PLANT LAYOUT

Submitted by:
Sarthak Jain
End Term Jury Submission Sai Sujay J.K.
Plant Location

Vietnam
 •Minimal labour cost
•Highly skilled workforce
•Good transportation facility
•Good lead time management
Advantages •Business friendly foreign investment law
•Available worker and land
•Strong infrastructure
•Good variety of products
 PRODUCT

Sweat shirt is one of the most

common manufacturing items in the
apparel industry. Normally, Sweat
shirt is made from fleece fabric. It
has higher GSM (Gram per square)
comparable to the other’s knitted
item and the price is also higher than
other’s item. As we know, the fabric
cost takes almost 50 % to 70% of
total manufacturing cost of the
garment.
Men’s full sleeve standard size Sweat shirt

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Therefore the fabric store includes a testing lab and also the trim store along with
a loading and unloading dock for the ease of transporting fabric rolls and trim
cartons. The dock is at a level to match the height of the loading truck so that it is
convenient to carry out loading and/or unloading of fabric rolls. The fabric store
has two exits/entrances in the form of rolling shutter, one leads to the spreading
and cutting department for the movement of material and the other leads to the
various departments situated beside it.

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 Fabric Measurement Consumption
To measure the fabric consumption sweat shirt, we calculate fabric consumption by using one of the
above formulas.

Formula - 01: In centimetre Formula - 02: In Inch

(Body Length + Sleeve Length + Seam (Body Length + Sleeve Length + Seam
Allowance) x (½ Chest + Seam Allowance) Allowance) x (½ Chest + Seam Allowance)
x 2 x GSM / 10,000 x 1000 + 10% x 2 x GSM / 1550 x1000 + 10% (Wastage
(Wastage and extra cutting) x Doz. + TF and extra cutting) x Doz. + TF (Trim
(Trim Fabric) Fabric)
If garment measurement uses in Inch
Item: Knitted fleece fabric, garment components are front, back and long sleeves. Fabric GSM (Gram
per square) is 260.
As per above measurement of this style, the body fabric consumption is;
= (BL + SL) x ½ Chest x 2 x GSM / 1550 x 1000 + 10% Wastage x Doz.
= (24.05 + 22.24) x 18.30 x 2 x 260 / 1550 x 1000 + 10%x 12
= 5.2 kg / Doz. RIB GSM is 340

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The following machines and equipment are required for different departments.

Fabric & Trim Stores

Equipment Dimensions

Fabric Rack (LxBxH) 10 feet X 6 feet X 8 feet

Fabric inspection area 16 feet X 15 feet

Office room 14 feet X 14 feet

Fabric and trim store area 65 feet X 41 feet

 Cutting room

◉ Per day quantity is 2200 + 3% extra = 2266

◉ Average consumption is 1.13 mtr so total fabric
required = 2560 meters
◉ 2 way marker so the lay up to table will be 4
meters.
◉ No. of plies = 125
◉ Spreading and cutting = 3 hours
◉ So we need 4 cutting tables
Cutting Room
No of Machines and Table:

Equipment Dimensions No. of equipment

Trolley 6 feet X 4 feet 4

Spreading & cutting table 26 feet X 5 feet 4

Band knife - 3
Cut part and fabric
12 feet X 4 feet 2
Storage rack
CAD plotter and digitizer - 1
Cutting and spreading
65 feet X 38 feet -
room area
SEWING AREA CALCULATION

Total number of pieces: 60000 pieces Machines in 1 line = 12

Number produced per day: 2200 pieces Total machines required= 96

Produced per day with 3% extra: 2266 pieces Number of line required to finish
283 sweatshirts per hour:
Total working days in a month: 26 days 96/12= 8 lines

Total working hours per day: 8 hours 8 lines contain: 96 machines

Number of sweatshirts produced per hour: Workstation space per machine: 4*4
283
The system used: Progressive unit
SAM of sweatshirt : 19.57 min bundle system
1 line can produce 35 sweatshirts per hour
Operation Bulletin of a Hoodie

