1. NATIONAL INSTITUTE OF FASHION
TECHNOLOGY, CHENNAI.
Plant Layout – End Term Jury
Layout of a Shirt Manufacturing Unit
PRESENTATION BY:
NAVEEN KUMAR
NILASHA TANDON
PAYAL BARDAN
RAVI ADITYA

2. Structure of the Manufacturing Unit
 AutoCAD 2D Layout
 AutoCAD 3D Layout

3. Departments Present in the Unit
 Spreading and cutting (110’ x 90’)
 Fabric inspection dept (100’ x 25’)
 Research and development dept (30’ x 25’)
 Human resources dept (60’ x 50’)
 Reception (50’ x 20’)
 Crèche (45’ x 15’)
 Locker room (50’ x 15’)
 Card swiping area (30’ x 15’)
 Toilets (30’ x 15’)

4. Departments Present in the Unit
 Medical room (50’ x 15’)
 Power supply dept (80’ x 15’)
 Maintenance dept (80’ x 50’)
 Industrial engineering dept (30’ x 15’)
 HOD cabin (30’ x 15’)
 Sewing floor area (320’ x 90’)
 Canteen (70’ x 30’)
 Effluent Treatment Plant (180’ x 20’)
 Washing area (130’ x 30’)

5. Departments Present in the Unit
 CAD lab (50’x25’)
 Finished goods warehouse (50’x80’)
 Finishing room (40’x90’)
 Packaging department (40’x90’)
 Fabric and trims warehouse (80’ x 30’)

6.  Ratio of cutting : sewing : finishing

7. Locational Analysis
Location
Village Vanj, Taluka Choryasi,
District: Surat
Type of SEZ
Sector Specific SEZ for Apparel.
Area: 56 hec.
Status
Notified - Functional
Connectivity:
Road, Rail,
Air and
Port
Road Network: 8 km-National
Highway (NH8),
SEZ is on Navsari- Surat State
Highway (SH)
ƒ Rail Network: 20 km from Surat
Railway St.
ƒ Nearest Port: 30 km from Hazira
port and 18
km from Magdalla port
ƒ Nearest Airport: 20 km from
Surat Airport

8. Locational Analysis
Land availability
& Lease Rates
Plots allotted to
industries @ Rs.
1500 sq. mt.
Available
Infrastructure
Internal roads,
Power, Water,
Drainage system
are available in the
SEZ
Training Facility
Established by ALT
Training College, an
Apparel Training
Centre is present in
the SEZ
Proposed
industries
All kind of apparel
manufacturing
industries are
permitted

9. Locational Analysis
Developer Company: Gujarat
Industrial
Development Corporation
(GIDC)
Contact
Information
Address:
GIDC, Block No. 4, 2Floor, Udyog
Bhavan, Gandhinagar-382 017
ƒ Contact Person & Designation:
Mr. Nayan
Raval, GM (Projects)
Tel. No.
+91-79-23250705
Website: www.gidc.gov.in

10. Assumptions
 Layout: Product specific
 Layout Type: Prefabricated
 Product: Casual shirt
 50% washed & 50% unwashed
 Available time: 480min
 No. of days working: 6
 No. of m/c= 700
 10% extra, so available m/c=640

11. Assumptions
 SAM of the shirt: 33.04
 No. of lines in sewing floor: 8
 No. of workstation req. for a shirt: 80
 Output per day @ 60% efficiency:5,712
 Output per day with 10% extra: 6,397
 No. of days working in a month: 25
 Output per month: 1,59,936

12. Fabric Store
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Length of the roll: 150m
Width of the roll: 6ft
Height of the roll: 1.5 ft
Average consumption per garment: 2 m
Fabric width: 60 inch
Fabric consumption per day:11,424m
No. of rolls req. per day: 76 rolls
Inventory: 10 days
Total rolls inventory: 762
Rack dimension: 6ftX 6ftX4ft
No. of shelves: 3
No. of rolls stacked in a height:24
Total rolls inventory in store: 762
Calculation sheet

13. Fabric store
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Inspection m/c: 9ftX7ft
Average speed: 6mts/min
Utilization: 90%
Available time: 432min
Inspection per m/c: 2592m
Daily needed fabric:68,544m
M/c req. =3
No. of racks required: 32
No. of shelves: 95
Area required for racks: 1,142 sq. ft.
Area required for fabric store: 2500sq. ft
Calculation sheet

14. Cutting room
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Available time: 480 min
Utilization: 75%
Efficiency: 60%
Average consumption: 2m
Marker length: 4m
Layer length: 4.008m
No. of sizes in a marker: 2
No. of layer: 80
Total garment in a lay: 160
Meter spread: 320.64m
No. of rolls req. :2.14=3
Bundle size: 20
No. of lays req. per day: 40
Calculation sheet

