NATIONAL INSTITUTE OF FASHION TECHNOLOGY,

KANGRA

PLANT LAYOUT ASSIGNMENT – I

Submitted To: Submitted By:

Mr. Ashidh K Dishita Kaushik

Assistant Professor Divnoor Sharma

Mehul Sharma

Swaraj Patil
 ACKNOWLEDGEMENT
We would like to express our special thanks of gratitude to Mr. Ashidh K,
esteemed faculty of NIFT Kangra, who gave us this golden opportunity to do
this project, which also helped us in learning about new things for which we
are really grateful.

We also thank NIFT Kangra for giving us such an opportunity to explore more
with constant learning.

We have taken efforts in this project, however, it would have not been
possible without the kind support and help of many individuals and NIFT
institution. We would like to extend our sincere thanks to all of them.

We would also like to thank our parents and friends who helped us a lot in
finalizing this project within the limited frame of time.

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 INTRODUCTION
Plant layout is “a plan of an optimum arrangement of facilities including
personnel, operating equipment, storage space, material handling, equipment,
and all other supporting services along with the design of best structure to
contain all the facilities.”

A properly designed plant layout provides an ideal synergy among raw

materials, manufacturing processes, available space, and the output. It ensures
the efficient utilization of all available space and flexibility of arrangements and
manufacturing operations, streamline the movement of inventory in the entire
manufacturing plant without hitches or unnecessary delays, maintains
adequate turnover of materials, reduces lead time and cost of material
handling, and also ensure the workers safety, comfort and convenience.

TYPES OF PLANT LAYOUT

The modern manufacturing factories are designed to have advanced and

sophisticated plant layouts. The three basic types of layouts by which
production sections are organized in a plant, which are defined by the type of
workflow are process layout, product layout, fixed-position layout. The fourth
type of plant layout which has gained wide acceptance and often regarded as a
hybrid layout is called cellular layout.

A. Process Layout
B. Product Layout
C. Fixed-Position Layout
D. Cellular Layout

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BENEFITS OF PLANT LAYOUT

• Reduces Material Handling cost

• Provides enough production capacity
• Ensures work production without delay
• Proper and efficient utilization of available floor apace
• Utilization of labour efficiency
• Volume and product flexibility
• Ease of supervision and Control
• Employee safety and health
• Ease of Maintenance
• High machine or equipment utilization
• Improving Productivity
• Reduces Hazards to Personnel
• Minimizes Material Handling, Time, Cost and Ensures Convenience

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I. LOCATION

Hindupur, Andhra Pradesh on Map of India

13°43'27.0"N 77°30'03.2"E

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 II. FACTORS DETERMING THE DESIGNING OF PLANT LAYOUT

This Plant Layout has been designed to achieve a minimum amount of

materials handling, reduce bottlenecks, minimize machine interference, and
also enhance flexibility, throughput, safety, and employee’s morale. To achieve
optimum layout effectiveness when designing a plant layout, many factors of
operation need to be seriously considered.

Plant layouts should be designed to assist the business to attain its production
output at the shortest possible time, in order to ensure repeat patronage and
customer satisfaction.

Efficient utilization of space is the provision of sufficient space around the

machines and the traffic lanes, as well as ensuring that adequate spaces are
made available for storage points within the facility.

Safety – as the importance of safety in all human endeavours should not be

overemphasized, a good plant layout should be designed to function efficiently
and ensure that accidents and its causes are reduced to the barest minimum.

