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The main thing to concentrate here is the no.

of machines used to match the


capacity of the plant. And the good way among few is to decide optimum output
for one line and multiply it with total no. of lines.
Another thing to note here is:
For setting a factory of one sewing machine we
require 175sqft of area.

So from operation bulletin we know total no. of machines to be set up, say
500, so total area required will roughly be equal to 500*175= 87500sqft.

Generally the ratio of cutting: sewing: finishing is 1.1: 3.0:1.3.

Importance of aisles
 Plant space economy: - Whereas a small building 20 ft wide may have one
aisle 3 0r 6 ft wide, taking 25 to 30 percent of the available floor space, a
building 600ft wide may have three main aisles, down centre and sides 300ft
apart, each 10 ft wide, taking only 3 percent of the space, with secondary
aisles raising this to 10 to 12 percent given to aisles in large plant.

 There should usually be a main aisle through the centre of the building,
straight if at all possible, starting and ending at outside entrances.

Below are some points that we should consider on macro level before getting into
details of each section:-
1. Whole covered area should have two aisles:
a) Primary – It should be 6ft wide.
b) Secondary – It should be 4ft wide.

2. Temperature: Normal temperature should be between 18o C. to 29.5 o


C.
3. Noise Exposure: Employees should not be subjected to more than 85
decibels during the working hours.
4. Hazardous material storage: Oil, chemicals and other hazardous
and combustible materials to be stored in secured and ventilated
areas near the exterior wall of the building and the same disposed in
a safe and legal manner.
5. H.R. office should be accessible from both inside and outside the
factory and should be close to the swing floor.
6. Maintenance and machine storage room should be close to the
production floor.
7. Training room should be very far to the production floor cutting any
involvement of new joiner’s with factory operators.
8. Whenever possible one should avoid long sewing lines, racks as they
hinder the movement of man and material when moving from one
side to other. Maximum running length should be 88ft. However not
valid if we are using trolley’s.
9. No offices should be there on production floor.
10. No sitting arrangements should be there except for operators.

Now before moving further to planning of each independent section it is


important to note some points that are common to layout of each and every
section :-
1. There should be at least two exits per floor, on opposite sides of the
room.
2. Exit doors to have a minimum width of 36 inches. The floor on each
side of the exit door should be level on both sides.
3. The doors should open on the outside.
4. All exit routes must be unobstructed at all times. Exit to be within 200
ft of all employees
5. Employee workstations to be no more than 200 feet from an exit.
6. Fire extinguishers appropriate to the types of possible fires in the
various areas of the factory, to be regularly maintained and charged,
the date of their last inspection to be displayed, and to be mounted on
walls and columns throughout the factory so they are visible and
accessible to workers in all areas. Facility floor maximum travel
distance 75 feet and/or warehouse 1 per 1,000 sq ft
7. Fire extinguishers to be mounted on walls and columns, maximum
4’6” feet (1.5 meters) above ground.
8. Fire Extinguisher within 75 feet for any employee.
9. All emergency exits to be equipped with emergency lighting, and all
exit routes adequately lighted. Emergency lighting has to be provided
for up to 60 minutes.
10. Fire alarms should be placed on each floor and emergency lights
should be placed above exits and on the stairwells. The alarm should
be audible throughout the factory.

11. FIRST – AID


 The factory should have at least one well-stocked first aid kit
on every factory floor and trained specific staff in basic first
aid.
 The box should be located on the production floor and should
have at least one kit for every 100 workers. First aid kit
contents:
o Adhesive bandages Adhesive tape
o Ammonia inhalants Antiseptic wipes
o Burn cream Combine pad
o Disposable gloves Elastic bandages
o Eye wash First aid cream
o Flexible fabric bandages Forceps (tweezers)
o Instant cold packs Alcohol
o Basic medicines available over the counter without
prescription
 Factory should have procedures for dealing with serious
injuries that require medical treatment outside the factory.
 At least 1-2 supervisors or other personnel, per floor to be
trained in basic first aid or CPR procedures.

12. DRINKING WATER:


 There should be at least one purified drinking station for
each production floor, clearly marked.
 Employees should have free access to drinking water at all
times.

13. TOILETS:-
 There should be separate toilets for both genders depending
upon the number of employees of each gender.
 The toilet requirement to be as follows:

No of Minimum number of Water closets


Employees
1 to 15 1
16 to 35 2
36 to 55 3
56 to 80 4
81 to 110 5
111 to 150 6
Above 150 One additional fixture for each
additional 40 employees

 Gents urinal to be kept in same ratio, where male employees are


more.
 The restroom should be well lit and ventilated, cleaned regularly
and have clean running water, soap, toilet paper and hand
drying capabilities.
 The factory should have 1 sink per every 50 workers.
 Toilets to be easily accessible, with availability on each floor and
no unreasonable restrictions imposed on usage.
 Toilets to be provided with supplies of soap, towels, and toilet
paper (for Western style toilets)

 SEWAGE TREATMENT PLANT


STP’s are needed if there is no gutter line in the area to
temporarily store sewage waste, which later on can be taken by
municipality. No. of such plants depends upon the people in the
factory and the frequency of municipality sewage waste
collectors. However technical person should be contacted to
advice on same.

