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Architectural Brief

Plant Layout

Presented by:

Shipra Singhai

Plant layout Architectural Brief

Product category: Jeans

Product: Five pocket Basic Jeans (men’s)

Variations: Slim Fit, Low Waist.

Nature of Business: Domestic

Rate of Production: 5000 pieces/day

Departments

i. Design Department

ii. Marketing and Merchandising Department

iii. Store Department

iv. Pre Production Department

v. CAD Department

vi. Cutting Department

vii. Sewing Department

viii. Finishing Department

ix. Quality assurance Department

x. Industrial Engineering Department

xi. Information Technology Department

xii. Maintenance Department

xiii. Administrative Department

xiv. Human Resource Department

xv. Safety Department

xvi. Security Department

xvii. Warehouse department

Marketing and Merchandising Department

This department caters to the marketing and sourcing of the product and its components. The marketing and merchandising departments also requires a list of workstations and cabins for officers and managers. Following are the list of activities that are carried out in this department.

Material Planning Initial Costing Purchase Orders Sample development Approval/Rejection

Marketing and Merchandising DepartmentPersonnel

Designation Number Description Area (mtrs)Marketing Head 1 Junior Marketing

Executives 4 9*4

Merchandiser 1 Junior

Merchandiser4

MachineMachine Number Description Dimension (ft)

Computer 10 IBM 3*5Furniture

Furniture Number Description Dimension (ft)Chair 10 1.5*1.5

Store Department

This department is required for the storage of trims and raw materials received. The department also keeps a record of trims received and issued to the production. Following are the activities carried out in this department.

Raw Material (fabric and trim receipt) Quality checking Issue material for production Packaging material storage Weighing machines

Spring balance

Store Department

Personnel

Designation Number Description Area (meters)

Store Manager 1

Helpers 4 putting and removing of rolls

40*15.5

Fabric/Shade Inspectors

3

Machine

Machine Number Description Dimension (ft)

Computer 2 IBM 3*5

Trolleys 4 4*3

Fabric Inspection Machine 2 Yash 9*8

Furniture

Furniture Number Description Dimension (ft)

Chair 4 1.5*1.5

Roll dimension Number of rolls in rack

total rolls in one Pigeon

Holerack dimensions

1.5 ft dia and 6ft width 18stack of 3

racks: 8*3= 54 rolls

6*6*4.5

Sampling Department

This department serves the purpose of sample making before the actual production. The department requires a set of machinery to manufacture these samples. Following are the basic activities carried out in this department.

Sampling Patterns, sample approved Machineries required Cutting tables Sewing Machines Iron tables Inspection tables

Sampling DepartmentPersonnel

Designation Number Description Area (meters)Pattern Master 1

Sampling Department

manager1

Supervisor 1 Cutting Master 1

15*10Sewing Operators 16 Ironing Opertors 1

Pattern Store

Fabric/Sample Store


Computer 1 IBM 3*5SNLS 10 Juki 35

DNLS(FOA) 5 Juki 35Irons 2 30

Pattern Table 1 5*7Furniture

Furniture Number Description Dimension (ft)

Chair 20 1.5*1.5

CAD Department

The purpose of the CAD department is to generate pattern for the garment and thus 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

CAD DepartmentPersonnel

Designation Number Description Area (sqft)CAD Executive 1

6*6

Pattern Masters 1 Junior Pattern

Masters1

Plotter & Digitizer 1


Computer 1 IBM 3*5Plotter 1 3*8

Digitizer 1 6*8Furniture

Furniture Number Description Dimension (ft)Pattern making

Tables1 8*6

Marker table 1 9*7Chair 4 1.5*1.5

Cutting Department

The department serves the purpose of spreading of the fabric on long tables and cutting the pattern pieces out of it. The critical factor in deciding the area of the department is the length of the cutting table. The process of numbering and bundling is also carried out in this department. The department requires the storage space for the cut fabric rolls, cut components, bundles etc. Following are the requirements for this department.

