pl

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. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. xvi. xvii. Design Department Marketing and 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 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 Department Personnel Designation Marketing Head Junior Marketing Executives Merchandiser Junior Merchandiser Number 1 4 1 4 Description Area (mtrs) 9*4 Machine Machine Computer Furniture Chair Number 10 Number 10 Description IBM Dimension (ft) 3*5 Dimension (ft) 1.5*1.5 Furniture Description 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 Store Manager Helpers Fabric/Shade Inspectors Machine Computer Trolleys Fabric Inspection Machine Furniture Chair Number 1 4 3 Description putting and removing of rolls Area (meters) 40*15.5 Machine Number 2 4 2 Description IBM Dimension (ft) 3*5 4*3 9*8 Yash Furniture Number 4 Description Dimension (ft) 1.5*1.5 Roll dimension Number of rolls in rack total rolls in one Pigeon Hole rack dimensions 1.5 ft dia and 6ft width 18 stack 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 Department Personnel Designation Pattern Master Sampling Department manager Supervisor Cutting Master Sewing Operators Ironing Opertors Number 1 1 1 1 16 1 Pattern Store Fabric/Sample Store Description Area (meters) 15*10 Machine Machine Computer SNLS DNLS(FOA) Irons Pattern Table Furniture Chair Number 1 10 5 2 1 Number 20 Description IBM Juki Juki Dimension (ft) 3*5 35 35 30 5*7 Dimension (ft) 1.5*1.5 Furniture Description 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 Department Personnel Designation CAD Executive Pattern Masters Junior Pattern Masters Plotter & Digitizer Machine Computer Plotter Digitizer Furniture Pattern making Tables Marker table Chair Number 1 1 1 1 Description Area (sqft) 6*6 Machine Number 1 1 1 Description IBM Dimension (ft) 3*5 3*8 6*8 Dimension (ft) 8*6 9*7 1.5*1.5 Furniture Number 1 1 4 Description 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 Department Personnel Designation Cutting Department Manager Cutting Supervisor Cutting Master Helper(Spreading) Helper(Trolley) Numbering Bundling Helper Machine Computer Straight Knife Cutting Machine Number 1 2 4 8 2 10 3 1 Description Area (sqft) Machine Number 1 4+1 Description IBM Dimension (sqft) 3*5 End Cutters Band Knife Fusing machine Furniture Cutting Tables Numbering Bundling Tables Chairs 6 1 1 Furniture Number 4 3 1 Description Dimension (ft) 60*6 20*6 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 Heat guns Flashers Tearing guns Tagging guns Grinding m/c Horizontal mannequins Vertical mannequins Conveyor booth -PP Stationary PP Spray booth Sand blasting No 24 12 5 8 4 34 12 1(24 heads) Area (sqft) 5x5=25x12=300 3x3=9x4=36 3x3=9x34=306 3x3=9x12=108 15x15=225 15x15=225 2(6 heads each) 2(4 heads) 20x20=400 Total=1600sqft Total area (60% extra)=1600+1600x60/100=2560sqft MACHINE PARTICULARS FOR WET PROCESS:MACHINES Ramson belly wash Tonello-420 Tonello-500 Danish-250 Smartex-340 smartex-225 Tonello-510 Tolkar-500 CAPACITY 200kgs 420kgs 500kgs 250kgs 340kgs 225kgs 510kgs 500kgs Nos. 1 1 1 2 3 2 1 2 Area(sqft) 100 100 100 200 300 200 100 200 Ozone Drier Drier 100kgs 50 kgs 150 kgs 1 1 9 100 100 900 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 Department Personnel Designation Finishing Supervisor Checking Ironing/Pressing Tag Attachment Folding Packing Helper Machine Computer Ironing Tables Tag Attachment Machine Form Pressing Snap machine Trolley Furniture Inspection Tables Packing Tables Tag Attachment Table Folding Table No. of stools Number 1 16 10 8 8 10 2 Description Area Machine Number 1 4 2 2 8 2 5*5 4*3 Description IBM Dimension (ft) 3*3 3*5 Furniture Number 16 8 8 8 1 Description Dimension (ft) 3*5 3*5 5*3 6*6 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 Department Personnel Designation QA Department Manager QA Supervisor Machine Computer Chair Number 1 2 Description Area (sqft) 100 Machine Number 3 3 Description IBM Dimension (ft) 3*5 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 Department Personnel Designation Industrial Engineering Manager Senior IE Junior IE Machine Computer Printer Stopwatch Chair Number 1 4 4 Description Area (sqft) 80 150 150 Machine Number 5 2 4 Description IBM Dimension (ft) 3*5 1.5*1.5 Furniture 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 Department Personnel Designation IT Department Head IT Executives Machine Computer Server Air Conditioner Chair Chair Number 1 2 Description Area (meter) Machine Number 3 1 3 3 Description IBM Split AC Dimension (ft) 3*5 4*1 1.5*1.5 Furniture 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 Department Personnel Designation Maintenance Head Helpers Number 1 2 Description Area (sqft) 100 100 Furniture 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 Department Personnel Designation Plant Manager Production Manager Documentation & Compliance Purchase Manager Purchase Executives Accounts Number 1 1 3 1 3 5 Description Area (sqft) 100 100 150 60 150 300 Machine Machine Computer Number 12 Description Dimension (ft) 3*3 Furniture Chair 12 1.5*1.5 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 Department Personnel Designation HR Head HR Executives Machine Computer Chair Number 1 3 Number 4 4 Description Area (sqft) 60 120 Dimension (ft) 3*5 1.5*1.5 Machine Description IBM Furniture 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 Department Personnel Designation Nurse Furniture Bed Stretcher Number 1 Number 1 1 Description Description Area (sqft) 200 Dimension (ft) 5*6 3*7 Furniture Chair 1 1.5*1.5 Security Department This department comes under administration. Following are the various requirements.   Security cabins Parking Maintenance Security Department Personnel Designation Security Head Security Guards Machine Computer Stool Number 1 6 Number 1 7 Description Area (sqft) 100(at gate) Machine Description IBM Dimension (ft) 3*5 1*1 Furniture 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 Warehouse Personnel Designation Warehouse Manager Helpers Machine Computer Trolley Number 1 2 Description Area (sqft) 100(at gate) Machine Number 1 2 Description IBM Dimension (ft) 3*5 4*3 Furniture Stool Warehouse Area Calculation Average Carton dimensions (ft) 3.5*4*3.4 number of pieces in Carton rejected storage area: Net Area 16 Use of cube: No of cartons can be stacked in column 5 Number of Cartons required 765 Floor space required 15 * 25 METER Other Structures or Areas required: I. II. III. IV. Canteen Reception Parking Conference room