PLANT LAYOUT

SUBMITTED TO:

SUBMITTED BY:

Mr. Pavan Godiawala

TAMANNA
M.FTECH 2010-12

FACTORY LAYOUT

1. GROUND FLOOR
a. Raw material storage department
b. Cutting department
c. Sampling department
d. Warehouse
e. Operator Canteen
f. Maintenance department
g. Boiler room
h. Training department, utility room, medical room, executive parking, labour parking

2. FIRST FLOOR
a. Director Cabin
b. Administrative department & H.R department
c. Production floor
d. Conference Room
e. I.E. Department
f. Q.A. Department
g. Compliance department
h. Display Room
i. Finishing department
j. Staff Canteen

WORKING IN AN INDUSTRY
BUYER

PRODUCT DEVELOPER

MERCHANT
SAMPLING

FABRIC

TESTING
MARKER PLANNING
SPREADING

CUTTING

BUNDLING & TICKETING

RESEARCH & DEVELOPMENT
PRODUCTION
WASHING
3 & PRESSING
FINISHING

PACKING & FINISHING

PRODUCT DEVEVELOPEMENT

PROCESS FLOW OF INTERNAL DESIGNING

MOCK OR SAMPLES WILL BE PREPARED FOR SELECTION

IF SELECTED THEN MEETING SAMPLES WILL BE MADE

COSTING AND NEGOTIATIONS

SALESMAN SAMPLE

GRADING

ORDER CONFIRMATION

FURTHER TO PD IT PASSED TO MERCHANDISING DEPT

EXTERNAL DESIGNING
LINE ADOPTION WITH BASIC DETAILS

SAMPLES WILL BE MADE (2 Pcs)

APPROVAL/COMMENTS

BUYER SENTS A TECH PACK

THEN AGAIN PROTO SAMPLE MADE (3 Pcs)

FIT SAMPLES MADE (3 Pcs)

APPROVAL/COMMENTS

BUYER WILL SENT FIT SAMPLE SPECIFICATIONS

SIZE SET ARE MADE

APPROVAL

REVISE FIT OR SEALER SAMPLE IS MADE

ORDER CONFIRMATION

MERCHANDISING
PROCESS FLOW OF MERCHANDISING DEPARTMENT

Start
Obtain tech pack from buyer

Costing

Analyze fabric
consumption from
CAD

Sampling

Obtain general
sewing data from
IED

Analyze cost of
trims and fabric

Develop sample as
per the tech pack

Prepare cost sheet

from sample

Develop proto
sample

Cost sheet & sample sent to buyer for approval

Confirmation
of order

Source trims &

fabric from
concerned dept.

Obtain PCD &

details from
production unit

Yes

No

Approv
al

Book washing &

embroidery capacity if
required

Cost sheet
reworked

Obtain GSD
from IED

Execution of order by entering details in ERP

Prepare sample as per buyer requirements

Forward the sample to buyer for approval

Hold pre production

meeting with the
production unit

Execute
bulk order

Yes

Follow up with
production
departments &
update the buyer

Approv
al
Submit required
documents to
documentation
dept

No

Comments received from buyer

should be incorporated and fit
sample reworked
Offer garments
for final
inspection.
Truck out

Follow up
on the
payments
for goods

En
d

SAMPLING
STEPS OF SAMPLING:

PROTO TYPE SAMPLE MADE

FIT SAMPLE MADE

8

PP SAMPLE MADE
SHIPPMENT
TOP
SIZE
SAMPLE
SET
SAMPLE
MADE
MADE
MADE

FABRIC SOURCING
Fabric requisition from merchandiser

Order placed

Fabric receive invoice/challan

Unloading after checking

Tally with supplier invoice for quantity

Send bill to gate for entry

Receive fabric in store

Forward fabric for inspection

Inspection report sends to the concern merchant or sourcing dept.

After comments reentry in the system with final comments if rejected or accepted

If accepted

Relocation in store

Issue against job order

FLOW FOR ORDER PROCESSING

RECEIVE PO FROM
MERCHANDISER

RECEIVE SHADE APPROVAL

PREPARE A FABRIC
REQUISITION

SEND GOODS FOR DYEING

RAISE THE REQUISITION TO

VENDORS

RECEIVE DYED GOODS

10

SEND
SEND YARDAGE FOR INTERNAL FOR
REDYEIN
SUBMIT FORTESTING
BUYERS APPROVAL
BULK FABRIC IN - HOUSE
G,
FOR COLOR AND QUALITY

SOURCE OUT THE GOODS

FINALIZE THE VENDORS

NO

PLACE THE ORDER

APPROVE
D

FIRST LOT IN - HOUSE

YES

LAB TESTING
SUBMIT FOR APPROVAL TO
MERCHANT
REOR
DE
R

NO

READY FOR ISSUE

APPROV
ED
YES

LAB DIPS PREPARED AT DYEING

UNIT IN NEAREST SHADE

SAND LAB DIPS FOR SHADE

APPROVALBY THE BUYER

FABRIC STORE

PROCESS FLOW OF FABRIC STORE:

FABRIC DISPATCHED FROM
SUPPLIER
FABRIC RECEIVING
11

SOLID/YARN

GRIEGE FABRIC

DYED/PRINTE
D

SEND IT FOR
PROCESSING
BACK TO INHOUSE AFTER DYEING OR
PRINTING

100 % CHECKING (4 POINT SYSTEM)

METER CHECKING BY SECURITY

GUARDS
LOT MAKING AND SEND IT TO THE
MERCHANDISING
QUALITY CHECKING FOR DEFECTS

KEPT IN STORE

FABRIC INSPECTION

12

Sta
rt
Receive
fabrics

Conduct shrinkage
test on minimum 2
bits/bale or
minimum 10 bits
of consignment

If No

Inform to stores and

prepare goods received
note (in case of imported
fabric)

Verify whether
quantity received
match with quantity
ordered

If No

If
Yes

Forward one
meter of each
consignment for
lab test

Inspection based on
four points system.
Match bulk with
approved dye lot,
width of fabric etc.