14. All stairways must have proper railings .Though it is good to use
ramp instead of stairs.

STARTING WITH LAYOUT


Now for the detailed setting of each department, let us assume that we are
planning to start a 500 m/c basic men’s shirts factory with daily production of
8000 shirts.
Now the first step will be calculation of area, we know for setting one sewing
machine:-
Area required is 175sqft, so for 500 m/c total area required will be
175*500=87,500sqft.
This will act as a check point that if a client wants to set up a 500 machine
factory the covered area should be 87,500sqft considering the LAND
COVERAGE AND FSI limits of the region.
Now after making the operation bulletin we would have zeroed upon the SAM of
a basic shirt, the next step is to reach the optimum output per line at 100%
efficiency after balancing.
Let’s say it come 800 shirts/8 hr/line. Now to match target output will have to set
10 lines producing 800 shirts/8hr/line, further it will also give us the no. of
operators, helpers, line feeders, supervisor & Q.C to run the line.
The fig. say is operator- 48, helper- 9, line feeder-2, Q.C. – 5 per line multiply it
with 10 to arrive at total figures.
On basis of this the layout of all departments is as follows:-
1. FABRIC STORE:
It should have access from outside as well as inside the factory. For store layout it
is very necessary to know the form in which we’ll receive the raw material.
If it is in form of rolls then the dimensions like Roll Diameter And Roll Length
will play crucial roll in deciding the storage system, usually racks, and hence the
layout.
Now daily production = 8000 shirts / day
Fabric consumption for solids = 1.65mt, checks = 2.2mt
Total fabric required will be = 8000*2(avg.) = 16000mts. * no. of days of
inventory planned (10) = 1, 60,000mts
Now roll diameter = 1ft, roll length (fabric width + handle) = 7 ft
Meters of fabric on roll = 90- 150mt (average = 100)
So, total rolls required per day is = 160, total rolls required for 10 days = 1600
Volume available on truck = 960 cu.mts. (approx.)
Total trucks required to bring required rolls (1600) = 10. This means at least one
truck will be there in the factory each day.
So, proper space should be there outside the store for movement of at least two
trucks simultaneously.
And entry to store should be big for easy unloading of raw material through trucks
directly and proper unloading system should be in place like slides, trolleys etc.

Now the store should have following divisions:-


a) Unloading area:- The place should have rack space equal to the %
fabric checking we want to happen i.e. if we want 10% out of total
received fabric to be inspected then the rack space should be equal
to around 20% of daily received fabric which in this case is
1600mts = 30 rolls .

b) Checking area: - It should include space for checking machines or


tables in case of manual checking, however the no. of tables and
machines can be calculated by dividing the total length to be
inspected by checking speed.

c) Main storage area: - After unloading the rolls should move to this
place after keeping aside 10% of total rolls aside for checking in
unloading area racks.
And it should have an arrangement of racks for storing fabric
equal to the inventory planned i.e. for 10 days.
Maximum height of racks should not be more than 8 ft and running
length should not be more than 88 ft. And rack should be slightly
above the floor to avoid excessive bending, but it is advisable to use
vertical space with proper arrangement of unloading it from height.
Now if we use height of racks as 8ft then leaving ground clearance
& space between each roll we can easily place 5 rolls in one column
and in length of 88 ft we can easily place 60 such columns.
That means 300 rolls can be placed in one such arrangement and
we need around 6 such arrangements to accommodate 1600 rolls of
inventory.

d) Stock lot area: - This can be utilized to store any extra/left over
fabric from the current lot. The area for this depends upon the
space available after allocating space to above mention.
2. CUTTING
Pieces to be cut daily = daily production = 8000 + 5% extra = 8500 shirts

Average consumption per shirt= 2mt, so total fabric required to be cut =


17000mts.

From above we are sure that we have to plan a cutting room with capacity
to cut 8500 shirts.

Now the next step should be to decide what marker we are planning to do
which is directly proportional to:-
o The length of table required to lay the fabric e.g. a six way marker
will require to lay fabric up to 12mt on one table.
o Space available in the cutting room i.e. if there is no room to put a
12mt table then we can’t plan a six way marker.
Let’s say we decided to do six way markers, now the calculations are as
follows:-
Total garment to be cut in one lay = 6
No. of plies = 150
Total garments cut in one lay = 900
The important thing to consider is the ratio of solids to check, say it is
50:50,
Spreading of one lay of solids with 150 plies on a six way marker will take
around 2 hrs
Cutting of same lay will take around 1 hr if done with straight knife by two
cutters.
For solids:-
Further calculations of no. of tables required will depend on the cutting
time i.e. if in 1 hr one can cut 900 garments then in 5 hrs the pieces cut with
six way marker will be= 4500.
So for cutting to happen continuously, the cutter should always have the
spread ready for next cutting for this to happen we should have at max 3
spreading tables as it takes 2 hrs to lay 150 plies on a six way marker.
For checks:-
Spreading time for a lay of 150 plies on a six way marker = 2.5hrs
Cutting time for same when doing block cutting = 1 hr (with one cutter)
So here also we require 3 spreading tables.
Total spreading tables = 6
Cutters = 3
Spreaders = 12(two per table)
Straight knife = 4

