SUBMITTED BYNAVNEET KUMAR(10)

SHARVARI SHANKAR (20)

AQUARELLE INDIA PVT LTD, BANGALORE

ABOUT THE COMPANY

Aquarelle Casual Shirt is an integral part of the AQUARELLE GROUP. This
company only deals with the production of casual shirts. It has two units in
India. Both the unitsare functional in Bangalore. Unit 1 is located in Jigni
Industrial area and Unit 2 is at Bannerghatta. The prime motive of the
company is customer satisfaction and the quality of the productMore than
20 styles are produced per month. The efficiency of this unit is more than
75% and is growing with time. This unit produces shirts for Lee, Levis,
Wrangler, Jack and Jones, Celio, Dustin, Ben Sherman etc. The main
customer is Levis with 40% share of the total order quantity. Jack & Jones
has emerged to be a competitor to Levis as far as order quantity is
concerned. The company has been appreciated by top brands in quality
terms and is being recognized as a long run player.

Location:
Bangalore , KARNATAKA

INDUSTRIAL SHED
The Structure is Framed and has a proper steel rooftop with triangular
trusses as the support and a well illuminated and ventilated work premise
of this industry.

STRUCTURE OF BUILDING
Introduction
Building structure used by the apparel industry to store raw materials or
for also production floor, manufacturing products of the industry is known
as an industrial building. The buildings are used for production shop floor,
warehouses etc. These building require large and clear areas unobstructed
by the columns. The large floor area provides sufficient flexibility and
facility for later change in the production layout without major building
alterations. The industrial buildings are constructed with adequate
headroom for the use of an overhead travelling crane.

Building construction
Typically the bays in the building have frames spanning the width direction.
Several such frames are arranged at suitable spacing to get the required

length .Depending upon the requirement; several bays may be constructed

adjoining each other. The choice of structural configuration depends upon the
span between the rows of columns, the head room or clearance required the
nature of roofing material and type of lighting. Gable frames was used as span is
large then buildings with trusses are used at the production floor.
The building consists of various sections:

Cutting Section
Sub assembly section
Assembly Section
Finishing Section

Floor
Different types of floor are required in any factory from their use
consideration such as production, workshop, stores, amenities, and
administration. The service condition will vary widely in these areas, so
different floors types are required. Industrial floors shall have sufficient
resistance to abrasion, impact, acid action and temperatures depending
on the type of activity carried out. High strength and high performance
concretes can satisfy most of these requirements economically and is the
most common material used. Foundation for vibrating machinery (such as
reciprocating and high speed rotating machinery) should be placed upon
rock or firm ground and it should be separated from adjacent floor to
avoid vibrations.

Roof
The type of roof covering, its insulating value, acoustical properties, the
appearance from inner side, the weight and the maintenance are the
various factors, which are given consideration while designing the roof
system. Brittle sheeting such as asbestos, corrugated and Trafford cement
sheets or ductile sheeting such as galvanized iron corrugated or profiled
sheets are used as the roof covering material.
Following table has building space detailsCUTTING DEPARTMENT AREA

AREA

Spreading/Cutting

1616

Ticketing

256

Relaying/Fusing Edge Trimming and

Front placket Kansai
Passage

2185

Total Area

7403

2813

SEWING LINE A

AREA

Sewing and End line Checking

3680

Passage

2220

Total Area

6350

SEWING LINE A

AREA

Sewing and End line Checking

4245

Passage

2090.88

Total Area

6336

SEWING ASSEMBLY

AREA

Sewing and End line Cheeking

3384

Passage

2857.92

Total Area

7328

FINISHING

AREA

Trim and Exam

700

Thread Sucker

190

Passage

2365.92

Boiler

306

Total Area

6572

ADMINISTRATION
Administration

AREA
4037

Production

33989

Store

3518

Parking

2665

Total Area

17326

STATEMENT OF AREA WRT NUMBER OF WORKERS IN EACH

DEPARTMENT
Cutting -94:7403
Sewing 545:20014
Finishing- 185: 6572

TOTAL CONSTRUCTION AREA OF FACTORY=78205 sq ft.

