Documente Academic
Documente Profesional
Documente Cultură
PRESENTED BY:
AKANKSHA (03)
PRATIBHA (16)
ANISHA(05)
PARVATHY(17)
LIST OF CONTENTS
1. Project Brief
2. Product Description
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1. INDUSTRY BRIEF
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1.1 PLANT LOCATION
• The plant location would be in Hyderabad.
• Our plant would be located in the industrial area of Patancheru, Hyderabad, Telangana.
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• Reasons for choosing this particular location are as follows:
• While doing the calculations, we had taken care of the standards followed in the industry and at the same time
we had done some assumptions on the basis of what we had seen in the apparel internship industry.
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2. PRODUCT OVERVIEW
Name of the Product Shirt
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2.1 FEATURES OF THE PRODUCT
• The products have desirable fashion features such as darts, panels, embroidery, etc
for providing an attractive look to the wearer.
• The construction of the product can vary from easy to complex depending on the
style variation.
• Small parts like collar and cuffs are separately prepared before being assemble into
the main garment.
• Operational Breakdown for all possible Operations.pdf
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3. PROCESSES AND PRODUCTION SYSTEM
Overall workflow of the manufacturing process
Cutting
Pressing and Finishing
Order Conformation PP sample development Printing
Embroidery
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3.1 PRODUCTION SYSTEM: PROGRESSIVE BUNDLING SYSTEM
The production system proposed for the facility is “Progressive Bundling System” with the
material flow being in a straight line motion.
On the sewing floor bundles of garment parts are moved sequentially from operation to
operation.
The bundle sizes vary according to cutting orders, fabric shading, size of the pieces in the
bundle, and the operation that is to be completed.
Bundles of garments are assembled in the cutting room where cut parts are matched up with
corresponding parts and bundle tickets.
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3.2 PLANT ESTIMATES
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4. DEPARTMENT WISE AREA DETAILS
SPACE REQUIREMENT FLOOR-WISE
FLOOR DEPARTMENTS AREA COVERED (IN Sq. Feet)
Basement SAMPLING 75
HOUSEKEEPING 50
MERCHANDISING & 210
FINANCE DEPT
MAINTENANCE STORE 200
PARKING 8,000
Ground Floor PACKAGING & WAREHOUSE 420
FINISHING 800
TRIMS STORE 90
PANTRY AREA AND WATER COOLER 100
HR OFFICE 80
IT OFFICE 60
CONFERENCE ROOM 200
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SPACE REQUIREMENT FLOOR-WISE
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SPACE REQUIREMENT FLOOR-WISE
PRODUCTION OFFICE 60
MAINTENANCE OFFICE 200
WAREHOUSE 1440
KITCHEN 300
Second Floor
TERRACE GARDEN 5000
CANTEEN 15000
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MACHINES USED AND THEIR COSTS
Sl. No. Machine type Company Model no. Unit Price (Rs.)
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5. PLANT LAYOUT
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Fig: Basement
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Fig: Ground Floor
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Fig: First Floor
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Fig: Second Floor
6. FLOOR WISE DEPARTMENT DETAILS
6.1 BASEMENT
• Department in Basement are :
• SAMPLING
• MERCHANDISING
• FINANCE DEPARTMENT
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6.1.1 SAMPLING DEPARTMENT
• In the Sampling department the buyer’s requirement is actually transformed into a garment based on the
styles & designs given by the buyer.
REQUIREMENTS QUANTITY COSTING
Manpower 10
Machines Required:
SNLS 7 =7*18,000=1,26,000 Rs.
FOA 1 =1*18,000=18,000 Rs.
DNCS 1 =1*30,000=30,000 Rs.
Button stitching 1 =1*30,000=30,000 Rs.
Button holing 1 =1*17,000=17,000 Rs.
Steam iron 2 =2*6,000=12,000 Rs.
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6. FLOOR WISE DEPARTMENT DETAILS
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6.2.1 PACKING AND WAREHOUSE DEPARTMENT
• The finished goods are packed into poly bags and put in cartons. The warehouse dispatches the packed
goods to the buyer.
Manpower 3
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6.2.2 FINISHING DEPARTMENT
• Finishing is the last stage of garment production before shipment where garment gets its desired look.
