Plant Layout Trouser Production using UPSBy Apar Singh (03)
Geetika Gulyani (06) Sanjit Pandey (16)
AcknowledgementPlant Layout assignment was an enriching
experience. It was an immense learning oppurtunity. It was possible
due to kind cooperation and guidanace of my faculty and friends. We
would like to thank Mr. Saikat Pramanik and Mr. Ram Mohan, the
faculty for Plant Layout for his continued support and guidance
without whom the project would not have been possible. By working
on the assignment not only did we learn the intricasies of
architectural brief but also improved our knowledge of the
topic.
Contents
Introduction Organizational Structure Flow Process Chart
Departmental Study Operation Breakdown Manufacturing Systems
Material Flow Building Structure Space Utilization Area Calculation
of Departments
Introduction
Nature 100% Exports Location Apparel Park, Gundlapochampally,
Hyderabad Product Formal trouser Production Capacity per day 3,000
Manufacturing System Unit Processing System (UPS)
In-House Facilities Stores, Sampling, Spreading and Cutting,
Sewing, Washing, Packing and Finishing, Quality Assurance. Export
Market Europe, USA
LocationGundlapochampalli is an apparel park. It has many
apparel related industries. The apparel park has been set up with
all the required infrastructural facilities to setup an apparel
industry. It has facilities like uninterrupted power supply from a
dedicated plant. Water supply, effluent and sewage control system,
roads, telecommunication services, etc.
Organizational Structure
Flow Process Chart
Departmental Study
This dpt looks after the planning of production right from the
confirmation of order to till its shipment
Other FacilitiesCanteen Creche/Dispensary Washrooms Water
Coolers Parking Area
Manufacturing System
The manufacturing system is Unit Production System (UPS). The
system is based on a concept of suspended bundles of trouser's
parts hung by special clamp that flow on a conveyer situated on the
left of the operator. The bundle of trouser's fronts and backs
including all the parts, are loaded onto two clamps (one for the
front's bundles and another one for the backs).
Both the clamps reach every work station along the line in such
a way that the operator is able to perform his operation without
detaching the garment components from the clamps. The bundle then
returns to a natural position and the clamp keeps moving on the
aerial conveyer from one workststion to another.
It is necessary to detach the bundles from the pliers only for
the following three operations: Front knee lining attach and back
serging; Outseam and inseam stitch; and Side seam and Inseam
ironing. Always in these specific operations, the workstation must
properly be equipped with workaids and stackers. Front and back
bundles on separate clamps with all the parts components attached
with special strap band help the operator concentate more on the
operation and not waste precious time in searching parts and
accessories.
Material Flow
There is a top-bottom (downward) flow of materials. We try to
use gravity and Washing Department is at bottom due to aheavy
machinery. There are lifts across floors of certain capacity. The
sewing floor uses Eton.
Third floor
Offices
Second floor
Stores
First floor
Sewing department
Ground floor
Finishing & washing department
Building Structure
The foundation is 9-10 feet deep with load bearing pillars as
per the soil of the land. Height of the building is 60 feet (15x4)
excluding the basement. Floors are coated epoxy and hard for
strength. Pillars (2x2 feet) are at a distance of 20 feet in
lengthwise direction & 25 feet in breadth wise direction. There
is one staircase for the operators and 2 lifts (for the material
flow & other general purpose).
Space UtilizationGround coverage Total Plot Area = 15000 sq ft
Area under construction = 50%= 7500 sq ft The dimension of factory
= (100*75) ft A clearance of 7500 ft has been provided. Area
calculation Required work place areas + Required temporary storage
areas + Cold regulation aisle space = Minimum space requirement for
the plant layout.
