NATIONAL INSTITUTE OF FASHION

TECHNOLOGY, CHENNAI.

Plant Layout – End Term Jury

Layout of a Shirt Manufacturing Unit

PRESENTATION BY:

NAVEEN KUMAR
NILASHA TANDON
PAYAL BARDAN
RAVI ADITYA
 Structure of the Manufacturing Unit

 AutoCAD 2D Layout
 AutoCAD 3D Layout
 Departments Present in the Unit

 Spreading and cutting (110’ x 90’)

 Fabric inspection dept (100’ x 25’)
 Research and development dept (30’ x 25’)
 Human resources dept (60’ x 50’)
 Reception (50’ x 20’)
 Crèche (45’ x 15’)
 Locker room (50’ x 15’)
 Card swiping area (30’ x 15’)
 Toilets (30’ x 15’)
 Departments Present in the Unit

 Medical room (50’ x 15’)

 Power supply dept (80’ x 15’)
 Maintenance dept (80’ x 50’)
 Industrial engineering dept (30’ x 15’)
 HOD cabin (30’ x 15’)
 Sewing floor area (320’ x 90’)
 Canteen (70’ x 30’)
 Effluent Treatment Plant (180’ x 20’)
 Washing area (130’ x 30’)
 Departments Present in the Unit

 CAD lab (50’x25’)

 Finished goods warehouse (50’x80’)
 Finishing room (40’x90’)
 Packaging department (40’x90’)
 Fabric and trims warehouse (80’ x 30’)
 Ratio of cutting : sewing : finishing
Locational Analysis

Location Village Vanj, Taluka Choryasi,

District: Surat
Type of SEZ Sector Specific SEZ for Apparel.
Area: 56 hec.
Status Notified - Functional
Connectivity: Road Network: 8 km-National
Road, Rail, Highway (NH8),
Air and SEZ is on Navsari- Surat State
Port Highway (SH)
ƒ Rail Network: 20 km from Surat
Railway St.
ƒ Nearest Port: 30 km from Hazira
port and 18
km from Magdalla port
ƒ Nearest Airport: 20 km from
Surat Airport
Locational Analysis

Land availability Plots allotted to

& Lease Rates industries @ Rs.
1500 sq. mt.
Available Internal roads,
Infrastructure Power, Water,
Drainage system
are available in the
SEZ
Training Facility Established by ALT
Training College, an
Apparel Training
Centre is present in
the SEZ
Proposed All kind of apparel
industries manufacturing
industries are
permitted
 Locational Analysis

Developer Company: Gujarat

Industrial
Development Corporation
(GIDC)
Address:
GIDC, Block No. 4, 2Floor, Udyog
Contact Bhavan, Gandhinagar-382 017
Information
ƒ Contact Person & Designation:
Mr. Nayan
Raval, GM (Projects)
Tel. No.
+91-79-23250705
Website: www.gidc.gov.in
 Assumptions

 Layout: Product specific

 Layout Type: Prefabricated
 Product: Casual shirt
 50% washed & 50% unwashed
 Available time: 480min
 No. of days working: 6
 No. of m/c= 700
 10% extra, so available m/c=640
 Assumptions

 SAM of the shirt: 33.04

 No. of lines in sewing floor: 8
 No. of workstation req. for a shirt: 80
 Output per day @ 60% efficiency:5,712
 Output per day with 10% extra: 6,397
 No. of days working in a month: 25
 Output per month: 1,59,936
 Fabric Store

 Length of the roll: 150m

 Width of the roll: 6ft
 Height of the roll: 1.5 ft
 Average consumption per garment: 2 m
 Fabric width: 60 inch
 Fabric consumption per day:11,424m
 No. of rolls req. per day: 76 rolls
 Inventory: 10 days
 Total rolls inventory: 762
 Rack dimension: 6ftX 6ftX4ft
 No. of shelves: 3
 No. of rolls stacked in a height:24
 Total rolls inventory in store: 762

Calculation sheet
 Fabric store

 Inspection m/c: 9ftX7ft

 Average speed: 6mts/min
 Utilization: 90%
 Available time: 432min
 Inspection per m/c: 2592m
 Daily needed fabric:68,544m
 M/c req. =3
 No. of racks required: 32
 No. of shelves: 95
 Area required for racks: 1,142 sq. ft.
 Area required for fabric store: 2500sq. ft