Each garment undergoes various finishing processes.
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6.2.3 TRIMS DEPARTMENT
• The accessories department controls the accessories sourcing from various suppliers and supply of
accessories to the various departments at specified time as per requirement.
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6.2.4 HR DEPARTMENT
• HR department is responsible for bringing people into the organization, helping them perform their
work, compensating them for their labours, and solving problems that arise.
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6.2.5 IT DEPARTMENT
• IT as a central server connected to all the computers in the factory. It Department helps on sharing of
records and provides access to outside internet to the systems.
Manpower 2
AC 1 =1*25000=25000RS
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6.2.6 FABRIC INSPECTION DEPARTMENT
• Fabric inspection consists of checking the actual GSM, shrinkage, shade and colour continuity card using
various testing tools.
Manpower 2
Computer 1(dimensions of computer table= 3’x2’) = 1*24000=24000 RS
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6.2.7 CAD DEPARTMENT
• CAD department is for marker making by aid of computers. This department is crucial as in achieving the
target of the company by reducing cost by efficient markers.
Manpower 2
Computer 1(Dimension Of Computer Table= 3’x2’) =1*24000=24000 RS
Gerber Plotter 1 =1*72000=72000 RS
Gerber Digitizer (16 1 =1*39000=39000RS
Button Cursor)
Table 1(Dimensions = 4’x2’) =1*2000=2000 RS
Chair 2 (Dimensions = 2’x2’) =2*2000=4000RS
Carpet Area 50 Sq. Feet (Approx.)
Lightning 150 Lux =1*600=600 RS
Ac 1 =25000*1=25000 RS
TOTAL = 1,66,600 Rs.
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6.2.8 SPREADING AND CUTTING DEPARTMENT
• Cutting is a unit basically refers to spreading of fabric, cutting of parts, fusing of parts and bundling. These activities
are manually done in the company.
• Spreading:
• No. of tables: 4
• Dimensions of each table: (50’X6’) x 4= 1200 sq. feet
• Cutting:
• No. of straight knife: 4
• No. of band knife:1: (dimension = 10’x6’) = 60sq. feet
• Dimensions of cutting table: (50’X6’)x 4=1200 sq. feet
• Ticketing & Bundling:
• Ticketing table dimensions: (30’x5’) = 150 sq. feet
• Fusing machine:
• Manpower: 3
• Dimensions: (12’x6’)= 70 sq. feet
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6.2.8 SPREADING AND CUTTING DEPARTMENT
REQUIREMENTS QUANTITY COSTING
TUBELIGHTS 60 = 60*600=RS36,000
FANS 34 = 34*2000=RS68000
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6.2.9 STORES DEPARTMENT
• Average Fabric Consumption: 1.2 m
• Per day requirement: 4000 x 1.2 = 4800m
• Per week requirement: 4800 x 7 = 33,600 m
Now, assuming that 1 roll has 100m fabric. Then,
• Total rolls to be stored for 7 days = 336 rolls.
• Given, this rack structure will accommodate 20 rolls at a time.
• Therefore, number of such racks required: 336 / 20 = 16.8 ~ 17 racks.
TABLE 2 =2*6000=RS12000
FANS 3 =3*2000=RS6000
TUBELIGHT 5 =5*600=RS3000
TOTAL =Rs. 51,000
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6. FLOOR WISE DEPARTMENT DETAILS
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6.3.1 SEWING DEPARTMENT
• After the fabric will be released from cutting section, it will be passed on to the sewing department for
sewing. The various parts of the garment will be stitched together to form the garment.
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6.3.1 SEWING DEPARTMENT
Each line has:
Machine Name No. of machines COSTING
Single Needle Lockstitch Machine 28 =28*18000=RS50,40000
Double Needle Lockstitch Machine 1 =1*30000 =RS30,000
Total =RS5443000
NO.OF LINES 9 =9*5443000
=Rs. 4,89,87,000
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6.3.1 SEWING DEPARTMENT
MANPOWER REQUIREMENT-(FOR 9 LINES)
Designation Quantity
Production manager 1
Line managers 9
Supervisors 9
Feeding helpers 9
Operators 295
Helpers 18
Quality manager 1
Total 361
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6.3.2 PPC OFFICE
• Where production is spread over a number of locations, a central department PPC is made to collect and
analyse the control information from each unit to report on individual and overall status.