If
Yes

Name shade lot as

ABC
Send to merchant for
buyers approval

If No

If
approved

If
Yes

Forward to
cutting dept.

Reject lot
End

13

TESTING LAB

14

Star
t

Fabric
Sourcing

Accessory
stores

Test

Test

Count

Merchandising

Buttons

Construction

Color
fastness to
washing
Color
fastness to
crocking

Lining
fabrics

Carry on
test on
fabric and
garment as
per buyer
requirement

On meeting
buyer
requirement
, samples to
be sent to
external lab
to get
approval

Dimensional
stability to
washing
Fabric
Strength
Fabric
Weight

En
d

ACC
ESSO
RIES STORE
WORK FLOW OF ACCESSORIES STORE
15

Merchandiser prepares swatch card

Swatch card is send to the purchase dept.

Accessories purchased by purchase dept.

Accessories received by receiving dept.

Testing of accessories is done

Storing of accessories in accessory store

Issuing accessories to the sampling and production dept.

TYPES OF ACCESSORIES

LABELS AND TAGS: Main label, size label, wash care label, price tag & hand tag

THREADS: Sewing threads.

BUTTON

INTERLINING AND FUSING MATERIAL: Shoulder pads paper foams etc.

NEEDLES

STATIONARY: Record books, role paper, pens etc.

16

PROCESS FLOW OF INDUSTRIAL ENGINEERING DEPARTMENT:

Receiving sketch/garment from merchant

sampling dept.

construction enquiry

Prod. Friendly solution

Calculate SMV
dept.

merchandising dept.

Prod. Cost
Tech analysis before fit stage-suggest amendments(stamp)
incorporate in sampling

PPC

prod. planning

merchandising dept.

start thinking innovation

tool room
Receive sample for thread consumption

Make opern bullttin & calculate T.C

merchandising. dept

Receive red tag sample

thread order

In depth style study & construction engineered way

folders tool room

develop customized

(innovate)

Prepare opern bullttin

prepare R & D report

17

Update SMV & finalize reports

Factory IE discuss & collects reports

Prepare work station layout

maintenance

m/c & work aid REQMT to

Line setting according to IE reports

procure from maintenance

Capacity check analysis & feedback

dept

R & D analysis and feedback

IE

Prod. Studies to increase efficiency

Improve methods

rebalance

line

Achieve target

18

MACHINE MAINTENANCE

FUNCTION OF MAINTENANCE DEPARTMENT:-

Care of the fittings

Adjusting settings

Oil changing

Graph maintenance

Outward/inward reports

Needle weekly reports.

Machine configuration chart

History card

Needle log cards.

19

CAD DEPARTMENT

PROCESS FLOW OF CAD:

Receive spec
sheet form
Receive
patterns from
pattern
Digitize
pattern to
feed in
Pattern
correction
Output to
Graphtec
plotter

Pattern
grading
Cut ratio
planning

Pattern sent
to
merchandiser
for sampling

Market
planning
according to
the cut plan
20

Output
marker to
plotter

Output mini
marker to
printer

WORK FLOW
IN CAD
DEPARTMENT

Send to
cutting room
for cutting

Send to
merchandiser
for costing

WORK FLOW OF SPREADING AND CUTTING:

SPREADING

RELAXATION FOR
8 HR.

CUTTING
MANUAL/AUTOMA
TIC

TICKETING

FUSING

CHECKING

BUNDLING
21

TRANSFER TO
PRODUCTION

SPREADING
PROCESS FLOW OF SPREADING:
FABRIC IS LOADED ON SPREADING MACHINE

PAPER IS SPREAD ON SPREADING TABLE

22

MANUAL SPREADING IS DONE

RELAXATION FOR 8 HR.

PROPER TENTION IS MAINTAINED WHILE

MARKER IS SPREAD OVER IT AND PASTED BY TAPE

TRANSFERRED TO THE CUTTING

PROCESS FLOW OF CUTTING DEPARTMENT:-

Cutting
package from
production
manager
Acquire fabric
from fabric
store
23

Cut sample to
check
Requir
e
Checki
ng
Yes

Send to CAD
for Change

No

Receive
changed
pattern from

Cut for initial

size set

Assemble and
check
Requir
e
chang
NO
es

Yes

No

Issue job
order
Cut plan
Bulk cutting

Sortin
g

24

Bundlin
g

Issue

PRODUCTION PLANNING & CONTROL

Start
On receiving the orders, allocate the same
to units based on line openings and
buyers ratings

Provide details to the respective units

on PCD, order quantity & sample

Take inputs from

IED on productivity
based on garment
analysis

Confirm the above details

given to concerned units in
consultation with GM & FM

Confirm in
consultation with
embroidery, washing
departments

Confirm order plan with

merchandising team

SEWING DEPARTMENT

Provide MIS report to management

every fortnight

Production floor follows Assembly Line system. Following are steps to start a production line:
To study the production file.