S.No Operation M/C

1. Shoulder Joining 4 Thread Overlock M/C
2. Neck Rib Tack With Body SNLS M/C
3. Neck Rib Joining 4 Thread Overlock M/C
4. Main Label Attach SNLS M/C
5. Sleeve Cuff Attach 4 Thread Overlock M/C
6. Sleeve Joining 4 Thread Overlock M/C
7. Sleeve Close & Open Tack 4 Thread Overlock M/C
8. Attach Front Bottom waist band SNLS M/C
9. Attach Back Bottom waist band SNLS M/C
10. Side Seam 4 Thread Overlock M/C
11. Edge Neatening 4 Thread Overlock M/C
12. Attach Care Label SNLS M/C
Sewing Room: Inspection
Table
No of Machines and Table:
4T OL 4T OL
Equipment Dimensions No. of equipment
SNLS SNLS
SNLS 4 feet X 4 feet 40

4T OLAuto 4 feet X 4 feet 56 4T OL SNLS

Operator Stool 1 feet X 1 feet 120

SNLS 4T OL
Trimming ,
inspection 5 feet X 2 feet 8 4T OL 4T OL
table
4T OL SNLS
Sewing area 60 feet X 52 feet -
BRIEF DETAILS OF ALL FLOORS

Ground floor
Entrance (biometric machine), HR Room
Fabric Storage department
Trims Storage department
Final Garment Packing dept.
Creche
(according to buyer requirements, Store finished garments in carton boxes along with metal detector)

1st Floor
Samplings section (6-7 sewing machines)
Spreading and Cutting department
Bundling and ticketing table-2Band knife table
Checking table
Cad Room (with table, monitor & chair)
(Cut part storing racks with no gap from the wall & also no gap on sides)
2nd Floor
Sewing and Inspection Department (Piece wise checking)
Initial packing ( that is packing individual garment in plastic
wrapper)
Maintenance Department
IE and supervisor office

3rd Floor
Cafeteria Mess section
(Long tables, table for plates & cups & serving area along
with hand wash Also cafe where workers can order & eat
food)
Solar Panels installation
Terrace
Solar Panels installation
 Groundfloor

Area: 140’ x 175’ = 24,500 sq.ft

Fabric Store Area: 101’ x 62’ = 6262 sq.ft

Fire Exit: 28’ x 10’ = 280 sq.ft

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 1st Floor
Cutting Room 101’ x 62’ =
Area: 6262 sq.ft
Fire Exit: 28’ x 10’ = 280
sq.ft

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 2nd Floor

Sewing Room 101’ x 62’=

Area: 6262 sq.ft
Fire Exit: 28’ x 10’ = 280
sq.ft

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 3rd Floor
Canteen Area: 101’ x 62’ =
6262 sq.ft
Fire Exit: 28’ x 10’ = 280
sq.ft

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 Terrace
Terrace Area: 101’ x 62’=
6262 sq.ft
Fire Exit: 28’ x 10’ = 280
sq.ft

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Electrical layout

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Sustainable Green industry layout Plan

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 SUSTAINABLE CONSTRUCTION

◉ Adoption of materials and products in buildings and

construction that will require less use of natural resources and
increase the reusability of such materials.
◉ Sustainable construction also enhances the resilience of the
industry as such materials are readily available in the world
market.
◉ Steel, other metals, glass and prefabricated parts using
combinations of these, as well as recyclable substitutes for
concrete are examples of sustainable materials and products.

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 SUSTAINABLE RAW MATERIAL FOR CONSTRUCTION

◉ To reduce the non-renewable energy (energy expended to process

and transport materials) in the building, the main walls are made of
compressed stabilized-earth block manufactured forty kilometres
from the site.
◉ The machine moulded blocks are made of local soil, sand, and
locally manufactured cement. The large size of the blocks minimizes
mortar joints.
◉ The walls require no plaster finish; they are simply sealed with
varnish on the interior and exterior. Polycarbonate sheets on roof.
◉ Glass strips, running continuously across the breadth of the roof at
regular intervals.

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◉ Windows use imported plate glass and aluminum frames.
◉ Floor finishes include polished concrete tile, rendered
and cut concrete, tile, and wood.
◉ Bamboo is used for window blinds and various forms of
sunscreen.
◉ Nonhazardous finishes and materials are used throughout
the building, ensuring good indoor air quality, which is
enhanced by high air exchange rates.
◉ Stabilizing plants, silt traps, and storm water collection
ponds were used to prevent soil erosion during
construction.
◉ Special mechanisms to recycle construction waste, which
reduced the amount of waste that went into landfills.

