMPTION
Total power consumed in all departments = 621340 watts/hr Total power consumed in 1 shift ie 8 hrs: 9941440watts= 9941 k watts
Power consumed by all machines in 1 hr= 115790 watts Power consumed by all machines in 1 shift ie. 8 hrs= 926320 watts = 926 k watts
Power consumed for filling water into the tank for 2 hrs a day = 8952 watts Total power consumed by all machines & water tank = 926320 + 8952 = 935272 watts. i.e. = 935 k watts. Therefore, total power consumed by the whole plant for a day = 9941 k watt + 935 k watt = 10,876 k watts. The capacity of the generator is 50% of the total power consumption of a day = 5438 k watts.
WATER CONSUMPTION
1 person consumes = 45 liters of water per day Total no. of employees = 1500 Total water required =45*1500 = 67,500 liters/day Size of tank =12*10*10 cubic feet Height of tank from ground level = 15 feet Number of tanks = 2 Number of motors = 2 each (3 HP each)
OTHER UTILITY AREAS
PARTICULARS Generator room Compressor Boiler Water tank (2) Assembly area Atm Future extension AREA 25*30(sq. Ft) 25*30(sq. Ft) 30*50(sq. Ft) 12*10*10(sq. Ft) 40*100(sq. Ft) 8*6(sq. Ft) (100*235+150*100) (sq. Ft)
CONCLUSION
The design of a process plant is a complex activity that usually involves many different disciplines over a considerable period of time. The design may go through many stages from the original research & development phases, conceptual design, detailed process design & onto detailed engineering design & equipment selection. Factors including safety, health, environment, economic & technical issues have to be considered before the design is finalized. ´APPAREL SOLUTIONSµ is one company which has considered all the above points before setting up its industry. It has efficiently utilizatized its resources & production techniques. Moreover, ´Apparel Solutionsµ is a plant which is very feasible & its plant layout can be adopted by any new industry to be successful.