Planning follow up with factory till

order execution

To study operation bulletin and set line accordingly.

End

Manpower tailors and helpers.

Load and feeding lines.
To arrange buffer or work-in-progress.
Manufacturing.
To make daily production and to achieve targets accordingly.
To understand bottlenecks stage of production.
Working steps of production dept:
Shrinkage production pattern is issued to production floor from CAD dept.
Ready patterns are made as per the requirement of production room.
Cutting receives from cutting dept.
Cross checking of cut panels with patterns.
25

Bundling of cut panels is done.

Operation wise feeding of cut panel into the line.
Inline checkpoints.
Output of line.
Final checkpoints.
Auditing of checked pieces.

PROCESS FLOW OF PRODUCTION DEPARTMENT

Star
t
Bulk Production
Cut parts received
from cutting
Sewing process
begins
In-Line
checking

Washing

Assembly
End line checking & AQL
audit
Button & button hole/ Bar
tack
Rough checking
Ironing
Final checking
Measurement
checking
Tagging
Packing
FSA Audit
Auditing by buyer
QA
Truck out

26

En
d

WASHING
PROCESS FLOW:

Start
Washing Normal wash
N
Hydro Extraction

Drying
Inspection
(Random)
Accounting &
despatch to
different units

27

End

FINISHING
PROCESS FLOW OF FINISHING

GARMENT COMES FROM PRODUCTION

WASHING

THREAD CUTTING

INITIAL CHECKING AND SPOTTING

ALTERATION

REIRONING
FINAL CHECKING
28

PRESENTATION/FINAL IRONING

MEASUREMENT

SENT FOR PACKING

PACKAGING
PROCESS FLOW OF PACKAGING
GARMENTS COMES FROM
INSPECTION
IT IS THEN FOLDED
1 OR 2 ARE PACKED TOGETHER
ALL PIECES PUT IN TO CARTONS

DETAILS ARE PASTED ON CARTON

CARTON IS SEALED

LOADED INTO TRUCKS

SENT FOR SHIPMENT

29

PACKING NORMS
Packages are sent under licensing rules for shipment. The rules are also specified by the individual buyer and
are universal for their respective order. Some of such norms include:
All garments packed in individual poly bags.
Poly bag sticker on poly bags, which may be printed by the factory.
Order must be completed (packed, ready for shipment) prior to bulk orders.
Order must be inspected and audited by the factory 100%.
Order must be of first quality, no repair or ungraded garments should be in license shipments.
Order must be shipped 100% complete otherwise notified.
The packed goods are now ready to be passed through the

CALCULATION FOR PLANT AREA

Given Parameter:

Plant size = 120*100 sq. mt

FSI =1.2

G.C = 40%

Front margin = 5 mt

Side margin = 5 mt
Total space = 120*100 = 12000 sq. mt
FSI = 1.2*12000 = 00 sq. mt (Maximum available floor space)
Ground coverage = .65*3600 = 2340 sq. mt
Available floor space = (60-12) * (60-21)
30

= 48*39 sq. mt
= 1872 sq. mt

SPACE ALLOCATION FOR EACH DEPARTMENT IN EACH FLOOR

GROUND FLOOR :
DEPARTMENTS

AREA (in sq

TOTAL NO.
31

TOTAL NO.

AIR

mts)

OF LIGHTS

OF FANS

CONDITION

EXCUTIVE PARKING

353.5 sq mts.

1 halogen

TIME OFFICE

13.77 sq mts.

MAIN ENTRY

15 mts.

UNLOADING AREA

91.8 sq mts.

STORE MANAGER

13.77 sq mts.

TRIMS AREA

12.39 sq mts.

REJECTED ROLLS

16.06 sq mts

TESTING LABS

23.87 sq mts.

LABOURWASH ROOMS

6.88 sq mts.

UTILITY ROOM

17.90 sq mts.

CRECHE

17.9 sq mts.

LOCKERS

35.8 sq mts.

SUPERVISOR

3.67 sq mts.

WASTE ROOM

18.36 sq mts.

REMENENT

18.36 sq mts.

CAD

28.4 sq mts.

CUT PANEL AREA

112.02 sq mts.

PATTERN MAKING

48.2 sq mts

MANAGER

28.12 sq mts.

MEDICAL

28.12 sq mts.

EXECUTIVE WASH
ROOM

4.59 sq mts.

EXECUTIVE CANTEEN

22.95 sq mts.

CONFERENCE

27.54 sq mts.

RECEPTION

20.66 sq mts.

PPC

27.54 sq mts

GM

20.66 sq mts

MD

21.34 sq mts

STUDIO

27.54 sq mts

32

PURCHASE

20.66 sq mts

EXPORT

20.66 sq mts

ACCOUNTS

20.66 sq mts

MIS

20.66 sq mts

HR

30.99 sq mts

LOGISTICS

13.77 sq mts

MERCHANDISER

27.54 sq mts

SENIOR MERCHANDISER

13.77 sq mts

WORKER PARKING

91.5 sq mts

FIRST FLOOR:
DEPARTMENTS

AREA (in sq
mts)

TOTAL NO.
OF LIGHTS

TOATAL
NO. OF
FANS

AIR
CONDITION

SAMPLING

530.3 sq mts.

