Documentos de Académico
Documentos de Profesional
Documentos de Cultura
ARCHITECHTURAL
BRIEF FOR
FASHION SHIRT
MANUFATURING
PLANT
Submitted By:
Akriti Sharma (03)
2
Introduction
About The Project
• The nature of the product is not staple thus variations are possible
in machine requirement as well as the production work flow.
3
Product Analysis
Product Overview
4
PRODUCT DESCRIPTION
• It must have desirable fashion features such as darts, panels, embroidery, etc
for providing an attractive look to the wearer.
• Variety of woven fabrics can be used as raw material for the product.
• The construction of the product can vary from easy to complex depending on
the style variation.
• Small parts like collar and cuffs are separately prepared before being
assemble into the main garment.
• The collar and cuff require fusing machines for attaching the fusible
interlinings to the respective parts.
5
PARTS LIST
1. Front 2 Make
2. Back. 1 Make
4 Sleeve. 2 Make
5. Collar. 1 Make
7 Cuff. 2 Make
9 Pockets. 1 or 2 Make
Labels
o Brand
o Size
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1+1+1+1 Buy
. o Fit
o Wash care
6
Sewing Operation Breakdown
The following operations are for sewing a men’s casual (fashion) shirt. These are
general operation irrespective of any variation.
MACHINE
Operation Number Operation name
REQUIRED
7
B16 Run stitch collar SNLS
Collar turning
B17 Cut collar point ,turn & fold collar
m/c
Button attach
B27 Sew button to point
m/c
Button Holing
B28 Sew button hole to cuff
m/c
Button stitch
B29 Sew button to front and cuff machine
Thread trimming
C01 Trim thread
machine
8
PRODUCT/PART VARIATIONS
1. Kimono sleeve
2. Pleated shirt
4. Multi-Panel shirt
5. Gather shirt
1. Sailor collar
2. Shirt collar
4. Stand collar
Collar
5. Roll collar
6. Madrin collar
7. Turtle neck
1. Cap sleeve
3. Petal sleeves
5. Lantern sleeves
6. Cowl sleeves
7. Leg-o-mutton sleeves
3. French cuff
4. Contoured cuff
5. Roll-up- cuff
1. Epaulets
2. Zippers
3. Buttons(metallic /plastic)
Decorative trims/parts
4. Patch work
5. Paupers or rivets
6. Hood
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Part 2
11
PROCESS INVOLVED / OPERATING ACTIVITIES
Dispatch
12
Processes involving specialized operations
Specialized operation required for meeting the requirements of the product variations
are as follows:
• Embroidery
• Printing
• Washing
Printing: Printing also can be done on any individual part or component before the
sewing/assembly operations. The parts requiring the embroidery are transported
from the cutting to the embroidery section. After embroidery the parts are transported
back to cutting and re bundled with original pieces and sent for sewing.
Washing: To provide a variety of effects the garments may be given washes or for
providing shrinkage. These operations are usually done after the production
operations are completed and just before the packaging. The garments which are
produced out from the sewing lines are sent directly for washing from where after
washing they are sent to the finishing department for finishing and packaging.
13
Process flow with specialized operations
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OPERATION BREAK DOWN FOR MAJOR DEPARTMENTS
FABRIC STORE
Identification of supplier
Receiving of fabric
Storage of fabric
Fabric check
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CUTTING DEPARTMENT
Spreading
Marker Making
Lay Checking
Cutting
Ticketing
Component checking
Bundling
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FINISHING DEPARTMENT
Button Holing/stitching
Washing
Thread cutting
Pressing
Checking
Re- pressing
Measurement check
Thread sucking
Folding
Tagging
Packing
Dispatch
17
Computer Aided Design (CAD)
18
RFD
19
SAMPLING
20
PART 3
PRODUCTION SYSTEM:
21
Production System: Progressive Bundle System
The production system proposed for the facility is “Progressive Bundle System” with
the material flow being “zigzag” motion.