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Lighting Requirement

Light Source Upgrade Alternatives

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Use of Day Light and Automatic Control Light
❑ A mix of top- and side-lighting, light shelves,
highreflectance ceilings.
❑ Automatically Control Lighting.
❑ Over time, all lighting systems become gradually less
efficient.
❑ Other efficiency losses include improperly functioning
controls, dirt accumulation on fixture lenses and lumen
depreciation.

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 Indoor thermal comfort
◉ Cross- ventilation .
◉ Cooling is achieved at the plant primarily by passive design and secondarily by
active systems.
◉ Passive design measures include the orientation and massing of building volumes,
controlled fenestration and ventilation, shading of the building and its surroundings,
and thermal mass and solar reflectivity of the facades and roofs.
◉ The massing of the building volumes and the positioning and sizing of windows
permit daylight to enter as natural illumination without causing substantial heat gain
◉ Thermal roof load, the largest contributor to heat gain and indoor discomfort in the
tropics, is controlled by a combination of photovoltaic roofs, and cool roofs.

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 IAQ(Indoor Air Quality)
◉ Production spaces and offices are ventilated and cooled by evaporative cooling
units. These units draw in fresh air, filter it, and add moisture to lower the dry-
bulb temperature.
◉ Indoor air is not recirculated, but extracted by suitably sized exhaust fans to
ensure effective moisture and heat removal.
◉ Humidistat in each cooling unit keep the indoor relative humidity at or below
80 percent.
◉ Window Heat Flow :
Infiltration Air leaks around the frame, around the sash, and through gaps in
movable window parts. Infiltration is foiled by careful design and installation.
Convection Pockets of high-temperature, low-density gas rise, setting up a circular
movement pattern.

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 WindowFilms

◉ Window films reduce heat gain due

to solar radiation and provide low
cost cooling load reduction.
◉ Buildings in sunny areas can
benefit from a variety of shading
techniques.
◉ Bamboo sheet shade screens reduce
heat gain up to 80 % compared to
normal glass.

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 Fan System

◉ Centrifugal fans (A) are the most

common fans used.
◉ They are often cheaper but usually
less efficient than axial fans (B).

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 COOLING

◉ The heat-island effect around the building is controlled by

shading, by covering parking areas, by using lighter, reflective
paving around the building instead of dark, heat absorbent
paving, and by shading the courtyards between the building
volumes.
◉ The combination of the many passive cooling measures
reduces the thermal load to a level that can be handled by
environmentally efficient cooling systems instead of power
hungry conventional systems

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SUSTAINABLE GREENBUILDING:
A green building is one which uses less water, optimizes energy
efficiency, conserves natural resources, generates less waste and
provides healthier spaces for occupants, as compared to a
conventional building.
The goal of the "green building" project is to reduce the impact of construction
on the environment by sustainable building using methods and materials that are
resource efficient and will not compromise the health of the environment or the
associated health and well-being of the building's occupants, construction
workers, the general public, or future generations. Sustainable building involves
the consideration of many issues, including land use, site impacts, indoor
environment, energy and water use, solid waste, and lifecycle impacts of building
materials. Energy consumption and associated greenhouse gas emissions will
therefore continue to rise unless actions to direct the construction industry
towards sustainable consumption and production are taken urgently.

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 Waste fabric recycling:
• All clothing has a useful second life. In our factory The collected garments are
sorted and graded as natural, synthetic and blended fabrics. Good quality clothing
is sent to charity institutions and is used as second hand clothing.
• Unwearable textiles are considered as damaged textiles, and are processed in the
factory as rags. Rags are collected and sent to the wiping and flocking industry.
• Other materials will be sent for fibre reclamation and stuffing. Fibres from the old
fabrics are reclaimed and are used for making new garments. Threads from the
fabric is pulled out and used for re-weaving new garments or blankets. Both
natural and synthetic fibres can be recycled this way. Incoming textiles are graded
into type and color. Initially the material is shredded into fibres called shoddy.
Later based on the end use, other fibres are blended with shoddy. The blended
mixture is carded, and spun for weaving or knitting.
• The garment is shredded for fillers in car insulation, roofing felts, loudspeaker
cones, furniture padding, panel linings and many other uses. Some old clothes are
being reused in a creative way by fashion designers to make fashionable garments
and bags.

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THANKS

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