Spreading Tables Cutting tables Numbering tables Bundling tables Checking tables Cutters required

Cutting DepartmentPersonnel

Designation Number Description Area (sqft)Cutting

Department Manager

1

Cutting Supervisor 2 Cutting Master 4

Helper(Spreading) 8

Helper(Trolley) 2

Numbering 10

Bundling 3

Helper 1 Machine

Machine Number Description Dimension (sqft)

Computer 1 IBM 3*5

Straight Knife Cutting Machine

4+1

End Cutters 6

Band Knife 1Fusing machine 1

FurnitureFurniture Number Description Dimension (ft)

Cutting Tables 4 60*6Numbering

Bundling Tables3 20*6

Chairs 1 1.5*1.5

Sewing Department

The department serves the purpose of sewing the garment and thus carrying out the production. The department contains 143 sewing machines and operators with proper space for lighting. The department is generally a large single floor the approximate area required for this department is calculated as 6000sq ft. Following are the various activities that go in the sewing room.

Approval of operation breakdown Special machines and attachments approval Sewing department Line balancing No. of machines required Deciding or approval of manufacturing system Sewing Checking Sending the garments for washing. Receiving the washed garments.

M/C TYPE

3T O/L-4

DNCS FLAT BED

DNLS (UBT)-5

SNLS-10

WORKING TABLE-3

3N FOA-3

DNCS FLAT BED

COMP.CYCLE M/C

AUTO.STEAM PKT CREASING

COMP.CYCLE M/C

4T O/L SAFETY STITCH

4N FOLDING & ATTACHING M/C

COMP.CYCLE M/C

LABEL CREASING M/C

COMP.CYCLE M/C

2N BELT LOOP MAKING M/C

SNLS AUTO.BELT LOOP ATTACH

AUTO BOTTOM HEMMER

1N CYLINDER BED LS BARTACK

1N CYLINDER BED LS BARTACK

EYELET B/H M/C

FASTENING M/C

Washing Department

Machine particulars for dry process:

Machine No Area (sqft)

Heat guns 24Flashers 12 5x5=25x12=300Tearing guns 5Tagging guns 8Grinding m/c 4 3x3=9x4=36Horizontal mannequins 34 3x3=9x34=306Vertical mannequins 12 3x3=9x12=108Conveyor booth -PP 1(24 heads) 15x15=225Stationary PP Spray booth 2(6 heads each)

15x15=225

Sand blasting 2(4 heads) 20x20=400Total=1600sqft

Total area (60% extra)=1600+1600x60/100=2560sqft

MACHINE PARTICULARS FOR WET PROCESS:-

MACHINES CAPACITY Nos. Area(sqft)Ramson belly wash 200kgs 1 100Tonello-420 420kgs 1 100Tonello-500 500kgs 1 100Danish-250 250kgs 2 200Smartex-340 340kgs 3 300

smartex-225 225kgs 2 200Tonello-510 510kgs 1 100Tolkar-500 500kgs 2 200Ozone 100kgs 1 100Drier 50 kgs 1 100Drier 150 kgs 9 900

Total =2300(sqft)

Total area (60% extra)=2300+2300x60/100=3680sqft

Finishing Department

The finishing department is meant for ironing, folding and packing of the garment the department will require tables for checking as well as tables for folding and packaging. Following are the activities.

Ironing Tags attached Checking Folding and Packaging

Finishing DepartmentPersonnel

Designation Number Description AreaFinishing

Supervisor1

Checking 16 Ironing/Pressing 10 Tag Attachment 8

Folding 8

Packing 10

Helper 2 Machine

Machine Number Description Dimension (ft)Computer 1 IBM 3*3

Ironing Tables 4 3*5Tag Attachment

Machine2

Form Pressing 2 5*5Snap machine 8

Trolley 2 4*3Furniture

Furniture Number Description Dimension (ft)Inspection Tables 16 3*5

Packing Tables 8 3*5Tag Attachment

Table8 5*3

Folding Table 8 6*6

No. of stools 1 1*1

Quality assurance 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.

Decision of Inspection points Solving quality problems Improving quality

Quality assurance DepartmentPersonnel

Designation Number Description Area (sqft)QA Department

Manager1

100QA Supervisor 2


Computer 3 IBM 3*5Chair 3 1.5*1.5

Industrial Engineering and Planning Department

The department is meant for planning the production of a new product in the same product category. The department requires a team of industrial engineers. Following are the list of activities in this department.