14

MAINTAINENCE

123.9 sq mts.

IE

19.2 sq mts.

QUALITY ASSURANCE

1.83 sq mts

SEWING AREA

2107.2 sq mts

1065

59

COMPLIANCE

36.7 sq mts.

TRAINING

31.22 sq mts.

MANAGER ROOM

13.77 sq mts.

STORE

31.22 sq mts.

BOILER

18.36 sq mts.

EXECUTIVE WASH
ROOMS

11.01 sq mts

--

EXECUTIVE CANTEEN

22.9 sq mts

WASTE ROOM

18.36 sq mts

33

DRINKING WATER

4.59 sq mts.

WASH ROOMS

4.59 sq mts.

RACKS

27.5 sq mts.

SECOND FLOOR :
DEPARTMENTS

AREA
(in sq mts.)

TOTAL NO.
OF LIGHTS

TOTAL NO.
OF FANS

AIR
CONDITI
ON

WASH ROOMS

9.18 sq mts.

EXECUTIVE CANTEEN

34.4 sq mts.

LABOUR CANTEEN

385.6 sq mts.

11

MEASUREMENT &
INSPECTION

128.5 sq mts.

65

AUDIT AREA

80.34 sq mts.

40

PACKAGING

144.6 sq mts.

50

DISPATCH AND
LOADING

96.4 sq mts.

CARTON STORAGE

18.36 sq mts.

WASHING AREA

146.9 sq mts.

10

WASHROOMS

4.59 sq mts.

DRINKING WATER

4.59 sq mts.

SUPERVISOR

2.52 sq mts.

WASHING MANAGER

27.5 sq mts.

FINISHING MANAGER

27.5 sq mts.

FINISHING ZONE

156.1 sq mts.

78

WORKFORCE IN DIFFERENT DEPARTMENT

ADMINISTRATION DEPARTMENT:-

34

DEPARTMENT

NO. OF EMPLOYEES

Executive

Accounts and finance

Human resources

Purchase

Export and import

MIS

Logistics

Merchandising

PPC

IE

CAD

Maintenance

TOTAL

42

SAMPLING DEPARTMENT:
Cutting master

Sampling manager

Sampling in charge

Pattern master

Supervisor

Tailors

35
35

Helpers

Ironer

checker

TOTAL

51

STORE DEPARTMENT:Fabric store

Store manager

Assistant manager

Checker

Workers/helpers

20

TOTAL

26

Store manager

Assistant manager

Workers/helpers

10

TOTAL

14

Trim store

CUTTING DEPARTMENT:

Production manager

Pattern master

Assistant pattern master

Cutting master

3
36

Workers/helpers

50

TOTAL

58

SEWING DEPARTMENT:
Production manager

Supervisor

Quality checker

Workers/helpers

268

Male:female(ratio)

70:30

TOTAL

277

QUALITY ASSURANCE DEPARTMENT:

Quality manager

Workers/helpers

TOTAL

FINISHING DEPARTMENT:

OPERATION

WORKER

HELPER

Button holing

Button attaching

Thread cutting

25

37

Pressing

20

Initial checking

15

Final checking

Re final checking

Spot removal

PACKAGING DEPARTMENT

Assistant manager

Quality checker

Workers/helpers

Equipment details of various department

FABRIC INSPECTION MACHINE

38

Specifications of Fabric Inspection Machine for Fabric up to 3500 mm are:

Speed of Machine: 30meters/minute.

2HP x 1440rpm, 415volts Electric Motor.
Reverse - Stop - Forward Arrangements [From Three Sides].
Roll Compact with 5" Dia.
M. S. Rubber Striped Rolls: 2 Nos.
Adopter for Paper Tube as per your requirement.
Revolution type Meter Counter.
Batching on Operator Side.
Transparent Horizontal Inspection Table with Bottom illumination.
Tension Device and Guide Rolls.
Cloth Inspection & Winding Unit are completely wired electrically, only main supply is to be
provided.

39

Equipment details of testing lab

1. AUTOMATIC TWIST TESTER

Specifications of Automatic Twist Tester:

Yarn test length

Range
Resolution
Elongation
Range

Motor Speed

Clamps

Averaging

Supply
Size

: 25mm to 500 mm adjustable (metric unit) OR 1 to 20 adjustable (imperial

unit). The test length is automatically taken into account for calculation and
final reading is displayed directly in TPM/TPI.
: Up to 9999 TPM or 99.99 TPI.
: 1 TPM or 0.01 TPI.
: Up to 9999 TPM or 99.99 TPI.
: With tolerance of -15mm or 0.6 inch for movement in
other direction.
: Up to 1500 RPM
: Manual control of rotation is possible by hand.
: Spring loaded clamps at motor end for easy clamping of yarn.
: Toggle clamp at spool end for easy, quick and continuous clamping of yarn
through spool.
: Reading of at least 20 samples can be stored and average TPM/TPI value is
calculated and displayed.
: 230 V AC, 30 Watts.
: 1000mm x 150mm x 200mm (approx).