III. DIFFERENT DEPARTMENTS IN THE INDUSTRY

The different departments in the industry would be:

• Merchandising
• Sampling & Planning
• Fabric Store
• Trim Store
• CAD, CAM & Cutting Department
• Sewing Department
• Finishing Department
• Quality Assurance
• Industrial Engineering
• Maintenance Department
• HR & Admin Department
• IT Department
• Training Department
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IV. DEPARTMENTS:
• Merchandising Department:
Roles of Merchandising department includes:
o Communicating with buying team through the mail, and over the
phone for day to day update and new queries. Sometimes has to
discuss issues on the video conferences.

o Receiving new development orders from the buying team and take
the necessary actions accordingly.

o Meeting with vendors/suppliers and explaining new development

requirement to the vendor team.

o Making the T&A for the new orders to track the progress carefully.

o Making progress report for new season samples and production

orders.

o Collecting the garment samples at different stages (eg.-

development, proto, pre-production, production sample), trims &
accessories, fabric swatches, fabric hanger from vendors.

o Submission of garment samples and trims & accessories, fabric

swatches, fabric hanger to buying team through courier for
approval.

o Doing regular follow up with vendors for samples and other

submissions.

o Doing regular follow up with the buying team for approval and
comments.

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• Sampling & Planning Department:
It determines the approval of future orders from buyers and fetches
business for a garment manufacturing or export company. Sampling is
one of key elements of the pre-production processes in a garment
industry.

• Fabric Store:
The responsible person is Store Keeper The lift can carry a weight of up
to 100kg.The supplier brings the fabric/accessories to the gate and the
receipt is checked at the gate, this order is then counted and when
everything is confirmed to be right then the order is received and a
challan is issued.

• Trim Store:
The receiving of trims is same as fabric but the section that stocks trims
is different. Two shelves are joined together to form one stocking zone.
They were numbered sequentially. The shelves were further given Bin
No. in alphabetical order, and a Bin card is attached to the shelves which
hold all the stocking information about the accessories stored.

• CAD/CAM Cutting:
Computer aided design technology allows the creativity of the textiles
designers to run free and hence it is being used more and more in
industry. CAD/CAM is heavily used in textile industry as a designing
medium as well as a tool for production.

• Sewing:
In this section, each and every sewing machine and job of machine
operators should be inspected on a routine basis for identifying,
correcting, and controlling faults and maintaining the quality of
products. To ensure the quality of the product, quality control personnel
have to control quality in a different section in the garment industry,
which is directly or indirectly involved with the production.

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• Finishing:
o Thread Trimming
o Checking Garments
o Removing Stains
o Attaching Buttons
o Mending
o Ironing

• Quality Assurance:
In this section, each and every sewing machine and job of machine
operators should be inspected on a routine basis for identifying,
correcting, and controlling faults and maintaining the quality of
products. To ensure the quality of the product, quality control personnel
have to control quality in a different section in the garment industry,
which is directly or indirectly involved with the production.

• Industrial Engineering:
Industrial engineering (IE) plays a vital role in the apparel industry, that’s
why Industrial engineering job roles are very important for the garments
factory. When we need to reduce costs and improve work efficiency in
this competitive era, the apparel industry hires an Industrial Engineer to
do that job smartly. The apparel manufacturing industry is growing
quickly by applying IE in their facility.

• Maintenance:
The function of Maintenance Department:
o Inspection of sewing machines and other machinery in the factory,
repairing and up gradation.
o Maintaining and ensuring continuous power supply in the factory.
o Maintaining proper water supply, compressors, boilers etc.
o Planning, design and implement any kind of expansion of the
factory.
o Supply purified water for factory using and washing plant.
o Maintain WHO standard PH value for ETP (Effluent Treatment
Plant).

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 o Purchase of new machinery.
o Issuing of different spare parts and accessories according to the
production requirement.
o Housekeeping
o New constructions, paintings, and furnishing of the factory.

• HR & Admin:
HR and Compliance are a big part to make an efficient apparel industry.
The human resources compliance department deals with several rules,
employees legal rights, laws, and acts to consider, such as the Fair
Labour Standards Act, abuse and sexual harassment, anti-discrimination
laws, employee’s salary, and many more.

• IT Department:
IT contributes towards the maximizing the value of textile supply chain
through integrating supply chain operations within and outside the
organization and collaborating the acts of vendors and customers based
on shared forecasts.

