PLANT LAYOUT

PRODUCTION, PLANNING AND

CONTROL

BY: ALISHA ARORA

M.SC FTM 3RD SEM

OBJECTIVE

The objective of the project is to make a layout for anapparel manufacturing unit which
produces 500 shirts per day. The aim of this project is to have a detailed knowledge about the
departments of the apparel manufacturing unit and also knowing their importance in the
factory. The space allocations for each department is very essential to know about the
specifications of the work area.
The detailed layout of the production ara of the factory helps in gaining the knowledge
about the equipments used in the manufacturing of apparels as well as the whole process of
producing them.
Tha layout not only tells about the departments and equipments but also makes aware of
the human conditions and human needs of the workers.
This project is being very helpful in gaining the inside knowledge of the pparel
manufacturing.

TABLE OF CONTENTS

TOPIC

1.INTRODUCTION

PAGE NO.

DEFINITION
IMPORTANCE
ESSENTIALS
TYPES OF LAYOUT
2. FACTORS INFLUENCING LAYOUT

3. DYNAMCS OF A FACTORY LAYOUT

4. MAKING A FACTORY LAYOUT

5. GENERAL STEPS OF MAKING A PLANT LAYOUT

6. PRODUCT SPCIFICATIONS

7. DEPARTMENTS INVOLVED IN MANUFACTURING

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8. WORK FLOW PROCESS

12

9.MACHINES REQUIRED

15

10.

SPECIFICATIONS OF THE LAYOUT

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INTRODUCTION
The efficiency of production depends on how well the various machines; production facilities
and employees amenities are located in a factory. Only the properly laid out factory can
ensure the smooth and rapid movement of material, from the raw material stage to the end
product stage. Factory layout encompasses new layout as well as improvement in the existing
layout. An ideal factory layout should provide the optimum relationship among the output,
floor area and manufacturing process. An efficent factory layout is one that aims at achieving
various objectives like efficient utilization of available floor space, minimizes cost, allows
flexibility of operation, provides for employees convenience, improves productivity etc.The
entrepreneurs must possess the expertise to lay down a proper layout for new or existing
plants. It differs from one factory to another. But basic principles to be followed are more or
less same. While deciding for layout for factory or unit or store, a small entrepreneur has to
consider the factors like the nature of the product, production process,size factory building,
human needs etc

DEFINITION
A factory layout can be defined as follows; Factory layout refers to the arrangement of
physical facilities such as machinery, equipment, furniture etc. with in the factory building in
such a manner so as to have quickest flow of material at the lowest cost and with the least
amount of the finished product.
According to Ringgs, the overall objective of factory layout is to design a physical
arrangement that most economically meets the required output-quantity and quality.
According to J.L.Zundi, Factory layout ideally involves alloction of space and arrangement
of equipment in such a manner that overall operating costs are minimized.

IMPORTANCE
Factory layout is an important decision as it represents long-term commitment. An ideal
factory layout should provide the optimum relationship among output, floor area and
manufacturing process.It facilitates the production process, minimizes material handling, time
and cost, and allows flexibility of operations, easy production flow, makes economic use of
the building, promotes effective utilization of manpower, and provides for employees
convenience safety, comfort at work, maximum exposure to natural light and ventilation. It is
also important because it affects the flow of material and processes, labour efficiency,
supervision and control, use of space and expansionpossibilities etc.

ESSENTIALS
An efficient factory layout is one that can be instrumental in achieving the following
objectives;
a) Proper and efficient utilization of available floor space
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b) To esure that work proceeds from one point to another point without any delay
c) Provide enough production capacity
d) Reduce material handling cost
e) Reduce hazards to personnel
f) Utilise labor efficiently
g) Increase employee morale
h) Reduce accidents
i) Provide for volume and product flexibility
j) Provide ease of supervision and control
k) Provide for employee safety and health
l) Allow ease of maintenance
m) Allow high machine or equipment utilization
n) Improve productivity

TYPES OF LAYOUT
The factory layout facilitates the arrangement of machines, equipment and other physical
facilities in a planned manner within the factory premises. An entrepreneur must possess an
expertise to lay down a proper layout for new or existing plants. It differs from plant to plant,
from location to location and from industry to industry. But the basic principles govering
factory layout are more and less more.
Manufacturing units
In case of manufacturing units, factory layout may be
of four types:
1) Product or line layout
2) Process or functional layout
3) Fixed position or location layout
4) Combined or line layout
Product or line layout:
Under this, machines and equipments are arranged in one line depending upon the sequence
of operation required for the product . The materials move form one workstation to another
sequentially without any backtracking or deviation. Under this, machines are grouped in one
sequence. Therefore matereals are fed into the first machine and fineshed goods travel
automatically from machine to machine, the output of one machine becoming input of the
next. The raw material moves very fast from one workstation to other station with a minimum
work in progress storage and material handling. The grouping of machines should be done
keeping in mind the following general principles:
a) All the machine tools or other items of equipments must be placed at the point demanded
by sequence of operations.
b) There should no points where one line crossed another line.
c) Materials may be fed where they are required for assembly but not necessarily at one point.
d) All the operations including assembly, testing packing must be included in the line.