Line planning Production per day calculation and follow up Operation Breakdown Calculation of Standard average minute (SAM) of garment Cost of machine per hour Efficiency calculation Ergonomics

Industrial Engineering DepartmentPersonnel

Designation Number Description Area (sqft)Industrial

Engineering Manager

1 80

Senior IE 4 150Junior IE 4 150


Computer 5 IBM 3*5

Printer 2 1.5*1.5

Stopwatch 4

FurnitureChair 9 1.5*1.5

MIS Department

This department serves the purpose of IT specialists that solve the software’s problems in the organization. The department also requires a server room for storing important data and managing the internet connection. The department also caters to troubleshoot the software related problems as and when they arrive. Following are the activities:

Computer Room/IT room Conference halls Software and Hardware Storage Maintenance Server

Information Technology DepartmentPersonnel

Designation Number Description Area (meter)IT Department

Head1

IT Executives 2


Computer 3 IBM 3*5Server 1

Air Conditioner 3 Split AC 4*1

Chair 3 1.5*1.5Furniture

Chair 3 1.5*1.5

Maintenance Department

The department stores basic tools for the maintenance of the machines. It also requires space for the maintenance job. Following are the activities of the department.

Tools and machinery storage for maintenance of sewing and finishing machines Tools and machinery storage for special machines Spare parts storage Building maintenance parts storage Machine maintenance UPS or power backup maintenance Air conditioning maintenance Record Keeping Electric supply decisions

Maintenance DepartmentPersonnel

Designation Number Description Area (sqft)Maintenance Head 1 100

Helpers 2 100Furniture

Chair 3 1.5*1.5

Administrative Department

The administrative department caters to documentation regarding to the following documented activities.

Purchase department Documentation Finance Accounts Shipment details and documentation Bank documents Letter of Credit Bills

The purchase department is a sub department under the administration. This department is responsible for issue of purchase orders to buy fabrics and trims and also other requirement of the plant. The purchase department also requires space for keeping records and workstations. Following are the activities that are carried out in this department.

Placing Purchase Orders Raw material Procurement Affirmation of Purchase order by Supplier

Evaluation of Supplier in terms of cost and quality

Administrative DepartmentPersonnel

Designation Number Description Area (sqft)Plant Manager 1 100

Production Manager

1 100

Documentation & Compliance

3 150

Purchase Manager 1 60Purchase

Executives3 150

Accounts 5 300Machine

Machine Number Description Dimension (ft)Computer 12 3*3


Human Resource Department

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.

Employee Benefits Recruitment Training and development Employee guidance Personnel documents

Human Resource DepartmentPersonnel

Designation Number Description Area (sqft)HR Head 1 60

HR Executives 3 120Machine

Machine Number Description Dimension (ft)Computer 4 IBM 3*5


Safety Department

The department caters to the maintenance of safety assets of the organization.

Installation and maintenance of fire extinguishers First aid Kit installation and Maintenance

Safety DepartmentPersonnel

Designation Number Description Area (sqft)Nurse 1 200

Furniture Number Description Dimension (ft)Bed 1 5*6

Stretcher 1 3*7


Security Department

This department comes under administration. Following are the various requirements.

Security cabins Parking Maintenance

Security DepartmentPersonnel

Designation Number Description Area (sqft)Security Head 1

100(at gate)Security Guards 6


Computer 1 IBM 3*5Furniture

Stool 7 1*1

Warehouse Department

This department stores all the finished orders. Here the orders are stored till they are shipped. Also the finished goods of a consignment whose production is in process is also stored here. Following are the various processes:

Cartons are brought in from finishing department Cartons are stored Cartons are moved to parking be shipped

WarehousePersonnel

Designation Number Description Area (sqft)Warehouse

Manager1

100(at gate)Helpers 2


Computer 1 IBM 3*5Trolley 2 4*3

FurnitureStool

Warehouse Area Calculation

Average Carton dimensions (ft)

3.5*4*3.4

number of pieces in Carton

Use of cube: No of cartons can be

stacked in column

Number of Cartons required

Floor space

required

rejected storage area:

16 5 765 15 * 25 METER

Net Area

Other Structures or Areas required:

I. CanteenII. Reception

III. ParkingIV. Conference room

documentpl

Documents

cad department

total area

requires space

machine particulars

purchase department

machinery

department

area