• Training:
Training of employees also lead to better quality, lower costs &
organizational effectiveness. Training of employees helps to develop
necessary manpower with required skill & efficiency. Management finds
trained manpower suitable for personal growth & development.

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V. PRODUCT DETAILS

The products that will be made here are:

• Jacket
• Trouser

To produce these products, the plant will have 4 Jacket Lines and 4
Trouser Lines.

JACKET

TROUSER

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 VI. AREA
• Total Plot Area : 83952 sq. ft
• Total Usable Area : 55800 sq. ft

Which is divided into two separate parts i.e. Area-1 and Area-2

• Area-1 : 27000 sq. ft

• Area-2 : 28800 sq. ft

318 ft

135 ft 144 ft

Mezzanine Floor
16.5 ft

AREA 1 AREA 2

264 ft
200 ft

Mezzanine Floor

16 ft 23 ft

41 ft 25 ft DINING & KITCHEN

100 ft

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VII. DEPARTMENT WISE AREA ALLOCATION
1. AREA 1

This area is divided into 2 floors. First is Ground floor and the second is
Mezzanine floor.

• Ground Floor - This floor consists of:

o Cutting section for the products
o Waistband and lining for trouser section
o Fabric Store
o Trim Store
o Testing Lab for Fabric
o Sponging machine
o Crèche
o Training Centre
o Healthcare and inspection machines

• Mezzanine Floor – Departments include:

o HR
o CAD
o Sampling
o Pattern
o Administration
o Visiting room
o Waiting Area

2. AREA 2

This area is divided into 4 floors.

• Ground Floor –
o The Warehouse
o Packing Area
o Production Office

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 • First Floor – This floor will have:
o 2 Jacket lines
o 2 washrooms on either side of the floor
o 4 lifts in the corner

• Second Floor – This floor will have:

o Jacket Line 3
o Jacket Line 4
o 2 washroom and
o 4 lifts will be same as the previous floor

• Third Floor –
o 4 Trouser Lines with
o Preparatory for Trouser in the centre.
o 4 lift as the previous floor

VIII. MACHINERY REQUIREMENT

Total number of 730 machines would be required for all 4 of Jacket and
Trouser lines.

• Jacket Line – 500 machines

• Trouser Line - 230 machines

Types of Machines Required

• For Jacket Sewing Line:

o 3 Thread Overlock Machine
o 5 Thread Overlock Machine
o Auto Dart
o Auto Face
o Auto Single Head Sergeing
o Auto Twin Head Sergeing
o Auto Welt
o Auto Zig

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 o Bartack
o Blind Hem
o Button Attach
o Button Hole
o Crotch Attach
o Fusing Machine
o Flat Iron Table
o Hook & Bar Attach
o Multi Needle Chain Stitch
o Pintack Machine
o Pressing Machine
o Single Needle Chain Stitch
o Single Needle Edge Cutter
o Slider Machine
o Single Needle Lock Stitch Machine – Differential Feed
o Single Needle Lock Stitch Machine – Drop Feed
o Single Needle Lock Stitch Machine – Needle Feed
o Tendum Needle Chain Stitch
o Trimming Machine
o TRS Inseam Press
o TRS Side Seam Press
o Waistband Seam Presing

• For Trouser Sewing Line:

o Single Needle Lock Stitch – Drop Feed
o Hook & Bar Attach Machine
o Slider Machine
o Tendum Needle Chain Stitch Machine
o Bartacking Machine
o Auto Button Machine
o Button Sewer
o Blind Hem
o Pintacking Machine
o 3 Thread Overlock Machine
o 5 Thread Overlock Machine

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IX. MANPOWER REQUIRED:

S NO. DEPARTMENT NUMBER OF EMPLOYEES

1. Merchandising 3
2. Sampling & Planning 10
3. Fabric Store 10
4. Trim Store 10
5. CAD/CAM Cutting 21
6. Sewing 632
7. Finishing 50
8. Quality Assurance 60
9. Industrial Engineering 10
10. Maintenance 8
11. HR & Admin 5
12. IT 4
13. Training 4

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