40

2. FABRIC ABRASION TESTER

Specifications of fabric abrasion tester:

Standards: GB/T4802.2, GB8690, ASTMD4966, ASTMD4970, ISO12945.2

Friction head: 8 pcs

Sample clip diameter: diameter 38mm and diamter90mm

Diameter grinding platform: diamter 120mm

38mm Sample clip and guide rod total weight: (200 1) g

Hammer: 395g 2g, 594g 2g

Counter counting range: 1-65535 times preset

Test speed (grinding speed): 50 2r.p.m

Power: 380V 5%, 50Hz, three-phase four-wire

Dimensions: 850mm 600mm 350mm

Weight: about 80kg

3. FABRIC PILLING TESTER:

41

Specifications of fabric pilling tester:

Model: YG502B

Standard: GB/T4802.1-1997

Main technical data: trajectory diameter 40, circular orbit

Brush Height 2-12mm adjustable

Dimensions 520x280x360

Weight 45kg

Power AC220V

4. FABRIC PICK COUNTER

Specification for fabric pick counter:

Y511B Fabric pick counter

Standard: GB/T4668, ISO7211

Magnification 10, 20

Figured scale travel 0~50mm

Dimensions 975335mm

42

5. WASHING COLOR FASTNESS TESTER

Specification for washing color fastness

Reciprocating travel 100mm

Rubbing finger pressure 60Times/min

Rubbing finger pressure 9N

Reciprocating times 10 times (automatic stop)

Rubbing head size Circular diameter 16mm

External Dimensions L760W270H240mm

Weight 20kg

Power- AC220 50Hz 40W

Manual

Applicable standards: Built according with: AATCC

Features: It applies for AATCC standard.

Model Y571M

Testing Times 1-99999

43

Rubbing Travel 105mm (Can be adjusted)

Rubbing Speed Manual

Rubbing Pressure 9N

Rubbing Head diameter: 16mm

External Dimensions 660160mm215mm (LWH)

Power Source :NO

6. COLOR ASSESSMENT CABINET

Specification of color assessment cabinet

Brand: JAG

Model: JAG60

Configuration: D65, TL84, F, UV (4 light sources)

Weight: 25Kg

Cabinet dimensions (W x D x H): 710x420x570 mm

Packing dimensions (L x W x H): 750x600x350mm

Light Tube Length: 600mm (24")

44

7. SINGLE FIBER TESTER

Specification of single fiber tester:

Electronic single fiber strength tester

Testing breaking strength; break elongation rate, fixed elongation, etc. of fibers, or thin metal wires.

Standard: GB/T14337, ISO5079, 11566, ASTM D3822, BS4029, AATCC, etc.

Unit: N, CN, KG, LB, IN etc.

Max Strength Range: 100cN, 200cN, 300cN, 500cN.

Scale limits: 2-120%

Scale value: 0.01N

Accuracy: < 0.5%

Sensor Accuracy: <0.05%FS

Resolution 0.01cN

Minim clamp distance: 10mm Digital setting, automatic fixing

Drawing speed: 2-200mm/min. Scale value: 1 mm/min. Accuracy: 1%

45

Return speed: 2- 200mm/min. Scale value: 1 mm/min. Accuracy: 1%

Work motion: 100mm. Elongation resolution: 0.01mm

Maximum elongation: 150mm

Host size: L370 W300 H550mm

Weight: 85KG

WASHING MACHINE
FABCARE WASHING MACHINE
specifications:

Fabcare 'Washing Machines' are designed for all types of Laundry Jobs, Technical and Enzyme
Washings.

Machines are available with different types and size to cater the need of different Fabrics such as
Denim, Cotton, Rayon, Knitted, Woolen Garments.

Automatic, Auto timed, Auto reverse, Auto Digital temperature control.

Front plate/Inner Basket/Outer Drum all in SS Heavy duty fabrication.

Heating system available in Electric/Steam Direct Injection/Indirect steam through Seamless pipe of
SS 316 quality Coils/Thermic Heat Transfer Fluids, Oil/Gas fired heated.

Available in 20, 35, 70, 140 Kg. Dry weight per charge capacity.

46

47

DRYING TUMBLER

MODEL CAPACITY

CAPACITY DRY WTPEPCHARGE : 30 KG 1:24

BASKET SIZE

MOTOR DRIVE BLOWER

STEAM CONN.
CONSUMPTION

ELECTRIC

: 18/24 KW

OVERALL DIMENSIONS

: 1150 X 1460 X 1980

NET WEIGHT

:SDS 30

: 950 X850
: 0.75 KW
: 15 (0.5" BSP)50KG/HR

: 560 KG

48

CUTTING ROOM MACHINE DETAILS

TYPES OF MACHINES USED & THEIR SPECIFICATIONS:1. BAND KNIFE MACHINESLF-BK-00850
MODEL EC-700
220V,50/60 HZ,1PH,3AMP
KNIFE SIZE 3500 mm.