15. Cutting room
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Spreading table length: 5.508m
No. of spreading table req.:7
No. of spreader req. :11
No. of spreader allotted:6
No. of spreading team: 6
No. of req. cutter: 5
No. of cutter allotted : 3
No. of allotted cutter: 2
M/c area: 2898 sq ft
OP. space area: 1416 sq ft
Total area : 4314 sq ft
Total area req. :9900
Calculation sheet

16. Sewing Room
 SAM of the shirt: 33.04
 No. of workstation: 80
 No. of sewing line: 8
 Total m/c: 640
 M/c area per line: 1063sq ft
 Op space area per line:447.5 sq ft
 Total area required: 3398.625 sq ft
Calculation sheet

17. Washing room
 50% washed and 50% unwashed
 Washing machine
 Tumble Drier
 Drier
 M/c area:1290 sq ft
 Op space area: 300 sq ft
 Total area req. 3900 sq ft.
Calculation sheet

18. Finishing Room
 Finishing SAM = 4.45 Minutes
 Thread Sucker
 Press Fold
 Spotting M/C
 Checking tables
 Sub Total Space = 1585 Sq. ft.
 Allowance (125%) = 1981.25 Sq. ft.
 Total Required Area 3566.25 Sq. ft.
Calculation sheet

19. Canteen
 No. of employees: 900
 Canteen is without cooking
 So area req. per employee is 12 sq ft
 So the canteen area is 2100 sq ft
 Two floor canteen
 Occupies 350 employees at a time.
 So there will be three shifts for employees
Calculation sheet

20. Sustainable Factory
OBJECTIVES
 Efficient management of energy and water resources
 Management of material resources and waste
 Restoration and protection of environmental quality
 Enhancement and protection of health and indoor
environmental quality
 Reinforcement of natural systems
 Analysis of the life cycle costs and benefits of
materials and methods
 Integration of the design decision-making process

21. Renewable Sources of Energy in Gujarat
 Wind power (capacity=3,187 MW)
 Solar power (capacity=856.81 MW)

22. 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.

23. SUSTAINABLE RAW MATERIAL FOR
CONSTRUCTION
 To reduce the non-renewable energy (energy
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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.

24. SUSTAINABLE RAW MATERIAL FOR
CONSTRUCTION
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Windows use imported plate glass and
aluminium 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 airexchange rates.
Stabilizing plants, silt traps, and stormwatercollection 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.

25. Understanding the Lighting Requirement

26. Light Source Upgrade Alternatives
Lamp Type
Rated Life Hours
Full-size fluorescent (T5,
high-performance T8)
20,000 to 30,000 - Lumen
maintenance % - 92 to 93
General area lighting of all
kinds, including open and
closed offices, training classrooms, and
high-bay areas. – Sewing, Finishing,
Washing Section
Compact fluorescent
6,000 to 12,000
Lumen Maintenance - 86 (%)
Incandescent replacements in table and
floor lamps, cans, wall washers, and
sconces
Quartz pulse-start
metal halide
20,000
Lumen Maintenance – 65 to 75
(%)
Outdoor lighting, high-bay
lighting, and remote-source
Lighting - Landscape
Ceramic pulse-start
metal halide
20,000
Lumen Maintenance - 80 (%)
Where color is critical- example cutting
section
Induction
100,000 hours
Lumen Maintenance
70 at 60,000 hours; 55 at
100,000 hours
Where maintenance costs
are high like parking, roadways and ware
house.
LED
50,000
Lumen Maintenance - 70 (%)
In color-based applications such as exit
signs, niche applications such as outdoor
signage, task lamps.

27. Use of Day Light and Automatic Control
Light
 A mix of top- and
side-lighting, light
shelves, highreflectance ceilings.
 Automatically
Control Lighting.

28. 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.
How to control this ??
 Follow a strategic lighting maintenance plan of scheduled
group re lamping and fixture cleaning.

29. 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.

30. 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.

31. 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. Convection occurs within multiple-layer windows
and on either side of the window.
 Radiation
Radiation is energy that passes directly through air from a warmer
surface to a cooler one.
Radiation is controlled with low-emissivity films
or coatings.
 Conduction
Conduction occurs as adjacent molecules of gases or solids pass
thermal energy between them. Conduction is minimized by adding
layers to trap air spaces, and putting low-conductivity gases in those
spaces.
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32. Window Films
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Window films reduce heat gain due to solar
radiation and provide low cost cooling load
reduction.
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Buildings in sunny areas can benefit from a variety
of shading techniques.
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Bamboo sheet shade screens reduce heat gain up to
80 % compared to normal glass.

33. Fan System
 Centrifugal fans (A) are the most common fans
used.
 They are often cheaper but usually less efficient
than axial fans (B).

34. 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

35. Light intensity levels for different departments
ACTIVITY
REQUIRED LUX LEVEL
Preparation of cloth
200-300-500
Cutting
500-750-1000
Matching
500-750-1000
Sewing
750-1000-1500
Pressing
300-500-750
Inspection
Hand tailoring
1000-1500-2000
1000-1500-2000

36. THANK YOU