PBS system is exactly what its name implies, a system whereby the garments are
gradually assembled as they move through successive sub-assembly and main
assembly operations in bundle form. The principles of this system are:
• A work store is positioned at the start and the end of every section of these
buffers is used to store work received from a preceding operation and to hold
work complete by that section.
• Due to these work stores or buffers, each section is not directly dependent on
the preceding section, but can absorb slight variation in output via the stocks
held within the section.
• Labors of all levels, that is skilled, unskilled, semi-skilled labors are involved in
this system where the operations are broken into small simple operation.
Hence the cost of labor is cheap.
• The quantity and quality of each component is checked during the individual
operation itself, so the quality is good.
• The component are moved in bundles from one operation to the next
operation, so there is less chance for confusion like, lot mix-up, shade
variation, size variation etc.
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• Bundle tracking is possible, so identifying and solving problems becomes
easy.
The material flow is zigzag movement of material. In case of the zig zag movement
the straight line is divided into two lines such that if the first operation is on the right
side of the centre table, the subsequent operation is done on the opposite side of the
table. The completed parts are placed on the table and the next operator picks up the
same.
• The workflow is also improved and the chances of the bundles breaking in the
middle of the line are minimized.
The pattern is well explained by the following illustration. For example if there are 6
operation in manufacturing a part. Let ,the operations be Op1, Op2, Op3, Op4, Op5
and Op6, and the operators be 1,2 ,3 4, 5 and 6 respectively, the material flow would
be
OP2
OP6
OP4
2
6
4
Centre table
Material Flow
OP1
OP3
OP5
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PART 4
CALCULATIONS
24
Man Machine and Material Calculations
• The calculations for the man, machine and material have to be done
department wise depending.
FABRIC STORE
Equipments Required
Storage pallets
• The main raw material fabric is to be stored on plastic pallets in the fabric store
by piling up rolls or arranging bales.
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• Fabric required for one day (3150gmts)=3150*2=6300 mts
Therefore,
• There for the number of rolls required for storage= 441 (approx)
• Cost effective
• Compatible with all existing lifting systems
• Easy to clean & wash
• Excellent resistance to most chemicals
• Maintenance-free
• Rot proof
• Extensive testing to ensures quality standards
• Secure
• Robust design to render long service
• Meets all GMP requirements
• Hygienic
• Water proof
• High impact strength and rigidity
26
Fabric Checking Machine
Inspection tables
• Quality Inspection- 3
• Quality assuarance-1
• Department in charge -1
• Office Clerks-3
• Helpers-5
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• Total manpower - 13
Material
• The raw material that is stored in the fabric store is only fabric for production.
Accessory Store
Storage cabinet
• A storage cabinet is required for storing the required trims for production.
• A storage cabinet with multi level rack is apt for its compactness and less space
consumption.
Inspection tables
28
Man(Personnel and labour)
• Quality Inspection- 4
• Quality assuarance-2
• Department in charge -1
• Office Clerks-3
• Helpers-5
• Total manpower - 15
Material
• The raw material that is stored in the accessory store is only the trims and
accessory required for production.
• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.
29
Thread Store
Storage cabinet
• A storage cabinet is required for storing the required threads and thread boxes
for production.
• A storage cabinet with multi level rack is apt for its compactness and less space
consumption.
Inspection tables
30
Man power(Personnel and labour)
• Quality Inspection- 2
• Quality assuarance-1
• Department in charge -1
• Office Clerks-2
• Helpers-5
• Total manpower - 13
Material
• The raw material that is stored in the accessory store is only the trims and
accessory required for production.
• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.
31
Spreading and Cutting
Similarly
There fore
Hence
• The length of the table (assuming 4 way marker with allowances)=12 mts.
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• The width of the table (assuming max width of 60”) =162.5 cm=1.6mts.
Cutting Equipments
• Straight Knife cutting machine can be stored under the table and don’t need
separate storage.
• 2 continuous Fusing machine required for fusing the fusible interlining on collar,
cuffs and placket.