Calculation sheet
 Cutting room

 Available time: 480 min

 Utilization: 75%
 Efficiency: 60%
 Average consumption: 2m
 Marker length: 4m
 Layer length: 4.008m
 No. of sizes in a marker: 2
 No. of layer: 80
 Total garment in a lay: 160
 Meter spread: 320.64m
 No. of rolls req. :2.14=3
 Bundle size: 20
 No. of lays req. per day: 40

Calculation sheet
 Cutting room

 Spreading table length: 5.508m

 No. of spreading table req.:7
 No. of spreader req. :11
 No. of spreader allotted:6
 No. of spreading team: 6
 No. of req. cutter: 5
 No. of cutter allotted : 3
 No. of allotted cutter: 2
 M/c area: 2898 sq ft
 OP. space area: 1416 sq ft
 Total area : 4314 sq ft
 Total area req. :9900

Calculation sheet
 Sewing Room

 SAM of the shirt: 33.04

 No. of workstation: 80
 No. of sewing line: 8
 Total m/c: 640
 M/c area per line: 1063sq ft
 Op space area per line:447.5 sq ft
 Total area required: 3398.625 sq ft

Calculation sheet
 Washing room

 50% washed and 50% unwashed

 Washing machine
 Tumble Drier
 Drier
 M/c area:1290 sq ft
 Op space area: 300 sq ft
 Total area req. 3900 sq ft.

Calculation sheet
 Finishing Room

 Finishing SAM = 4.45 Minutes

 Thread Sucker
 Press Fold
 Spotting M/C
 Checking tables
 Sub Total Space = 1585 Sq. ft.
 Allowance (125%) = 1981.25 Sq. ft.
 Total Required Area 3566.25 Sq. ft.

Calculation sheet
 Canteen

 No. of employees: 900

 Canteen is without cooking
 So area req. per employee is 12 sq ft
 So the canteen area is 2100 sq ft
 Two floor canteen
 Occupies 350 employees at a time.
 So there will be three shifts for employees

Calculation sheet
 Sustainable Factory

OBJECTIVES
 Efficient management of energy and water resources
 Management of material resources and waste
 Restoration and protection of environmental quality
 Enhancement and protection of health and indoor
environmental quality
 Reinforcement of natural systems
 Analysis of the life cycle costs and benefits of
materials and methods
 Integration of the design decision-making process
 Renewable Sources of Energy in Gujarat

 Wind power (capacity=3,187 MW)

 Solar power (capacity=856.81 MW)
 SUSTAINABLE CONSTRUCTION

 Adoption of materials and products in buildings and

construction that will require less use of natural resources
and increase the reusability of such materials.
 Sustainable construction also enhances the resilience of the
industry as such materials are readily available in the world
market.
 Steel, other metals, glass and prefabricated parts using
combinations of these, as well as recyclable substitutes for
concrete are examples of sustainable materials and
products.
SUSTAINABLE RAW MATERIAL FOR
CONSTRUCTION

 To reduce the non-renewable energy (energy

expended to process and transport
materials) in the building, the main walls are
made of compressed stabilized-earth block
manufactured forty kilometres from the site.
 The machine moulded blocks are made of
local soil, sand, and locally manufactured
cement. The large size of the blocks
minimizes mortar joints.
 The walls require no plaster finish; they are
simply sealed with varnish on the interior
and exterior.
 Polycarbonate sheets on roof.
 Glass strips, running continuously across the
breadth of the roof at regular intervals.
SUSTAINABLE RAW MATERIAL FOR
CONSTRUCTION

