planning for setting up a denim jeans manufacturing unit

1. PLANT LAYOUT
SUBMITTED BY
AMIT ONKAR
ASHMITA JAIN
MANSI JAIN
RIDDHI MALVIYA
SUNANDA GHORAI
DFT VII
MENTORED BY:
PROFESSOR
PAVAN
GODIADVALA

2. COMPANY PROFILE
• Denim jeans manufacturing industryTYPE OF INDUSTRY
• 2000 pieces/ dayCAPACITY
• 60 metres*40 metresAREA
• Assembly lineMANUFACTURING
SYSTEMS
• Ahmedabad, GujaratLOCATION
• 1FSI
• 35%GROUND COVERAGE

3. OPERATING
ASSUMPTIONS
• 1
• 8
• 300
• 60%

4. CAPACITY PLANNING:
Average consumption:
1.4 mts per jeans
Shelf size= 4.5 feet * 4.5
feet * 6 feet
Number of racks
required = 34
Considering the average
spreading and cutting
time for 50 plies of
denim and a 2 way
marker as 2 hours, in
one day from 1 table,
yield= 400 pieces
Number of tables = 5
Total = 400*6= 2000
pieces
According to the SAM
value of each machine,
for 2000 pieces per
day,the total machines
required are 86
For reference:reference
sheet
Average machine
dimensions considered
while doing the planning
is 1.2*0.8 metres

5. FLOOR WISE LAYOUT
DESIGNING
• BASIC:
• Our industry is facing the north direction.
• According to ground coverage, the building dimensions
are 35 metres * 24 metres
• Number of floors= 3
• Margins= 8 metres from 3 sides and 17 from one side
• Maximum material flow movement: Using trolleys
• Manpower: 300 ( approximately)

6. GROUND FLOOR :
MATERIAL FLOW FOR BULK PRODUCTION
Approved fabric is sent to the cutting room.
There are 6 cutting/spreading tables, 1 fusing/recutting
table,1 inspection table,1 band knife, 1 fusing machine,
ticketing and bundling table
Unchecked material is stored as rolls in
a zigzag manner on the floor
After inspection, approved material is
stored in the racks; rejected is stored
on the floor near the exit
There is an overlock machine to
convert thaans to rolls
Material (denim fabric in the form of rolls) enters the industry,
checked and recorded here.
It includes the guards at the gate

7. GROUND FLOOR :
OTHER DEPARTMENTS
• Entry door is from the outside to
provide easy accessibility from the
staircase and lift
• It is large enough to accommodate
2 stretchers, 2 permanent doctors,
1 attendant and first aid boxes
• To make it convenient to send and
receive couriers

8. FIRST FLOOR :
MATERIAL FLOW FOR BULK PRODUCTION
The stitched garments are sent to the transport department to be sent to a denim washing unit
(Outsourced due to space constraint)through a ramp connecting the first floor to the ground floor
Material (cut pieces from the
cutting room) goes to the sewing
room through the lift
According to the SAM of each
automatic machine, the total
machines are 86
The manufacturing system is
assembly line
Materials like threads and lining are issued from the trim store and sent to the sewing room

9. FIRST FLOOR :
MATERIAL FLOW FOR BULK PRODUCTION
From packing, the polythene packed jeans are transferred to the packaging department
,are put into the cartons , the cartons are marked and dispatched via the transport
department
After being received from
the outsourced unit, the
stitched jeans are brought to
the finishing room.
They are inspected, buttons
and rivets are attached,
finishing and checking is
done.
Material flow in the finishing
room is done using
overhead hangers.

10. FIRST FLOOR :
OTHER DEPARTMENTS

11. SECOND FLOOR :
MERCHANDISING AND SAMPLING
DEPARTMENTS
• 29 Cubicles for the merchandising department
• 39 machines in sampling
• 2 cutting tables ; 1 inspection table and 1 finishing
table
• CAD Department

12. SECOND FLOOR : ADMIN
BLOCK
• HR AND ADMIN DEPARTMENT
• CONFERENCE ROOMS- 4
• RECEPTION

13. TERRACE
• Capacity: seating for 108 people
• Separate wash basins
• To conserve water
• 4 solar panels and space for
solar panel maintenance

14. OTHER AREAS COMMON
TO ALL FLOORS
• 3 washrooms each for men and women
• 3 seats/urinals per washroom
• Enough to provide 4.5L/person/day
• 1 on each pillar
• 1 on each floor. It is one way and is used only in case of
a fire or fire drill ( It’s 1 metre above the ground level)
• 2 material lifts per floor and 1 people lift (for the admin
people)
• 1 staircase per floor 1.5 wide

15. SPECIAL FEATURES OF
THE INDUSTRY
• The industry we have set up, a
fully automatic denim
manufacturing unit, is
environmental friendly,
ergonomically appropriate and
fully optimized and efficient in
every way.

16. SPECIAL FEATURES OF
THE INDUSTRY
• Greenery and plantation
• Optimum use of natural lighting
• Shades on the windows facing the south, since the sun is
strongest towards the south direction.
• Solar panels
• 5 solar panels generating 200 W/hour save127.5*10=
Rs1275/day
• Efficient use of the glare free north light
• Rain water harvesting on the roof-top
• Parking of trucks is done at a tilted angel to save space as
well as allow easy parking
• Every area in the plant has been accounted for.
• Planning and placement of each department is done in a
symmetrical way so as to allow easy passage between
departments. Also, when a person stands in an aisle, his
view on both sides till the end is unrestricted.

17. SPECIAL FEATURES OF
THE INDUSTRY
• Because of outsourcing denim washing, there is going to be
a lot of material transfer from the 1st floor (Sewing room) to
the ground (Transport) and vice versa (Transport to
Finishing room).
• To save time and effort, we have installed a ramp, which
goes from the first floor to the ground.
• Apart from work, workers spend most of their time in the
cafeteria. The rooftop cafeteria has a shade on top and is
large enough to accommodate at least 1/3rd of the total
workers.
• Air sucking vents on the floor of the ground floor help in
maintaining a lower temperature.
• Fire Safety: Fire extinguishers on every pillar, Appropriate
amount of Fire exits
• Number of washrooms and water coolers
• Size of departments like crèche and canteen
• A lot of aisle space

18. THANK YOU