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6.3.3 QUALITY DEPARTMENT
• Quality department assures quality production by appointing checkers, Quality control and Assurance
personnel within sewing lines to monitor the production.
AC 2 =2*30,000=60,000 RS
TOTAL 1,00,200
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6.3.4 IE DEPARTMENT
• The Industrial engineering department is primarily responsible to make sure that production goes on
smoothly. The monitoring of the line from the line setting period, throughout the production process is
being done.
Manpower 2
Computer 2(dimensions of computer table= 3’x2’) =2*24000=48000 RS
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6.3.5 WAREHOUSE
• The movement of fabric In and fabric Out are ensured by the Warehouse. The finished goods
are stored in the warehouse and dispatched according to the date of delivery.
TABLE 2 =2*6,000=RS12,000
FANS 3 =3*2,000=RS6,000
TUBELIGHT 5 =5*600=RS3,000
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6. FLOOR WISE DEPARTMENT DETAILS
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AMENITIES REQUIREMENT
Different amenities requirements are as follows:
• 2 water cooler per floor
• 4 toilets per floor
• 2 for operators (men and women)
• 2 for supervisors and officers (Men and women)
• Parking space at the basement
• Total Setbacks of entire building is proposed to be 5000 sft.This set back is for transport
parking and loading/unloading of the trucks.
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BUILDING TYPOLOGY
COLUMN
Framed structure
Foundation:
• The foundation will be built by digging 8-9 ft. down in hard soil.
Firstly a base of plain concrete cement is there for 6 inches and
then a reinforced concrete cement block of 1 ft.
• The column foundation starts after that and the plinth and normal
ground level are the same. PLINTH
LEVEL
RCC
PCC
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Roofing:
• All the three floors should be of flat RCC roofing at height of 15 feet.
Flooring:
• Stone flooring ( Very Durable, Stain Resistant, Cool Underfoot)
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Ventilation
• Windows are kept in around 20% of the total area.
• Exhaust fans are adjusted in the sewing floor.
• The office area would have proper A/C facility
Lightning
• Every floor has proper lightning facility using tube lights along with special light frames
having 2 tube lights each above the work area where required.
• Sewing machines, inspection tables, finishing tables, press tables etc have special
arrangement for extra lightning fixed above the machines/tables.
• For inspection light required is maximum.
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TOTAL COSTING
OF ALL
DEPARTMENTS
S .NO NAME OF DEPARTMENT / FACILITY AREA REQUIRED (IN SQ. FEET) COST (IN RS.)
96,700
1 Merchandising 110
1,10,600
2 Finance 80
1,88,200
3 HR 80
94,200
4 IE 75
79,200
5 PPC 50
42,400
6 Fabric warehouse 1440
52,600
7 Testing Lab 50
43,800
8 Trims Store 90
1,66,600
9 CAD 50
3,30,600
10 Sampling 75
92,200
11 Quality Dept 70
27,600
12 Packing 420
86,200
13 Crèche 100
1,14,800
14 Medical room 150
14,000
15 Security 40
1,05,000
16 Canteen 1600
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35,000
17 General Manager office 60
S .NO NAME OF DEPARTMENT / FACILITY AREA REQUIRED (IN SQ. FEET) COST (IN RS.)
1,68,000
18 Conference room 200
67,200
19 Reception 150
82,800
20 IT 60
58,800
21 Manager’s cabin 55
650
22 Generator room 55
650
23 Boiler room 50
24 Production manager 50 72,800
• The only setback achieved while making the layout was the space constraint given to us. As a bigger plot of land
could have made the material flow of the production processes easier saving the industry a lot of time, hence,
money.
• However, for future expansion, sufficient provisions have been left so that there isn’t any problem if such a
situation arises.
• The making of this hypothetical garment industry’s plant layout utilized all our knowledge regarding the garment
industry and also our knowledge gained from our exposure to different garment industries during internships
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THANK YOU
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