2. END CUTTER
MODE EC-3
LF EC-00900
220 V,50HZ,1 PH,0.5AMP
EASTMAN M/C CO.
NEW YORK,US
3. STRAIGHT KNIFE

49

Motors
110v, 1ph:
Weight
34 lbs. (15.4kg)
Horsepower
.65hp
Blade Size
(inches): 5"
(cm): 12.7cm
Cutting Capacity
(inches):3.5"
(cm):8.89cm
Stroke Size
(inches):1.125"
(cm): 2.86cm

SEWING MACHINES DETAILS

TYPES OF MACHINES USED
1. SINGLE NEEDLE LOCK STITCH

50

Specifications :
Bed dimensions:
Length: 18 3/4" (477 mm) Width: 7" (178 mm) Space to right of needle: 10 5/16" (262 mm)
Outside diameter of machine pulley: 2 61/64 (75 mm) effective diameter for V-belt
Regular machine: Singer clutch motor high speed 1/2 H.P.
Under bed thread trimmer (U.T.T): Singer AC servo motor/EC (N.P.) motor
Including the operation panel C-30
Needle bar Stroke: For 200A: 1 3/16 " (30 mm) For 300A: 1 3/18" (35 mm)
Clearance under presser foot: By hand 7/32 " (5.5 mm) By knee 1/2" (13 mm)
2.DOUBLE NEEDLE LOCKSTITCH :

SPECIFICATIONS ;

Max sewing speed -3000rpm

Max. stitch length-5mm
Needle bar stroke-33.4mm
Needle-DPX5 #14.
Bed size-517mm*478mm
Weight of machine-43kgs
Power required- single phase 100,420V,200.
Three phase 200,240V/650VA.
With automatic UBT.

5 THREAD OVERLOCK

51

SPECIFICATIONS :

Brand: Juki
Application: For light-weight materials
Feed Dog: 4-Row
Feed System: Bottom-Feed
Max. Sewing Speed: 7000 rpm/spm
Max. Stitch length: 1.5~4mm
Needle Bar Stroke: 24.5mm
Needle System (at time of delivery): DC X 27
Lubrication: Automatic
Lubricating Oil: Juki New Defrix Oil #2(Equivalent to ISO VG32)
Lift of Presser Foot by Hand: 7 mm
Number of Threads: 2/3/4/5 Threads

3. BUTTON STITCHING MACHINE :

SPECIFICATIONS :

Max. sewing speed- 1500 spm.

Number of stitches-8, ,16 and 32.
Applicable buttons- round shaped ,flat(2 holed,4 holed),shank/snap/metal.
Needle bar stroke-48.6 mm
Needle size -TQ x 7 #18 ~#20TQ x 1 # 14~#18.
Button clamp lifting height / system- >9mm/Automatic System.
3. BUTTON HOLE SEWING MACHINES

52

Max. SewingSpeed -3,000 spm

Number ofStitches -83~225 (by gear change method).
Max lift of work clamp-12 mm (15/32)
Needle bar stroke -34.6 mm
Length ofbottom holes -6.4-38.0 mm
Needle Size -DP x 5 # 11~ 16

FINISHING MACHINES DETAIL

1. FUSING MACHINE

Specifications: - CONTINOUS FUSING MACHINE: -

AE-300

MODEL
POWER SUPPLY
HEATER
53

SINGLE PHASE
3 KW

MOTOR

0.40 KW

CURRENT

17 A

TEMPERATURE

200 C

PRESSURE

1 KG/CM2

BELT SPEED

8.7 M/MIN

FUSING WIDTH

300 MM

2. PRESSING

MODEL

NX-2429

NO. OF
MOTORS

POWER

DIMENSIONS(L*W*H
) INCHES

WEIGHT KG.

.75 HP, 1 PH/3PH

50*30*36

80

54

RAW MATERIAL STORE DEPARTMENT

CALCULATION:Total area=390 sq mt
Rack size=7*6
Fabric Gsm=220
Fabric weight-100 kg
Fabric width =56
Capacity of 1 rack=1800 kg.
Fabric diameter=2.5
55

Total no. of racks=28racks

Total capacity of racks=28*1800
= 50400 kg.

CUTTING DEPARTMENT

CALCULATION
Total area=694 sq mt
No of pieces cut per day=2000
3% extra=2000*3*2060/100 pcs/day
Avg consumption/t-shirt=0.9 mtr
Avg consumption /t-shirt=220*100/.9*56*2.5=1.4 kg
Marker way=10 way
Total no. of layers=100
Total garments/cut=10*100=100 pcs/cut
For one cut (assumption)
Spreading:
One lay spreading time=35 sec=30/60=0.50 min
Total spreading for 100 layers=0.50*100
=50 min
Lay preparation time=10 min
Total spreading time for one cut=50+10
=60 min
Total cutting for one lay or cut=100 min
Total required time for one cut finishing=100+60
=160 min
Total no. of cuts/ day=480/160=3 cut
From 3 cut=3*1000
=3000 pcs
Production of cutting department=4*3000
56

=12000pcs/day
9000 pcs issued to sewing department
In sewing department=4 line
1 line capacity=2000 pcs
4 line capacity=2000*4
=8000 pcs
Thus WIP in cutting department=12000-8000
=4000 pcs/day
Total fabric required per day in cutting room
=9000*1.4
=12600 kg

COMPLIANCE ISSUES FOLLOWED IN THE INDUSTRY:

Displays
Factory Act Abstract
Minimum Wages Abstract
The Payment of Wages Abstract
The Payment of Gratuity Abstract
The Maternity Benefit Act Abstract
The Payment of Bonus Abstract
ESI Abstract
EPF Abstract
Form 11
Weekly Holiday Notice
Notice Nearest Hospital, Fire Station, Police Station etc.
Notice Important Officials Phone Numbers
Form V (National & Festival Holiday)
57

