NATIONAL INSTITUTE OF FASHION TECHNOLOGY, New Delhi

PLANT LAYOUT & FACILITY DESIGN

ARCHITECTURAL BRIEF

OF

TANK TOP MANUFACTURING UNIT

SUBMITTED TO: SUBMITTED BY:

Ms. Bhavna Verma 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 top2- Lace top3- Cotton cull top4- Crop top5- V tank top6- Pull over top7- Racer tank top8- Bustier top9- Kela top10- Stella top11- 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 any 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:

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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 department 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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DEPARTMENTS SIZE( IN FEET)

Reception/ Waiting Room 20×10

CEO’s Cabin 20×10

Conference Room 20×30

Buyers Room 30×10

PPC Cabin 20×10

Staff Canteen ×10

HR Cabin 20×10

Canteen 20×35

Merchandising 20×10

Purchase account & finance

Department

20×10

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

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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

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

STORE DEPARTMENT

CUTTING ROOM

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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% of 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 forceDesignation Number Area (sq.ft.)finishing Head 1 100Finishing executives 4 100finishing operator 16 -Pressing 2 7×3 = 21 Folding & packing 3 7×4= 28 eachArea required for equipmentsInspection Tables 1 3×3 =9Stain removing station 1 8×8 = 64Total area 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 forceDesignation Number Area (sq.ft.)QA Head 1 10 × 10 = 100QA executives 4 -Computer 3 2×4 = 8Seam slippage testing m/c 1 -Tear strength testing 1 -Wash fastness testing m/c 1 -Rubbing fastness m/c 1 -Light fastness 1 -Pilling testing 1 -Chair 5  1×1= 1Total area 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 DepartmentNo. of work forceDesignation Number Description Area (sqft)Training head 1  

Supervisor 2  MachineMachine Number Description Dimension (ft)Computer 3 2×4Chair 5   1×1 Sewing m/c 15 2×3 =6

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

Product development Cycle (PDC) Dept.

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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% of Toatal Area)

Crèche: 20× 20 = 400 sq. feet

Dispensary:

Equipments Quantity Area sq. ft. Beds 3 6×3= 54Checking table 1 6×3=18Doctor cabin -Equipment storage -

Total area 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 tube 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

FABRIC STORE AND TRIM STORE:

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

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, single 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

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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

Operator = 24 × 7lines

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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

Total Drinking Water requirement/day= 1550 ltrs

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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

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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

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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)

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Security Salary register file (If outsourced)

Security ESI, PF Challan (If Outsourced)

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