From here the cut pieces will move to band knife however checks will be
relayed before band knife cutting.
SAM of relaying one whole garment by one operator = 3 minutes
Total time to relay 4250 pieces = 25500 which translates into 27 relay
helpers.
Time to cut relayed pieces on band knife = 18 seconds
So, total no. of band knives required = 6
Relay helpers = 27
Band knife = 6
Relaying tables = 7 of 8ft*6ft
So, area of cutting room depends upon the area required to place all these
tables, plus given below:-
Fusing machine (large bed) = 2 for collar, cuff, flap & collar band.
Roller fusing machine = 2 for front placket.
Dye cutting machine.
Area of these can be acquired from catalogues given by manufacturers.

However when we are using automatic cutting and spreading, the


calculations done above will depend again on the cutting &spreading speed
which further can be your criteria in choosing these machines. The
calculations done above can help in doing for your investment.

However the aisles running in cutting room between tables will follow the
specification:-
4ft for man movement space + 3ft for trolley.
Cutting room should also have space for storing cut parts equal to the days of
inventory planned. Calculations for that are already explained in store
section.

3. SEWING
a) For setting sewing room the basic requirement is no. of
machines, helper & checking tables

And the operation bulletin will give these figures. Say for 500 machine
shirt’s factory the figures above mentioned are:-
Machine- 48, helper table- 9, checking tables – 5

b) Now next step should be what material movement system is


planned.

I. For over head system – distance between two machines and two
lines will depend upon the specification given by the vendor of such
systems.
II. For centre table –
i. Width of table should be – 15 inches for preparatory & 24
inches for assembly as assembly involves handling of larger
parts.
ii. Distance between two machines in a line should be 22
inches with or without work aids i.e. space for entering the
workstation should be 22 inches.
iii. Distance between two lines should be 4 ft i.e. straight line
distance from the end of maximum width machine in a line
to the start of another machine in another line.
III. For trolley movement –
i. Instead of centre table the space will be used for movements
of trolleys with in the line so this space should be around 8-
10 ft.
ii. Distance between two lines should be 6ft for easier
movement in between lines.
Note: - For any of the system we should avoid long lines usually not more than 88ft
because it results in increased movement from one side to another, so there should
be break after 88ft.
c) The placement of machines should be such that one side of operator
should always be free for movement i.e. when using centre table the
operators either side of table should face each other as this way they
will always be disposing to their right side which has centre table.
d) Two pigeon hole should be placed one at start of line before
preparatory to store cut parts to load to preparatory and one after
preparatory & before assembly to load parts to assembly.
e) Attention should be laid on fact that flow of work should be smooth in
the line with proper demarcation as to how a bundle will move in the
line.

4. FINISHING
The layout of finishing depends upon the product being produced.

IF THERE IS NO WASHING THEN WE CAN HAVE A PACKED POLY


BAG OUTPUT FROM END OF SEWING LINE AS IN THIS CASE THERE
IS NO NEED TO SORT THE PIECES SHADE AND SIZE WISE.

FOR WASHING, THEN, ALL THESE PROCESSES SHOULD BE A PART


OF THE FINISHING AREA AND SPACE SHOULD ALSO BE
ALLOCATED TO SORTING BEFORE CARTON PACKING.
EFFLUENT TREATMENT PLANT – If washing is in house then ETP
can’t be dispensed with though apparel parks have centralized ETP’s but it
is critical to check their capacity. The main purpose of ETP is to recycle
chemical rich water so that it can be used for gardening, mopping, cleaning,
toilets etc.

Actually the need to have an ETP depend upon the local laws i.e. whether
the factory should have:-
 ZERO DISCHARGE.
 % DISCHARGE ALLOWED.

The last two steps will be FINAL AUDIT & CARTON PACKING both should
be in finishing room whatever the case may be.

Now if followed above calculation and steps the area required for major
operations in a garment factory can be calculated, however for proper
functioning space should also be allocated to below departments:-
5. Internal Laboratory
6. CAD room
7. Cutting room waste storage
8. AAMT training center
9. Maintenance room
10. Machine storage
11. Provision for Metal disposal
12. Office space for 25-30 people and Sample room
13. Compressor room, Diesel storage, Generator area, Parking area
14. Staff dining room, Medical room, crèche.
15. Worker’s canteen:-
The total area required for setting up canteen hinges on the information
whether the canteen will be having cooking facility or not.
Area required without cooking. – 10/15sqft per person.
Area required with coking. – 25sqft per person

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