A case study on plant setup of a t-shirt manufacturing unit

1. National Institute of Fashion Technology,
Chennai
Presented By:
Abhishek Raj
Sarthak Sagar
Shriya Arora
Pammi Kumari
DFT-VII
Plant Layout
Plan for T-Shirt Manufacturing Unit
Department of Fashion Technology

2.  Product Description
 Required Raw Materials
 Location Analysis
 Proposed Factory Layout
 Area Description
 Material Flow
 Machines and Equipment
 Man Power
Contents

3. Product Description

4.  The product will manufacture is T-Shirts.
 Round Neck T-Shirt
 Crew Neck T-Shirt
 V Neck T-Shirt
Product Description

5. S.No. Operation Avg. SAM Machine Type
1 Neck Rib & Run stitch 0.55 SNLS
2 Join shoulders 0.45 4 O/L
3 Attach Collar Insert Neck Rib 0.45 SNLS
4 Serge Margin 0.31 4 O/L
5 Top Stitch Neck Line 0.34 3 O/L
6 Attach Sleeve 0.39 4 O/L
7 Sew Side Seam with Labels 0.42 4 O/L
8 Hem sleeves 0.69 3 F/L
9 Bottom Hem 0.56 3 F/L
TOTAL 4.96
Operation Breakdown –
Crew Neck

6. Process Flow
1 •Join Shoulder (with Mobilon tape)
3 •Attach Collar
4 •Set Neck Tape
5 •Down Stitch Neck Tape
6 •Top Stitch Neck Line
7 •Attach Sleeve
8 •Side Seam O/L
9 •Hem Bottom & Sleeve
10 •Attach Care Label and Main Label
FRONT BACK COLLAR / RIB SLEEVE
2 •Join Collar

7.  Raw materials required for T-Shirts –
 Knitted Fabric
 Single Jersey
 Double Jersey
 Rib
 Dyed or Printed
 Threads
 Buttons
 Zippers
 Embroidery
 Printing
Required Raw Materials
 Tags
 Labels
 Packing Cover
 Cartons

8. Location Analysis

9. Brandix India Apparel City

10.  Brandix India Apparel City (BIAC) is a revolutionary development in the apparel
industry; a unique, integrated apparel supply chain city, managed by Brandix
Lanka Ltd.
 Spread over 1000 acres in the port city of Visakhapatnam (or Vizag for short) in
the eastern state of Andhra Pradesh, it brings alive an avant garde 'Fibre to
Store' concept.
 BIAC will bring together world class apparel chain partners from the design table
to consumer brands in flawless integration.
Overview

11.  BIAC is first in the world to support a fully integrated vertical supply chain
 Fibre to Store Concept
Infrastructure

12.  Special Economic Zone
 Land Area Covers 1000 acers
 Received ISO 14001:2004 EMS certification in 2011
 Environment friendly and sustainable campus
 Follow CTPAT – Customs-Trade Partnership Against Terrorism
Infrastructure

13. Infrastructure
Selected
Land Area

14.  Population (Census Data 2011)
 84.66 M in the state
 4.28 M in Vizag district
 Employable Population:
 Within 20 minutes of BIAC
 Population 260,000
 Employable 45,000
 Within 45 minutes of BIAC
 600,000 (Age: 18-35)
 105,000 Employable (18%)
 65% literacy rate
 Two Universities in Vizag
Human Resource Availability

15.  Cotton production in India
 35.5 M bales (Cotton year 2012)
 2nd largest Cotton producer in the world with 21% global share
 Cotton production in Andhra Pradesh
 3rd largest Cotton producing state
 12% of the country’s production
 Cotton with long staple fibres
 Energy
 Natural gas supply from Godavari Basin
 Ample supply of coal from neighbouring states
 Water
 Perennial water supply: Godavari River
Natural Resource Availability

16.  Visakhapatnam City : 40km
 Airport : 42km
 Port : 35km
 Railway : 10km
 Highway : 5km
Connectivity

17. Common Infrastructure
Telecommunications
WTP ETP
Rain Water Harvesting

18. Common Infrastructure
Internal Roads
Power Sub-Station
Power Sub-Station
Solar Power

19.  Presently running Companies in BIAC campus:
 Ocean India - fabric mill for knitting, dyeing and printing
 Screenline Printing - printing services
 Shore to Shore- Manufacturing tags and labels
 Vardhman – Threads Suppliers
 Brandix Apparel India- ladies innerwear
 Seeds Intimate Apparel- Bras and Brallets
 Quantum Clothing - ladies innerwear and men’s shirts
 S & S- manufacturing underwires for bras
 Pioneer Elastics - China based company manufacturing and dyeing
narrow elastic
 Thermax- Providing energy solutions for other manufacturing units
Operational Units

