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JACKET MANUFACTURING INDUSTRYPRESENTED BY:NIVEDITA KUMARIB.F.TECHVII SEMESTER

National Institute Of Fashion Technology, Gandhinagar PLANT LAYOUT

BRIEF GIVEN FOR THE PROJECT:

The brief given for the project is as follows:

Product : JACKET. 3 different styles Style no. 1: Notch collar, 3 buttons @front, front patch pocket , full lining, center vent, 6 button @slv (kissing stacked)Style no. 2: Notch collar, 3 buttons @front, welt pocket , full lining, center vent, 6 button @slv (kissing stacked)Style no. 3 : Notch collar, 3 buttons @front, welt pocket , full lining, side vent, 6 button @slv (kissing stacked)The pieces to manufacture are 1500 per day.Unit production system along with mezzanine floor.

Objective of the study:

To prepare a plant layout for a jacket manufacturing unit with a capacity of 1500 jacket/day considering the following:

Understanding of capacity & space requirements Selection of appropriate material handling equipment Decisions regarding environment and aesthetics Identification and understanding of the requirements for information flow Process flow of different departments

Company details:

Name of the company EVERGREEN APPERALSArea4800 sq. meter (80 L * 60- W)FlooringTwo floor (Ground floor, first floor)and mezzanine floor .Product categoryJacket ProductThree different style Jackets Nature of BusinessExport Rate of Production1500 pieces/dayNo of shift per day1Hours per day8 hoursGround Coverage45%

Company location and site

GIDC Apparel Park Area is developed in Ahmedabad in Gujarat-380026. The Industrial Area is located about 4.8 Kms. from Ahmedabad Junction and 13.7 Kms. from Ahmedabad International Airport. The Industrial Area is well connected by Road NH-8, Rail- Ahmedabad Junction and the Airport- International Airport. The river Sabarmati runs near to the Industrial Area -8.3 kms.

Company factors PARAMETERSAHMEDABAD APPAREL PARKDevelopers NameGIDCLOCATIONAHMEDABADSTATUSFUNCTIONALAREA (HECTARES) 38CONNECTIVITY OF SEZ (national highway / state Highway)NH 8Distance from the nearest Airport (Km)AHMEDABAD INTERNATIONAL AIRPORT(13.7km) DISTANCE FROM THE NEAREST PORT (Km) HAZIRA 320KANDLA 500DISTANCE FROM THE NEAREST RAILWAY (Km)AHMEDABAD KALOPUR (4.8 km)PROPOSED PROJECTSAPPARELINDUSTRIAL PRESENCE ARTEX APPARELS, PARAMOUNT APPAREL INDUSTRIES etc.

Company Selection Criteria

Roads: 12.00 Mts. Roads are formed in Industrial Area.Water supply works: The Gujarat water supply and sewerage board, irrigation canals, and sardar sarovar project are meeting the requirement of water to Industrial Area out.Electricity: The entire Industrial Area is covered by station erected SabarmatiOpen Drainage System: The GIDC has taken up RCC drainage system and also storm water drainage for discharging the storm water.Telecommunication System: The Telephone Exchange for the GIDC, Apparel Park BSNL exchange office and Naranpura exchange office that help in communication.Post Office: The nearest Post Office is Paldi in Fatehpura police chowki Town, through which the postal service are available.Commercial Infrastructure: For commercial infrastructure like Bank (Axis bank, Syndicate bank), local shopping (4d square mall, Alpha one mall) etc., available near apparel park.Transportation: The Industrial Area is located very adjacent to Ahmedabad junction and Ahmedabad international airport NH-8 Highway. Hence has a very convenient transportation system.Railways: The Ahmedabad Station is situated at a distance of 4.8 Kms. Form Industrial Area.

Compliance of the site with site selection criteria

Latitude & Longitude - 23148N,723448EClimate Conditions -Annual Max. Temp. 38 CAnnual Min. Temp. 13 CAnnual Rain fall - 93.2cmRelative Humidity 47 %Predominant wind direction-NW, NENearest Town- It is in AhmedabadMajor Settlement It is nearest to the railway station and airportKankaria lake 2.2 Kms ,Teen Darwaza- 6 kmsNearest Railway Station- Ahmedabad Junction-4.8 kmsNearest Airport Ahmedabad international and domestic Airport 13.7 Kms,International Airport Ahmedabad international airportNearest Highway NH-8

PRODUCT ANALYSIS

Various fabrics used in a jacketPARTS NAMENO. OF PARTSShell 21Lining23Small parts 20Knitted fusing 5Parts fusing14Reinforcement3Total 86