Process layout:
In this type of layout machines of similar type are arranged together at one place. The
process or functional layout is followed from historical period. It evolved from the handicraft
method of production. The work has to be allocated to each department in such a way that no
machines are chosen to do as many different job as possible i.e. the emphasis is on general
purpose machines. The grouping of machines according to the process has to be done keeping
in wind the following principles:
a) The distance between departments should be as short as possible for avoiding long distance
movement of materials
b) The departments should be in sequence of operations
c) The arrangement should be convenient for inspection and supervision.
Fixed Position or Location Layout:
In this type of layout, the major product being produced is fixed at one location. Equipment
labour and components are moved to that location. All facilities are brought and arranged
around one work center. This type of layout is not relevant for small scale entrepreneur.
Combined layout:
Certain manufacturing units may require all three processes namely intermittent process the
continuous process and the representative process combined process. In most of industries,
only a product layout or process layout process or fixed location layout does not exist. Thus,
in manufacturing concerns where several products are produced in repeated numbers with no
likelihood of continuous production, combined layout is followed. Generally a combination of
the product and process layout or other combinaion are found, in practice, e.g. for industries
involving the fabrication of parts and assembly, fabrication tends to employ the process
layout, while the assembly areas often employ the product layout.

FACTORS INFLUENCING LAYOUT

While deciding his factory or unit or establishment or store, a small-scale businessman should
keep the following factors in mind:
a) Factory building: The nature and size of the building determines the floor space available
for layout. While designing the special requirments, e.g. air conditioning, dust control,
humidity control etc. must be kept in mind.
b) Nature of product: Product layout is suitable for uniform products whereas process layout
is more appropriate for custom-made products.
c) Production process: In assembly line industries, product layout is better. In job order or
intermittent manufacturing on the other hand, process layout is desirable.
d) Type of machinery: General purpose machines are often arranged as per process layout
while special purpose machines are arranged according to product layout.
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e) Repairs and maintenance: Machines should be so arranged that adequate space is avaible
between them for movement of equipment and people required for repairing the machines.
f) Human needs: Adequate arrangement should be made for cloakroom, washroom, lockers,
drinking water, toilets and other employee facilities, proper provision should be made for
disposal of effluents, if any.
g) Plant environment: Heat, light, noise, ventilation and other aspects should be duly
considered, e.g. paint shops and plating section should be located be in another hall so that
dangerous fumes can be removed through proper ventilation etc. Adequate safety
arrangement should also be made. Thus, the layout should be conducive to health and safety
of employees. It should ensure free and efficient flow of men and materials. Future expansion
and diversification may also be considered while planing factory layout.

DYNAMICS OF PLANT LAYOUT

Plant layout is a dynamic rather than a static concept meaning thereby if once done if is not
permanent in nature rather improvement or revision in the existing plant layout must be made
by keeping a track with development of new machines or equipment, improvements in
manufacturing process, changes in materials handling devices etc. But any revision in layout
must be made only when the savings resulting from revision exceed the costs involved in such
revision. Revision in plant layout may become necessary on account of the following reasons:
a) Increase in the output of the existing product
b) Introduction of a new product and diversification
c) Technological advancements in machinery, material, processes, product design, fuel etc.
d) Deficiencies in the layout unnoticed by the layout engineer in the beginning.

MAKING THE FACTORY LAYOUT

Layout of the plant is decided based on process sequence, building structure, shop floor
transportation, type of layout (product or process based or a combination of both) and
arrangement of machines. The aim of every layout is to maximize utilization of available
space in order to speed up the material flow. Highly specialized machines and small parts
assembly may be configured with a line arrangement for final assembly.
Factors to be considered for designing an effective layout include number of workers both
male and female, number of machines (size, weight by models), entrance, exit and passages
(size, width, position, number of each of them) for production as well as administrative wing,
change room, lunch room, lavatories, medical emergency room and provision for those
governed by local laws. Utilities like boiler, air compressor, vacuum pumps, generator,
electric panel, air conditioning machine, underground water storage tanks for boiler and
washing machines, water softening plant, waste water recycling plant, drainage system are
also equally important.
Other factors that need attention before laying out the factory plan include ceiling height (33.5 metres from floor), lighting (large windows of 2 or 3 stages) and illuminance levels (600
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Lux for production and 800 Lux for inspection areas) besides ventilation. Also, the workplace
should have sufficient number of mens and womens toilets and drinking water outlets in the
vicinity.