Standing Order (Tamil & English)

Needle Control Policy
Voluntary Work Policy
Sexual Harrassment Policy
Health and Safety Policy
Child labour abolition policy
Anti discrimination policy
Urgent Business need policy
Zero abusement policy
Working hours policy
Broken needle policy
Sexual harrassment policy
Hiring / Recruitment policy
Environmental policy
Security policy
Buyers code of conduct
Workmen Committee Members Photo with Name
Health & Safety Committee Members Photo with Name
Canteen Members Photo with Name
Transport Committee Members Photo with Name
Harrassment & Discrimination committee Members Photo with Name
Unit Work Flow
Organisation Chart with manpower details
Weekly Holiday Announcement
Excise Certificate

Building
Name Sign to All Rooms / Area
Indicators / Direction from Security Gate onwards
Storage above Storage limit Carton Box etc.
Aisle marking
Aisle width minimum 112 cm.
Indicators Arrows in the passage
Aisle without block
Health
Drinking Water
At least4.5 Litres water provided per day per employee
Water Testing Certificate
Drinking water not in plastic pot
Drinking Water, Cup availability
Drinking Water centre (one place to every 150 employees upto 500)
58

Drinking Water centre (one place to every 500 employees above 500)
Water Cooler / Heater available at every canteen, dining hall, rest room etc.
Drinking Water Signage in English and Tamil
Locate from 20 feet away from toilet
Locate maximum 50 meteres distance from work spot
Drinking Water vessale cleaned at least once in a day
Water Reservoir or Tank Cleaned at least once in a week
Water centre cleaning condition
Water Vessal Cleaning log sheet
Water Centre Incharge person with cleanliness
Suggessation Box Register

Toilets
Toilet Seat to Every 20 Women
Toilet Seat to Every 20 men upto 100
Toilet Seat to Every 50 men beyond 100
All toilet seat with proper privacy and lock facility
Urinal Accomodation Min. 61 cm for every 50 employees upto first 500
Urnial Accomodation Min. 61 cm for every 100 employees for above 500
Effective water Sewage system
Soap/ Towel
Bathroom Lock
Water tap
Dust Bins
Buckets with mug at toilets
Toilet White Washed once in every four month
Tiles/Mosaic floors washed with Detergent or disinfectant once in four month
Daily Cleaning Log sheet provided
Adeaquate Water Tabs
No smoking Sign in Gents Toilet
59

Awareness Quotes in Toilets

Ladies / Gents Toilet Name Sign in Dual Language and Picture
Spittoons
Adequate Spittoons
Sipittoons filled by Sand or Suitable disinfectant
Spittoons covered by bleaching powder layer
Spittoons scrapped or cleaned at least once in every day
Others
500 Cubic feet for every employees
Disposal of Wastes and effluents
Room Temperature
Lighting facility
Trees on factory campus

Safety Guards
Metal Glows on good Condition
Rubber Mat to ironers
Rubber Glows to ironers
Ironers wearing slipper
Motar Guard
Needle Guard
Eye Guard
Sharp Tools
Paddle Mat
Scissors and trimmers are tied
Sharp Boxes
Mask
Needle disposal once in six month
Broken Needle Register
Human resources
Dining Hall
60

Dining Hall with sufficient Space

Dining Hall with Sufficient Chair/Table
Water Facility
Ambulance Room
Doctor Visit
Nurse
Medicines
Medicines Issueing Record
Creach
Sufficient Space
Creach Attender
Creach Children Detail
Daily Register
Cradle
Toys
Postures
Wash Room Facility
Toilet
Milk
Eatables Available
Drinking Water
Ventilation
Chairs for mothers
Shady plaground for older children
First Aid
First Aid Boxes with All medicines
First Aid Boxes Location List
First Aid Box Daily Checklist
First Aid Training employees (20 %)
First Aid Trainer Name & Photo List
First Box once for 150 employees
First Aid Stations
Fire
Sufficient Fire Extinguisher
Fire Extinguisher all in good Condition
Fire Extinguisher Location List
Fire Extinguisher Service Checklist
Access area without hindarance
Fire Extinguisher kept in 3 feet
Fire Signage in Tamil & English
Usage Guide in dual language
Fire Extinguisher Colour Background Marking
Space beneath marked
Space beneath kept empty
Refilling Service Done
Fire Certified persons photo
Evacuation Drill (External) Every Six Month
61