Area DistributionGround Floor Reception, Creche/Dispensary,
Washing, Finishing, Packing, Warehouse
First Floor Sewing, IE, PPC,QA, Maintenance
Second Floor Fabric and Trim Store, Spreading, Cutting,CAD,
Sampling,, IT, HR, Finance and Accounts, PPC, R&D
Third Floor Canteen, Owner office, MD office, Conference Room,
Showroom,Merchandising Dpt
Space Calculations Floor Wise
Ground FloorArea (sq ft) 100 100 2700 2250 1050 1050
FirstFloorDepartment PPC IE Maintenance QA Sewing
Toilet+Lift+Stair+Dri nking Water Total Area Area 150 100 100 150
4875 1050
Department Reception Creche/Dispensary Washing Finishing &
Packing Warehouse Toilet+Lift+Stair+Drin king Water,Generator room
Total Area
7500
7500
Second FloorArea 900
Third FloorArea 800 450 450 450 375 250
Department Stores (Fabric, Trim and General) R&D Spreading
& Cutting HR, Finance & Accounts
Department Canteen Owner office
100 2625 120
MD office Conference Room Merchandising Dpt Showroom
Toilet+Lift+Stair+Drink 1050 ing Water Total Area 7500
Toilet+Lift+Stair+Drink 1050 ing Water Total Area 7500
Manpower RequirementMerchandising Sampling CAD Stores PPC
Spreading & Cutting IE Maintenance Sewing Finishing &
Packing 6 12 5 10 1 10 2 1 183 67
QA Washing IT HR Reception Canteen Security Sweeper Driver
Miscellaneous
1 37 2 2 1 5 3 7 5
WarehouseCapacity UtilizationStore capacity is kept such to
store 7 days fabric + 5 % extra To produce 3000 pcs of formal
trouser/day, the fabric required = 3000 x 2.4 meters = 7200 meters
Stores must have a capacity of (7 x 7200) +
(0.05 x 50400) = 50400 + 2520 = 52920 meters
So for storing, 52920 meters of fabric; 15 racks are required.
Every rack has 5 shelves, each of height 24 , length 72 and width
36 .
Each roll has 100-120 meters of fabric. Each rack can store 30
rolls, 6 rolls in a shelf. Average dimensions of a fabric roll:
Diameter: 12 Width: 60
Area Calculation of Departments
Merchandising Department375 150-200 Lux 6 6 12 6 1
All Floor Area dimensions are in square feet.
Floor Area Lighting Table Revolving Chair Chair Computer
Printer/Scanner/Photocopier
Sampling DepartmentFloor Area Lighting Spreading Table Table
Chair Computer 450 150-200 Lux 2 2 7 1
CAD DepartmentFloor Area Lighting Inspection Table Table
Revolving Chair Chair Computer 180 150-200 Lux 1 5 5 3 5
Stores DepartmentFloor Area Lighting Table Chair Computer 900
200-900 Lux 10 16 13
PPCFloor Area Lighting Table Chair Computer 100 150-200 Lux 1 3
1
Spreading and Cutting DepartmentFloor Area Lighting Spreading
& Cutting Table Fusing Table Bundling & Ticketing Table
Computer 2625 350-400 Lux 2 4 1 4 1 120 150-200 Lux 2 2 4 2
IE
Floor Area Lighting Table Revolving Chair Chair Computer
Equipments of Cutting RoomCapacity Calculation
Spreading Technique: Two way usually No. of plies in a lay= 80
plies approx. Lay length= 4-6 metres (max) No. of garments in a
lay= 240 pieces SAM for spreading + cutting + inspection for 1 lay=
75 For 240 pieces, it takes 90mins, For 1500 pieces, it takes 8
hours No. of pieces per day =3000
minutes
then tables= 3000/1500 = 2 tables
Equipment RequirementS . No. 1 2 3 4 5 6 Material/Utility Racks
Cutting Table Straight Knife Band Knife Bundling & Ticketing
Table Fusing Machine 36*60 36*96 36*36 Dimension 72*36*24 90*36
Number 10 3 3 1 2 2
Maintenance DepartmentFloor Area Lighting Table Chair Computer
Almirah Rack 100 250-300 Lux 1 4 1 2 2
Sewing DepartmentFloor Area Lighting Table Chair 4875 350-400
Lux 4 196
Production Floor AreaTotal Area of the Sewing Floor: (300 * 300)