20.  Presently running Companies in BIAC campus:
 Ocean India - fabric mill for knitting, dyeing and printing
 Screenline Printing - printing services
 Shore to Shore- Manufacturing tags and labels
 Vardhman – Threads Suppliers
Internal Suppliers

21. Raw Material - Fabric
(Dyed and Printed)

22. Raw Material – Tags and Lables

23. Raw Material - Threads

24.  Single Shift
 Working Time per day = 420min (7 hours)
 No. of working days per week = 6
 No. of days working in a month: 25
 Output per day @ 60% efficiency : 10,000
 Output per month: 2,50,000
Estimated Production Requirement

25. Machines and Equipment

26.  Required Sewing Machine –
 Lock Stich
 SNLS
 DNLS
 Flat Lock
 Over Lock
 3 O/L
 4 O/L
 Chain Stich
 Embroidery M/C
Machines and Equipment
 Required Equipment –
 Straight Knife
 Round Knife
 Iron
 Ironing Table
 Inspection Table
 Packing Table
 Trolleys
 Baskets

28.  SAM of the T-Shirt:
 Crew Neck : 6
 No. of m/c for final production= 400
 No. of m/c for pilot run = 20
 No. of m/c for training room = 20
 10% extra, so available m/c=440+44= 484
 No. of lines in sewing floor: 40
 No. of workstation req. for a T-shirt : 10
No. Machine Required

29. 175 sq. ft.*no. of m/c
=(175*400)sq. ft.
=70,000 sq. ft.
Factory Space Required

30.  Total Area – 70,000 sq. ft.
 Raw Material Warehouse – 2058 sq. ft.
 Finish Goods Warehouse – 3262.5 sq.
ft.
 Machine yard – 1406.5 sq. ft.
 Production Area – 11,074 sq. ft.
 Cutting Area – 3390 sq. ft.
 Embroidery – 942.5 sq. ft.
 Printing – 942.5 sq. ft.
 Office – 426.6 sq. ft. (7 offices)
 Staff washroom – 1269.12 sq. ft.
Area Description
 Washroom – 977.2686 sq. ft.
 Utilities / Crèche – 675.33 sq. ft.
 Canteen – 13650 sq. ft.
 Medical room – 628.8 sq. ft.
 Assembly – 5520 sq. ft.
 Parking – 12600 sq. ft.
 Front office – 1200 sq. ft.
 Green Area – 1925 sq. ft.

31.  Length of the roll: 100m
 Width of the roll: 5.5 ft
 Height of the roll: 1.5 ft
 Average consumption per garment: 1 m
 Fabric width: 60 inch
 Fabric consumption per day:10000m
 No. of rolls req. per day: 100 rolls
 Inventory: 2 days
 Total rolls inventory: 200
 Rack dimension: 6ftX 6ftX4ft
 No. of shelves: 3
 No. of rolls stacked in a height:24
Fabric Store

32.  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: 25
 No. of shelves: 3
 Area required for fabric store: 2058sq. ft
Fabric Store

33. R.M Warehouse descriptions

34.  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
Cutting room

35.  Spreading table length: 15 ft
 No. of spreading table req.: 11
 Total area : 4314 sq ft
Cutting room

36.  SAM of the t-shirt: 5.33
 No. of workstation: 400
 No. of sewing line: 40
 Total m/c:
 M/c area per line:122.5 sq. ft.
 Open space area per line:105 sq. ft.
 Total area required: 7175 sq. ft.
Sewing Room

37. Production floor descriptions

38.  No. of employees: 633
 Canteen is with cooking
 So area req. per employee is 25 sq ft
 So the canteen area is 9750 sq ft
 Occupies 320 employees at a time.
 So there will be two shifts for employees
Canteen

39. Man Power

40. Required Man Power

41. Material Flow

42. Raw
Material
Warehouse
•Arrival
•Unloading
•Inspection
•Rack Allocation
•Issued to
Cutting
Cutting
Section
•Spreading
•Cutting
•Bundling
•Ticketing
•Issued to
Sewing
Embroidery
/ Printing
•Panels
•(If Required)
Sewing Line
•Parts
Preparation
•Assembly
•End Line
Inspection
•Issued to
Finishing /
Packing
Embroidery
/ Printing
•Embroidery
•Printing
•Garment
Finishing
•Issued to
Packing
Packing
Area
•Tags and Labels
•Final Inspection
•Ironing
•Packing
•Handover to FG
Warehouse
Finish
Goods
Warehouse
•Rack / Space
Allocation
•Loading
•Dispatch
Material Flow

43. Proposed Factory Layout

44. Proposed Factory Layout

45.  2D Layout
 3D Layout
Proposed Factory Layout

46. Thank You