Evacuation Drill (External) File

Evacuation Drill (Internal) Every Three Month
Evacuation Drill (Internal) File
Sufficient Fire Safety trained employees
Fire safety trained employees name & Photo List
Fire Buckets to Diesel Storage Area with Water and Sand
Fire Buckets to Boiler Room with Water and Sand
Fire Buckets to Genset room with Water and Sand
Fire Buckets to E.B. Panal Board with Water and Sand
Fire Buckets to Motor Room with Water and Sand
Fire Buckets to Appropriate place.
Fire Tray with sand
Diesel Storage area floor filled by sand
Evacuation Plan in all Floor / Area
Emergency Exit
Emergency Exit on Open
Emergency Exit Signage
Emergency Exit with outside open facility
Emergency Exit Board Light with UPS Connection
Emergency Light to All room / Area Adequate
Emergency Light to All staircase
Emergency Light to All Exit & Emergency Exit
Emergency Light daily On/Off Log Sheet
Emergency Light Location List
Emergency Light kept on 6 feet hight
Sufficient Spare Emergency Light in stock
Emergency Electricity Switch off System (floorwise)
Signage Emergency Electricity Switch Off
No Hindrance Emergency Switch off Access Area
Chemical Users Awareness
Medical Certificate to Canteen employees
Committees
Workmen Committee
Workmen Committee Meeting
Workmen Committee Meeting File (with Circular, Agenda, Minutes, etc.)
Workmen Committee Meeting Photos
Health & Safety Committee
Health & Safety Committee Meeting
Health & Safety Committee Meeting File (with Circular, Agenda, Minutes, etc.)
Health & Safety Committee Meeting Photos
Canteen Committee
Canteen Committee Meeting
Canteen Committee Meeting File (with Circular, Agenda, Minutes, etc.)
Canteen Committee Meeting Photos
Transport Committee
Transport Committee Meeting
Transport Committee Meeting File (with Circular, Agenda, Minutes, etc.)
62

Transport Committee Meeting Photos

Harrassment & Discrimination Committee
H & D Committee Meeting
H & D Committee Meeting File (with Circular, Agenda, Minutes, etc.)
H & D Committee Meeting Photos
Documents
Personnel File to All
Application Form
Passport Size Photo
Educational Qualification Certificate
Age Proof
I.D. Proof
Address Proof
Technical Certificate
Previous Company Experience/Relieving order
Old Salary Slip
ESI Nomination Form 1
PF Nomination Form 2
Gratuity Nomination Form F
Factory Act Nomination Form 34
Track Record
Appointment Order
Insurance
NDA with Signature
Employee Manual
I.d. Card to All
Adequate Swiping machine
Punching Card to All
ESI Card to All
PF Slip to All
Awareness Programme
Stress Relieve Counselling
Meetings
Performance appraisal
Leave Card
Full & Final Settlement
Exit Interview
Gratuity
Bonus
Salary Breakup
Salary on Date
Induction Programme
Induction Register
63

Manpower
Manpower Departmentwise Male/Female Strength Report
Presentism Report
Late Report
Absentism Report
Daily Staff In-Out Register
Is there Under Age
Contract Employees
Punch report
Leave card to each employee
MIR (Material Issue Register)
Salary
Salary date before 7 every month
Bank Salary Account to all
Salary Registers with employees signature monthwise
Minimum Wages
Basic
D.A.
Other Salary Breakups
Over Time
Double Salary to Over Time
Any unwanted deduction for employee
Unpaid salary are reversed
Pay Cover Availability
Security
Adequate Securities
Lady Guards
Staff Movement Register
Visitors Note
Others In-Out Register
Material Inward Register
Material Outward Register
Vehicle Movement Register
Visitor Pass
Visitor Slip
Guards Knowledge about their Roles & Responsibilities
Securities Personnel File
Securities Uniform/Cap/Shoe/Belt etc.
Securities Knowledge about Fire Evacuation & Fire Safety
Security Agreement file (If outsourced)
Security Salary register file (If outsourced)
Security ESI, PF Challan (If Outsourced)
Housekeeping

64

Adequate Housekeeping Employees

Lady Housekeeping employees
Gents Housekeeping employees
Housekeeping Supervisor
Areawise work allocation
Housekeeping Time Schedule
Toilet Cleaning Log Sheet
Brooms Availability
Broom Stick Availability
Water Mop Availability
Thread Mop Availability
Buckets Availability
Phenoil Availability
Harpic Availability
Soap on All toilet & Bathroom
Towel on All toilet & Bathroom
Tissues & Hand Wash Shampoo Availability on Visitor Restroom
Daily Cleaning Schedule
MSDS for apropriate place.
Maintenance
E.B.
E.B. Service Card
Electricity Board Cardonned off from work place
E.B. Meter Reading Register
E.B. File
Rubber Mat to E.B. Panel Board
Rubber Mat to All swtich Board
Authorized Persons Photo Display on E.B. related Rooms
Caution board and danger signal on Electricity related Rooms
Electrecians File
C or B license certificates of Electrecian
Rubber Glows to all Electrecian
Safety instructions Displayed on E.B. Related Rooms
Broken Wire
Loose Wire
Broken Switch
Boiler room
Boiler room cardonned off from work place
Fire Safety Instruments availability
Authorized persons Photo list
Genset
Genset Running Note
Genset File
AMC to Genset
Gloves
Safety shoes
65

Ear Muff
Tray of Sand
Machinary
Machinary Detail
Machinary File (Machinarywise) with purchase, service etc detail.
AMC to all machinary
Machinary Service Card
Material Safety Data Sheet (MSDS)
Personal Productivity Equipment (PPE) Issue Register
PPE Awareness
Logistics
All Staff Bus/Van R.C. Book Copy
All Staff Bus/Van Insurance Copy
All Drivers Licence Copy
Transport In - Out Time Register
Transport Travellers Name List
Transport Committee
Transport Agreement Copy
Load Van R.C.Book/Insurance Copy
Company Drivers Licence Copy
Company Van Trip Sheet Book
General
Fixed Asset Stock Register
Diesel Consume Register
White Petrol Consume Register
Gen Set Usage Note
Gen Set AMC
Electrical Plan
AMC to Computers
AMC to Swiping Machines

66