sq. ft. = 9000 sq. ft. 1 Square Inch = 0.00694444444 Square Feet
Hence, 94.5 square feet Area for Material Handling Eton System :
length of system * width : 100 * 3 : 300 square feet Total
Production Floor area : (630.25 + 94.5 + 300 ) square feet =
(1024.75 + 50 % Free Space) = 1537.13 square feet Area Left for
conveyor system : Total Area + 100 % space : (1540 + 1540) : 3080
square feet To double the production in future extra area given to
increase production : 8500 square feet
Machine RequirementAllocated Machine Description SINGLE NEEDLE
LOCK STITCH 3 THREAD OVER LOCK MACHINE DOUBLE NEEDLE CHAIN STITCH
BAR TACKER SINGLE NEEDLE CHAIN STITCH 133 Dimensions of work area
(ft *ft) 1.5 * 1.5 Total Area
299.25 ft2
10 10 17 4
1 * 1.5 2*2 2.5 * 2 2*2
15 ft2 40 ft2 51 ft2 16 ft2
3 BLIND STITCH MACHINE DART MAKING MACHINE Total 2 174
1.5 *2
9 ft2
10 * 10
200 ft2 630.25 ft2
Area for Working Tables/machines
Allocated Machine Table Feeding Table In-Line Pressing Table
Inspection Work Stations Thread Trimming Table Label Creasing
Machine Pocket Creasing machine Total 3 15 3 4 3 3 21
Dimensions of work area (inch * inch) 36*36 60*60 96*36 96*36
30*30 30*30
Total Area
1296 3600 3456 3456 900 900 13608
Finishing and Packing DepartmentFloor Area Lighting Tables
Ironing Table Chair Computer Floor Area 350 Lux 24 10 4 1
QA Department LightingTable Revolving Chair Chair Computer
150-200 Lux 2 1 3 1
Washing DepartmentFloor Area Lighting Table Chair Computer
Inspection Table Washing Machine Tumble Dryer Hydroextractor 2700
350-400 Lux 12 16 1 4 3 2 2
IT DepartmentFloor Area Lighting Table Chair Computer 100
150-200 Lux 1 4 1
HR DepartmentFloor Area Lighting Table Chair Computer 120
150-200 Lux 1 3 1
ReceptionFloor Area Lighting Table Revolving Chair Sofa 100
150-200 Lux1 1 1 (seating capacity 10)
Owner's OfficeFloor Area Lighting Table Chair Sofa Computer 450
150-200 Lux 2 9 2 (each of capacity 5) 1
Conference RoomFloor Area Lighting Conference Table Revolving
Chair Chair Mannequins 450 150-200 Lux 1 2 18 8
Creche/DispensaryFloor Area Lighting Table Chair Computer 100
150-200 Lux 1 3 1
CanteenFloor Area Lighting Table Chair 800 150-200 Lux 70
280
Managing Directors CabinFloor Area Lighting Table Chair Computer
450 150-200 Lux 1 3 1
WashroomFloor Area Lighting Exhaust Fan 80 150-200 Lux 4
Generator RoomFloor Area Lighting 225 150-200 Lux
Boiler RoomFloor Area Lighting 100 150-200 Lux
Future Plans
The average floor height is taken as 15 feet, in case the
storage needs to be increased the height of racks can be increased.
4500 sq. Feet area left on the third floor for
expansion purpose.
Lighting
Office area: 200 lux (Fluorescent tube lights). Fabric store:
200 lux (normal) - 900 lux (inspection). Spreading & Cutting
area: 300 lux (0.6 lights/sq. ft.) Each sewing workstation has an
attached lamp. Sewing floor: 500-700 lux (0.6 lights/sq. ft.)
Washing area: 350-400 lux Finishing and packaging area: 350 lux
Few normal lighting fixtures are connected from the emergency
lighting distribution board.
Walls and ceilings are painted with light, pale, matt colors to
avoid reflection of light and glare.
Ventilation
Local exhaust ventilation systems. Ventilation systems like
suction and Fans, standing fans and windows in the Production
department. Special ventilation system in Washing area. Air
conditioners in the office area.
hoods, ducts, tubes.
Bibliography
http://www.hitex.co.in/ap_biz_textiles.pd Facility Layout and
Location, 2nd edition,by Francis McGinnis and White
hank You