UNDERSTANDING INTERIOR SPACE

AIR CIRCULATION
Air conditioning is the process of treating air also as to control
simultaneously its temperature, humidity, cleanliness and distribution to
meet the requirements of "conditioned space". An air conditioning system
may use heating, cooling, humidifying, de-humidifying and filtering units
of combination of these depending upon the outside weather. At aquarelle
all codes for industrial ventilation is used.
Air conditioning plants are installed to maintain correct ambient condition
for spinning and weaving process to work smoothly. Norms of temperature
and relative humidity for Garment industries are established through
controlled experiments in laboratories and mills.
Engineering controls at aquarelle include:
The use of increased general ventilation throughout the factory by
opening windows, by ensuring that doors etc are not blocked;
The use of spot cooling by the use of fans to reduce the temperature in
certain sections of the factory.
The use of local exhaust ventilation systems in hot spots such as the
ironing section to directly remove the heat as close to the source of the
heat as possible

 The use of fan at properly.

Whatever method is used to reduce workplace temperature, it is
important that adequate supplies of drinks are made available to workers.

VENTILATION
Ventilation of industrial buildings is also important. Ventilation will be used
for removal of heat, elimination of dust, used air and its replacement by
clean fresh air. It can be done by means of natural forces such as aeration
or by mechanical equipment such as fans. The large height of the roof
may be used advantageously by providing low level inlets and high level
outlets for air. It is not only essential to provide a comfortable temperature
inside the factory, you must ensure;
An adequate supply of fresh air;
The removal of stale air; and
The prevention of any build up of contaminants (dust, spot cleaning chemicals,
etc).

It is important not to confuse ventilation and air circulation inside the

factory. What we tend to see inside many garment factories is air
circulation, namely moving the air around inside the factory without
renewing it with fresh air from outside. In the case of air circulation, fans
are placed near workers.
Measures Taken at aquarelle-

General ventilation by allowing the free flow of air through the factory
from one side to the other referred to as horizontal air-flow. This can be
achieved by opening doors and windows and putting more air bricks in the
walls to take advantage of any prevailing wind. However it is all to
common to find doors and windows etc., locked for security reasons or
blocked with excess stock or boxes of finished goods awaiting export. As a
result, ventilation is limited.
Ensure that the air-flow to and from fans is not blocked.
Proper Exhaust at proper distance

NOISE DISTRIBUTION
Noise is probably one of the most widespread and underestimated of
industrial hazards. High noise levels are experienced in many parts of the

garment industry, especially in those factories that have weaving

machines. Not all the sound we hear is classed as noise after all, we all
enjoy different types of music. We experience sound in different ways.
What some people find enjoyable and stimulating, others may find noisy
and unpleasant. Thus, the perception of what is sound or noise is
personal, however it is clear that workers can have their hearing
damaged, in some cases permanently, if the sound/noise levels are too
high. Most people define noise as unwanted or unpleasant sound.
Ear plugs are worn in the internal part of the ear and they are made of a
variety of materials including rubber, mouldable foam, coated plastic or
any other material that will fit tightly in the ear). Ear plugs are the least
desirable type of hearing protection from an efficiency and hygiene
perspective. On no account should workers be encouraged to stuff cotton
wool in their ears to act as some form of ear plug all that happens is that
some of the cotton wool gets left behind when the plug is removed and
causes an ear infection. From a health and safety perspective, ear muffs
are more efficient than ear plugs providing they are worn correctly. They
must fit over the whole ear (not press the ear flap against the side of the
head) and seal the ear from the sound waves. Workers who have beards
or wear glasses have difficulty in getting a tight seal around the ear.