Storage racks
33
Man power (Personnel and labour)
• Office Clerks-3.
• Recutting operator- 1.
• Total Manpower - 21
Material
• The raw material that is stored in the cutting room is only fabric for production.
• The material is available in small sizes and large quantities thus storage must
be done in racks /cabinet.
34
SEWING
Equipment Required
Sewing Machines
The following list provides the amount and type of machines required for
production /sewing of a single garment based on the sewing operation breakdown
(refer Product analysis).
The list is also representative of the machines required in setting a single sewing line
35
Specialized machines
Machines required for catering to special purposes such as collar turning , cuff
turning and ironing .
Inspection tables
Sewing lines
Therefore,
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• Total labour required for producing 3000 gmts in 480 mins using the efficiency
formula= Minutes required/Minutes available
• Since, 34 operators are required per sewing line, the number of sewing lines
required for desired production level =208/34= 6 sewing lines (appox).
• In line with the production system proposed (PBS –zigzag motion), considering
the machines are arranged in two rows separated by a centre table.
• For calculation purpose, a single unit of a sewing line consists of two machines
on either side of the centre table inclusive of the centre table measurement
and operator workspace allowance.
OP6
Centre table
OP5
37
• Measurement of the single unit of sewing line :
Manpower
• Helpers -30
• Quality checkers-12
• Production manager-1
38
FINISHING
Machine requirements-
Different machines required are washing machine, hydro extractor, tumble dryer,
pressing machine, boiler.
39
Number of washing machine used = 2
• The hydro extractor which will be utilized is of fabcare, model number- HDS 25.
• The tumble dryer which will be utilized is of fabcare, model number- DTS-60.
• The pressing machine which will be utilized is of ramsons, model number- VEIT
4255-65.
• Inspection Tables are required for different purposes which are initial checking,
thread trimming and final inspection.
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Number of tables required = 12 (4 for 1st inspection+ 4 for thread cutting +4 for final
inspection)
Area of the table = 2.1 mts* 1.47 mts = 3.087 mt2 = 33.21612 sq ft.
Packaging
• 1 Metal detector for detecting metal parts within garments before packaging
Total area required for the finishing machinery = 27.11 sq ft. +34.86 sq ft. + 24.54sq
ft. +18.93 sq ft. + 16.70 sq ft. + 33.21 sq ft. + 32.22 sft +265.23 sft = 452.80 sft.
MANPOWER
• Washers – 7
• Pressers-5
• Helpers -20
• Quality checkers- 10
• Quality assurance-5
• Finishing incharge =1
• Packers- 20
• Total manpower= 68
41
PRINTING
Machinery details
Printing machines
Curing machines
• 1 chamber heater.
• 4 Inspection tables
42
Manpower
• Printers-5
• Colour developer-2
• Screen developers-5
• Helpers -8
• Total manpower- 30
43
Embroidery
Machine details
Embroidery machines
Manpower
• Embroiders-5
• Patch cutters-2
• Helpers-6
• Total manpower- 15
44
SAMPLING
Machinery Details
Storage Racks
• 2 storage racks
Table
Area
• Total area of sampling department = 3700 sft
45
Manpower planning
• Cutting master – 2
• Pattern maker – 5
• Stitching master – 50
• Helpers – 10
• Sampling head – 1
• Total manpower – 68
46
CAD DEPARTMENT
Machinery
• 4 Desktops
Manpower Details
• CAD operators- 4
• Helper – 2
• Total operators - 6
47
AMENITIES REQUIREMENT
48
PART 5
Area allocation
49
Store department–
Fabric store
Accessory store
Thread store
50
Spreading and cutting department-
51
Sewing department –
Finishing department –
52
Printing and embroidery department -
53
Auxiliary departments-
HR 150 sq ft
IE 200 sq ft
Design 200 sq ft
Administrative 300 sq ft
PPC 200 sq ft
Canteen 50 sq ft
Auxiliary-
54