PRODUCT SPECIFICATIONS

PRODUCT: mens shirt

STYLE NO.: AX123
FABRIC: 100% cotton
BRAND: Armani exchange
COLOUR: royal blue
STYLE DESCRIPTION: slim fit, full sleeves
CAPACITY: 500 pcs./ day

DEPARTMENTS INVOLVED IN THE MANUFACTURING OF SHIRT

MERCHANDISING

SAMPLING

CAD

PRODUCTION FLOOR

CUTTING

LAYERING

PINNING

SEWING

KAJ-BUTTON

PREPARATORY
LINE

TICKETING AND
BUNDLING

ASSEMBELY LINE

THREAD CUTTING

FINISHING

POST- PRESS
CHECKING

STITCHINGALTER

CHECKING
WIP( work in
progress)

SPOTTING
SECTION

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PRESSING AND
FOLDING

PRESENTATION
CHECKING

PACKAGING

TAGGING

DYEING LOT
SEGREGATION TABLE

PACKING
AREA

WAREHOUSE
SECTION

SHIPMENT

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WORK FLOW PROCESS OF THE SHIRT

PREPARATORY LINE
COLLAR- 2 PIECE
1. COLLAR BACK
2. NECK BAND
3. FUSING

FabricNeck
band 2
pcs.

Fusing
attach

Turning

Topstitch

Fusing
attach

Neck band

Turning and
pressing
Neck band
attach

Collar back

1 fabric piece
attach

Ready collar
CUFF
Cuff pattern

Fusing attach

Marking

3rd piece attach

Stitch and cutting

Turning
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Ready cuff

Top stitch

FRONT

Right front

Left front

Placket attached

Fold and stitch

BACK

Label attach

Yoke

Back and front yoke

attached to back

Top stitch
SLEEVE

Placket

Pattern- 2 pcs.

Folding and pressing

Attached to one
side

Second placket

Fold and attach

on other side

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ASSEMBELY LINE

FRONT AND BACK ATTACHED

(SHOULDER SEAM)

SLEEVE ATTACH

SIDE SEAM

COLLAR ATTACH

CUFF ATTACH

KAJ- BUTTON

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MACHINES REQUIRED FOR EACH OPERATION

COLLAR
5 single needle lock stitch machines
1 turning machine
1 pressing unit

CUFF
4 single needle lock stitch machine
1 pressing unit
1 helper

FRONT
2 Single needle lock stitch machines

BACK
3 single needle lockstitch machines

SLEEVE
2 single needle lock stitch machines
1 pressing unit
ASSEMBELY LINE
9 single needle Lock stitch machines

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SPECIFICATIONS OF THE LAYOUT

DIMENSION: 70ft*125ft
The factory layout prepared consists of two floors. The ground floor has offices and
departments of the factory and the first floor is the detailed production floor layout.
The layout used in the production floor is a combined layout of product and process layout.
GROUND FLOOR SPCIFICATIONS
The departments and spaces are allocated for the following:

Reception area: 30ft * 15ft

VIP lounge: 30ft* 20ft

CAD department: 15ft * 25ft

Conference room: 15ft * 30ft

Washrooms: 10ft *30ft

Administration and finance office: 35ft *30ft

Production, planning and control department: 35ft * 20ft

Merchandising department: 37.5ft *25ft

Sampling department:35ft *25ft

Fabric store for sampling: 15ft *15ft

Canteen: 37.5ft* 15ft

SPECIFICATIONS OF THE PRODUCTION FLOOR

Accessories store: 15ft* 20ft

Fabric store: 40ft* 20ft

Fabric audit room: 20ft* 10ft

Sorting and bundling: 3 tables

Each table: 5ft* 3ft

Cutting area: 2 tables

Each table: 12ft* 6ft
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Racks area: 4 racks

Each rack: 2ft*5ft*7.2ft

Sewing area: 50ft* 10ft

In process Pressing area: 3 press stations

Each press station: 5ft *5ft

Thread cutting area: 6.25ft* 16.25ft

Finishing department: 29ft* 40ft

1. Post press checking: 5ft* 12.5ft
2. Rework and alterations: 5ft* 12.5ft
3. Spotting section: 5ft* 12.5ft
4. Pressing and folding: 10ft *15ft
5. Quality check: 10ft *15ft

Packaging department: 29ft * 50ft

1. Tagging section: 5ft* 7.5ft
2. Dyeing lot segregation table: 17.5ft *7.5ft
3. Storage area(warehouse section): 29ft* 20 ft

Production managers office: 10ft *10ft

Maintenance department: 10ft * 20ft

Medical room: 10ft *8ft

Washrooms: 10ft* 40ft

DESIGNING THE WORKSTATION

A workstation in the layout consists of the machine or equipment and the chair for the worker.
It also includes some extra space for the sake of workers comfort during performance of the
operation.
DIMENSIONS: 3.5 ft* 3.75 ft

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The workstations are arranged in the layout in accordance to the workflow of the garment to
be manufactured. The racks are arranged the two workstations in order to keep the parts of
the garment.
The rack also consist of a lower shelf so that the parts of both the workers should not mix
with each other and it also provides convenience in work.
The workstations are arranged in the sewing area with total of 28 machines covering the area
of 50 ft* 10 ft.

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