Given Variations in a jacket variation1CollarNotch collarLiningFullButton at front3Button at sleeve3PocketWeltCuff button Kissing stackedVent styleSide

variation2CollarNotch collarLiningFullButton at front3Button at sleeve3PocketpatchCuff button Kissing stackedVent styleSide

Given Variations in a jacket variation3CollarNotch collarLiningFullButton at front3Button at sleeve3PocketWeltCuff button Kissing stackedVent stylecenter

LINE. NOSTYLE DESCRIPTIONSAMNo. of worker @ 100 % efficiencyNo. of worker @ 75 % efficiencyLINE 1Patch pocket with center vent717498LINE 2Welt pocket with center vent687094LINE 3Welt pocket with side vent67.26993

Line Efficiency% = (Line output X garment SAM X 100)/(Number of operators X minute worked in day)For line 1: 75%=500*71*100/x * 480= 98 workers For line 2: 75%=500*68*100/x * 480= 94 workers For line 3: 75%=500*67*100/x * 480= 93 workersLine Target = (Total working minutes in a day X No. of operators in a line X Line eff%)/Garment SAM For line 1: 480*98*75%/71= 496garments For line 2: 480*94*75%/68= 498garments For line 3: 480*93*75%/67= 500garments

Calculation for each line target and manpower required

Operation breakdown of a Jacket

List of DepartmentsCovered Merchandising DepartmentHR Department ConferenceReceptionMedical RoomAdminMD RoomCEOGM RoomProduction Planning DepartmentFinance DepartmentDesign DepartmentSampling RoomStoreCADCuttingSewingFinishingMaintenanceIESecurityCanteenToiletsCreche

Takes into account :Types of constructionBuilding foundationsRoofing structuresBuilding materials etc..Construction

Concrete frame structures:Consists of a frame or skeleton of concrete. Horizontal members are calledbeams, and vertical members are calledcolumns.Humans walk on flat planes of concrete calledslabs.Columns carry the primary load.Material used is RCC. Concrete is very strong in compression, easy to produce at site, and inexpensive.Bears dead load, live load, dynamic load etc.

Types of construction

Transfer the weight of the building to the ground.Soil study is done to determine safe bearing capacity of soil (amount of weight per unit area the soil can bear).Ahmedabad has black soil. Safe bearing capacity- 15000 kg/meter sq.Pile foundation to be used for long span building like a factory.A long cylinder of a strong material such as concrete is pushed into the ground so that structures can be supported on top of it.

Foundation

End bearing pile foundation

End bearing piles- thebottom end of the pile rests on a layer of especially strong soil or rock. The load of the building is transferred through the pile onto the strong layer. In a sense, this pile acts like a column.

Roof closes the framed structure.Must be able to withstand-wind load, human load & earthquake load.Flat roof style is used.

Roofing

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Finish material applied over a floor structure to provide a walking surface.Steel fiber concrete flooring- provide superior resistance tominimize cracksin hardened concrete, as well asmaximum resistance to withstand heavy loads.Increased durabilityLow maintenance costs

Flooring

Light should be uniformly diffused.Lighting should be adapted to the type of work.The level of illumination, measured in lux, should be increased not only in relation to the degree of precision or miniaturization of the work but also in relation to the worker's age.

Lighting Visual taskMin illumination (in lux)Examples Casual seeing100Locker roomsOrdinary rough task150-300Counting of cut partsModerately critical300-500Machine workCritical500-700Fine sewing, inspectionVery critical1000-1500Fine grinding workExtremely critical2500-3000 or moreRepairing

Sound exposure above 85DB is considered noise.Machines must be checked periodically for noise level.In order to reduce vibrations, heavy machinery should be kept at the ground floor.The vibrations get transfers to the soil.

Noise & vibration

Windows Windows provide ventilation in the room.Windows should cover atleast 20% area of the floor in each department.Double or triple glazedinsulated windows, provide much better insulation than single-pane glass windows.Transparent glass windows used in administration (office)

Window shades to avoid glares

Seeks to minimize the negative environmental impact of buildings by moderation in the use of materials, energy, and development space.Conscious approach to energy and ecological conservation in the design of the built environment.

Sustainability aspect

GREEN ROOFING

Solar panels on parking lots

The building must be ready to face the natural calamities as well as hazards like fire. Detection system, alarm system and suppression system to be up to date.Sand to be used for fire caused by electricity.

Safety precautions

According to OSHA, industrial buildings must have 1 fire extinguisher of class B at a distance of 15 meters.Fire extinguishers

THANK YOU !