FACTORY LAYOUT

BASEMENT
1. Pattern Making
2. Industrial Engineering
3. CAD
4. Cutting Department
5. Relaxation
6. Fabric Store
GROUND FLOOR
1. Dry Finishing
2. Sewing Floor
FIRST FLOOR
1. Admin Area
2. Washing Area
3. Wet Finishing
4. Warehouse
5. Ironing and Packing
TERRACE
1. Canteen
2. Boiler Room
PROCESS FLOW CHART

Unloading From the Truck

Inspection

Loading into the Racks

Relaxation

Spreading

Cutting

Ticketing And Numbering

Panel Checking

Bundling

Sewing

Dry Finishing

Wet Finishing

Washing

Drying

Final Inspection

Ironing

Packing

Warehouse

Dispatch
 WORKFORCE IN DIFFERENT DEPARTMENT
Administrative
Department No. of Employees
Executive 2
Accounts and Finance 2
Human Resource 3
Logistics 2
PPC 2
IE 3
CAD 2
Maintenance 2
TOTAL 18

Store Department
Store Manager 1
Checker 2
Workers/ Helpers 4
TOTAL 7

Cutting Department
Production Manager
Pattern Master
Cutting Master
Workers/ Helpers
TOTAL

Sewing Department
Production Manager

Supervisor

Quality Checker

Workers/ Helpers

TOTAL

Finishing Department
Executives 3

Supervisor (Dry Finishing) 1

Supervisor (Wet Finishing) 1

Supervisor (Washing) 1
Supervisor (Drying) 1

Supervisor (Ironing) 1
Supervisor (Packing) 1

Supervisor (Warehouse) 1
Worker/ Supervisor
 CALCULATION FOR PLANT LAYOUT

Plant Size:
o Length: 150 ft
o Breadth: 80 ft
FSI: 1:1.25
Ground Coverage: 60%
Front Margin: 15 ft
Side Margin: 8 ft
Total Space: 150*80 = 12000
FSI: 1.25* 12000= 15000
Ground Coverage = 7680 ft^2
Available Floor Space: 60* 120 = 7200 ft^2

SPACE ALLOCATION FOR EACH DEPARTMENT EACH FLOOR

DEPARTMENTS Area (in sq ft ) Total No. of Lights

Pattern Making 187 sq ft 6
IE 32 sq ft 1
CAD 150 sq ft 5
Cutting Department 900 sq ft 30
Fabric Store 4200 sq ft 135
Unloading Area
Dry Finishing 750 sq ft 25
Sewing 5700 sq ft 190
Admin Area 544 sq ft 18
Washing 1560 sq ft 82
Wet Finishing 2220 sq ft 74
Ironing and Packing 656 sq ft 22
Warehouse 1804 sq ft 60
Canteen 4200 sq ft 135
Boiler 750 sq ft 25
Workers Washroom 580 sq ft 19
Executive Washroom 36 sq ft 1
For the air ventilation Central air conditioning is one of the most convenient and energy-efficient
ways to get relief from the hot, humid summer weather in Bhubaneswar.

WASHROOM
Three washrooms each for men and women and one washroom in admin area
DRINKING WATER COOLERS
Enough to provide 4.5 L per person per day
FIRE EXTINGUISHERS
One on each pillar
FIRE EXITS
One on each floor. It is one way and is used only in case of a fire or fire drill
LIFT
One material Lifts per floor of 64 sq ft area
STAIRCASE
One Staircase per floor of 72 sq ft area

ASSUMPTIONS
Layout: Product Specific
Product: Denim Jeans
Available Time: 480 min
No. of days working: 6 days
No. of machines: 140
SAM of the denim: 24 mins
No. of Sewing Lines: 3
Output Per day at 60% efficiency: 2000 pcs
No. of days working in a month: 25
Output per month: 50000
FABRIC STORE:
Order Quantity: 40000 mts
Fabric Required: 40000* 1.3= 52000 mts
Maximum store Capacity: 54000 mts
10% inspection, 5200 m will be inspected i.e., 65 rolls
480 mins will be required to check 5200 m
Diameter of roll: 0.5 ft
Fabric Roll: 80 m
One Inspection machine in the fabric store for inspection
Average consumption per garment: 1.6 m
Per day fabric consumption: 3500m
Inventory: 20 days
Mtr/day: 2000* 1.3= 2600
=2600 * (5%)
=2730 approx
For stock of 20 days= 20*2730
= 54600 mts
Length= Rolls required = 683 rolls (80 mts/ roll)
Width= 700 rolls
Racks: 6ft / 6ft , 17 rolls can be accommodated
So, total 42 racks are required
Area= 55 length * 54 ft= 2970 sq ft
Occupied area= 36* 42 = 1512 sq ft

CUTTING ROOM:
Available Time: 480 mins
Utilization: 75%
Efficiency: 60%
Average Consumption: 1.6mts
Marker Length: 10.4 mts
Layer Height: 5 inch
No. sizes in a marker: 8 way marker
No. of layer: 65
Total garment in a lay: 520
Bundle size: 20
No. of lays required per day: 5
Spreading table length: 12mts
No. of spreading table required: 2
No. of spreader allotted: 1
No. of spreading team: 4
No. of required cutter: 5
No. of cutter allotted: 3
Total area required: 900 sq ft

SEWING ROOM:
SAM of the denim: 24 mins
No. of workstations: 138
No. of sewing line: 3
Total m/c: 160
Total area required: 5700 sq ft

WASHING ROOM:
140 kg Washing Machine = 3
Tumble drier
Drier
M/c area= 36 sq ft
Operational are: 120 sq ft
Total area required: 1560 sq ft

FINISHING ROOM:
Finishing SAM: 5 mins
Machines Requies:
Thread Trimmer
Press Fold
 Checking Tables
Sand Blasting
PP spray
Hydro- Extractor
Chevron
Laser Technique machine
Total required Area: 3074 sq ft

CANTEEN:
No. of Employees: 350
Canteen is with the cooking part
So canteen area is 4200 sq ft
All employees can accommodate together