 Windows use imported plate glass and

aluminium frames.
 Floor finishes include polished concrete
tile, rendered and cut concrete, tile, and wood.
 Bamboo is used for window blinds and various
forms of sunscreen.
 Nonhazardous finishes and materials are used
throughout the building, ensuring good indoor
air quality, which is enhanced by high air-
exchange rates.
 Stabilizing plants, silt traps, and stormwater-
collection ponds were used to prevent soil
erosion during construction.
 Special mechanisms to recycle construction
waste, which reduced the amount of waste that
went into landfills.
Understanding the Lighting Requirement
 Light Source Upgrade Alternatives
Lamp Type Rated Life Hours
Full-size fluorescent (T5, 20,000 to 30,000 - Lumen
high-performance T8) maintenance % - 92 to 93
Compact fluorescent 6,000 to 12,000
Lumen Maintenance - 86 (%)
Quartz pulse-start 20,000
metal halide Lumen Maintenance – 65 to 75
(%)
Ceramic pulse-start 20,000
metal halide Lumen Maintenance - 80 (%)
Induction 100,000 hours
Lumen Maintenance
70 at 60,000 hours; 55 at
100,000 hours
LED 50,000
Lumen Maintenance - 70 (%)
General area lighting of all
kinds, including open and
closed offices, training classrooms, and
high-bay areas. – Sewing, Finishing,
Washing Section
Incandescent replacements in table and
floor lamps, cans, wall washers, and
sconces
Outdoor lighting, high-bay
lighting, and remote-source
Lighting - Landscape
Where color is critical- example cutting
section
Where maintenance costs
are high like parking, roadways and ware
house.
In color-based applications such as exit
signs, niche applications such as outdoor
signage, task lamps.
Use of Day Light and Automatic Control
Light

 A mix of top- and

side-lighting, light
shelves, high-
reflectance ceilings.

 Automatically
Control Lighting.
 LIGHTING
 Over time, all lighting systems become gradually less
efficient.
 Other efficiency losses include improperly functioning
controls, dirt accumulation on fixture lenses and lumen
depreciation.
How to control this ??
 Follow a strategic lighting maintenance plan of scheduled
group re lamping and fixture cleaning.
 Indoor thermal comfort

 Cross- ventilation .
 Cooling is achieved at the plant primarily by passive design and
secondarily by active systems.
 Passive design measures include the orientation and massing of
building volumes, controlled fenestration and
ventilation, shading of the building and its surroundings, and
thermal mass and solar reflectivity of the facades and roofs.
 The massing of the building volumes and the positioning and
sizing of windows permit daylight to enter as natural
illumination without causing substantial heat gain
 Thermal roof load, the largest contributor to heat gain and
indoor discomfort in the tropics, is controlled by a combination
of photovoltaic roofs, and cool roofs.
 IAQ(Indoor Air Quality)

 Production spaces and offices are ventilated and

cooled by evaporative cooling units. These units
draw in fresh air, filter it, and add moisture to lower
the dry-bulb temperature.
 Indoor air is not recirculated, but extracted by
suitably sized exhaust fans to ensure effective
moisture and heat removal.
 Humidistat in each cooling unit keep the indoor
relative humidity at or below 80 percent.
 Window Heat Flow

 Infiltration
Air leaks around the frame, around the sash, and through gaps in
movable window parts. Infiltration is foiled by careful design and
installation.
 Convection
Pockets of high-temperature, low-density gas rise, setting up a circular
movement pattern. Convection occurs within multiple-layer windows
and on either side of the window.
 Radiation
Radiation is energy that passes directly through air from a warmer
surface to a cooler one.
Radiation is controlled with low-emissivity films
or coatings.
 Conduction
Conduction occurs as adjacent molecules of gases or solids pass
thermal energy between them. Conduction is minimized by adding
layers to trap air spaces, and putting low-conductivity gases in those
spaces.
 Window Films

 Window films reduce heat gain due to solar

radiation and provide low cost cooling load
reduction.

 Buildings in sunny areas can benefit from a variety

of shading techniques.

 Bamboo sheet shade screens reduce heat gain up to

80 % compared to normal glass.
 Fan System
 Centrifugal fans (A) are the most common fans
used.
 They are often cheaper but usually less efficient
than axial fans (B).
 COOLING

 The heat-island effect around the building is controlled by

shading, by covering parking areas, by using lighter,
reflective paving around the building instead of dark, heat
absorbent paving, and by shading the courtyards between
the building volumes.
 The combination of the many passive cooling measures
reduces the thermal load to a level that can be handled by
environmentally efficient cooling systems instead of power
hungry conventional systems
Light intensity levels for different departments

ACTIVITY REQUIRED LUX LEVEL

Preparation of cloth 200-300-500
Cutting 500-750-1000
Matching 500-750-1000
Sewing 750-1000-1500
Pressing 300-500-750
Inspection 1000-1500-2000
Hand tailoring 1000-1500-2000
THANK YOU