Noise distribution measures

Purchase quieter machines;

Enclose entire machines or particularly noisy parts of machines with
soundproof casing. Remember that no part of the enclosure should in
contact with the machine otherwise the sound waves will be transferred
through to the outside.
The number of holes in the enclosure (access points, holes for wires,
piping etc.) should be minimised and fitted with rubber gaskets where
possible;
Regularly service and maintain machines;
Replace worn or defective machine parts;
Reduce the vibration in component parts and casings. Ensure that the
machines are mounted correctly on rubber mats or other damping
material and that mounting bolts are secured tightly;
Replace metal parts with others made of sound absorbing materials e.g.
plastic or heavy duty rubber;

Vibration Combined with noise

Many machines in garment factories are mounted incorrectly or are in

need of servicing and, as a result, vibrate and cause a noise problem. As
the machines vibrate, they transmit their vibrations to the workers. The
part of the body affected depends upon which part of the body is in
contact with the machine. These vibrations can injure muscles, joints and,
in particular, the blood vessels. For example, workers whose hands and
fingers are in contact with machines which vibrate can suffer from a
condition known as Vibration White Finger. The solution rests primarily
with reducing the vibration from the machine.

LIGHTING
From the workers perspective, poor lighting at work can lead to eye
strain, fatigue, headaches, stress and accidents. On the other hand, too
much light can also cause health and safety problems such as glare
headaches and stress. Both can lead to mistakes at work, poor quality and
low productivity. Various studies suggest that good lighting at the
workplace pays dividends in terms of improved productivity and a
reduction in errors. Improvements in lighting do not necessarily mean that
you need more lights and therefore use more electricity it is often a case
of making better use of existing lights; making sure that all lights are
clean and in good condition; and that lights are positioned correctly for
each task. It is also a case of making the best use of natural light. It may
sound like common sense, but it is essential for the light to focus on the
work in hand and not directly, or indirectly in to the workers eyes. The
more detailed the task, the more light that is needed for the workers to
carry out the job efficiently

Measures taken to control lighting

Make full use of daylight in the factory;

Choose appropriate visual backgrounds for walls, ceilings etc;
Find the best place for the light source to avoid glare etc;
Use the most appropriate lighting devices and fixtures;
Avoid shadows;
Ensure regular cleaning and maintenance.

ELECTRIFICATION
Electrification is done to ensure equipped and effective energy
consumption at the plant.
Electrification is designed according , With the systematization of production,
distribution and consumption of energy in the plant ,critical points for energy
savings at each level and area.

General overview:
In Garment Sector, Planned electrification is necessary as:

Energy saving potential for garment industry is up to 30%

Energy cost accounts for 10-15% of production cost whereas energy waste
is up 20-32% due to old technologies and outdated energy management
systems.
The sewing Saver also has a lot of potential as sewing is main operation at
the shopfloor

Measures taken for electrification at aquarelle

Distribution on medium / low voltage of electricity to all consumers,

whether for driving force, control, lighting or thermal output;
Production and distribution of compressed air both for production
equipment and cleaning;

Production and distribution of steam / hot water for both production

equipment and air conditioning;
Production and distribution of conditioned air to both comfort and the
upkeep of optimal environmental conditions for production;
Distribution of fuel for direct burning on production equipment;
Production of light for use in both productive and non-productive areas;

POWER REQUIREMENT ON THE PRODUCTION FLOOR

Departme
nt

Departmen
tal
breakup
based on
activity

Sewing

FAN

Nos

Watt

Lux

12

250

800

36

600

Unloading

36

800

Ticketing

250

28

800

Bundling

150

36

800

Allies

200

36

800

400

36

800

Factory
surroundi
ng
Fabric
Store
Cutting

LIGHT

EXHAUST

Nos

WATT

Nos

WATT

42

70

250

80

70

160

Finishing

Carton
Packing
Utility
area

Thread
cutting
Ironing

150

28

800

48

70

36

28

800

90

Folding

24

28

800

Tagging

12

28

800

Bagging

28

800

20

28

800

10

70

Washroom

20

28

600

Canteen

15

28

600

Boiler Room

36

600

Electric
room

36

600

90

70

160

160

50

16

CONCLUSIONAt aquarelle, Layout and plant is designed efficiently

,hence
Well Ventilated Plant
Well Electrified and planned energy consumption
Design of the industry is such that it saves upto 30 % of
energy
Spacious and well illuminated work space.
Ergonomically built work stations