MINOR PROJECT

ON DESIGNING A
MANUFACTURING
SET UP - 2
FINAL JURY SUBMISSION

Akash Kumar
Yashwant Mithilesh
Shreya Bhojraj Bhagat
Santhvana Wilson

BFT SEM:7
 ACKNOWLEDGEMENT

Even failures can be turned into success and brilliance if one is guided by knowledge
and wisdom. This report also required such guidance without which the endeavor
would not have been successful. We would like to take this opportunity to express
our gratitude towards those who ensured the completion of the report by giving their
precious time to respond to our survey questionnaires.
We would first like to thank our advisor DR. K. RAM MOHAN, Associate
Professor at NIFT, Hyderabad. He was always available whenever we ran into a
trouble spot or had a question about the research or writing. He consistently allowed
this paper to be our own work, but steered us in the right direction whenever he
thought we needed it.
Finally, we express our profound gratitude to our parents for providing us with
unfailing support and continuous encouragement throughout the study. This
accomplishment would not have been possible without them.
 1. BRIEF ABOUT THE INDUSTRY
The manufacturing set up we’re planning to design is a denim jeans manufacturing
industry. Denim jeans has many numbers of variations based on stitching method,
fits, style, design, washing and finishing. We are planning to design an industry
producing jeans having 4 product variations:
1. Basic five pocket jeans
2. Five pocket jeans with embroidery on back pockets and thighs
3. Five pocket jeans with flaps on back pocket and with laser finishing
4. Other variations which is adjustable with machinery and resources available
can also be manufactured.

TYPE OF INDUSTRY Garment manufacturing apparel industry

Area 30,000 sq. ft. (170 ft. * 180 ft.)

No. of buildings 1 four floored building with terrace (96’-8” *96’-8”),

Administration block (60’-8” * 52’-7”, Security building,
Creche, Septic tank, Generator room, Boiler room.
Product category Denim jeans (4 different styles)

Nature of Business Export

Rate of production 6000 pieces

No. of shifts per day One 8-hour shift

2. DEPARTMENTS IN THE INDUSTRY

The industry we’re designing have three different blocks - An administration block,
a production block and extra services which includes all the departments and spaces
in the industry that offer services and assistance to the workers and others and are
spread across at different places in the layout.
2.1 ADMINISTRATION BLOCK

1) General Manager Cabin

2) Human Resource Department

3) Factory Manager Cabin

4) Production Manager Cabin

5) PPC Department

6) Marketing & Merchandising Department

7) Accounts & Finance Department

8) Conference Room

2.2 PRODUCTION BLOCK

1) Sampling Department

2) CAD Department

3) Fabric Receipt Area

4) Fabric Store

5) Trim Store

6) Spreading & Cutting Room

7) Sewing

8) Finishing & Packaging Section

9) Ware House

10) Quality Assurance Department

11) Industrial Engineering Department

12) Maintenance Department

13) Training Department

2.3 EXTRA SERVICES

1) Security Department

2) Main Entrance

3) Garden

4) Reception Area

5) Boiler

6) Generator

7) General maintenance

8) General Store room

9) Crèche

10) Canteen

11)Water

12) Safety Department

13) Toilet
 3. GREEN MANUFACTURING
The manufacturing unit we are designing will incorporate all the green
manufacturing practices. The basic idea is to set up a green building that will work
with:
• Efficient use of energy, water and other resources
• Use of renewable energy, such as solar energy
• Pollution and waste reduction measures, and the enabling of re-use and
recycling
• Good indoor environmental air quality
• Use of materials that are non-toxic, ethical and sustainable
• Consideration of the environment in design, construction and operation
• Consideration of the quality of life of occupants in design, construction and
operation
• A design that enables adaptation to a changing environment
3.1 SOLAR INITIATIVES
The industry will have on grid solar panels where solar system is tied to our local
utility’s GRID. This will be done in our industry because then our energy
requirements in the industry will be covered if our solar system under or over-
produces in regard to our varying energy needs required in the industry. This means
that our utility system acts as our battery space. If we are producing more energy
with our solar panels or system than we are using, the excess energy is sent to our
grid’s power company, allowing us to build credit that we can cash out with at the
end of the year, in a process called net metering. Being grid-tied is beneficial because
we don’t have to buy an expensive battery back-up system to store any excess
energy.
The industry will also have a micro inverter solar system so there won’t be any
requirement for a different inverter unit which is also beneficial in the long run. Just
an initial investment would suffice and fulfill the whole energy requirements which
will result in cost reduction and profit to the industry in the long-term manufacturing.
The solar panels will be set up on all the three roofs – on the production block, on
the administration block as well as above the creche. More area for setting up the
solar panels is required in this industry as there is a total power requirement of 1kwh
every day.
As mentioned, there will be a connection of the solar panels to the electric
department and on sunny days and also on the days when energy requirement is less,
the extra surplus energy from the solar panels is sent to the electrical department and
it is stored there. There is no separate installation
of batteries to store the energy is involved in this
case and that is cost beneficial too as installing
batteries will be expensive as well as space
consuming too.
When natural light is used when available during
daytime, and solar-powered lights are installed
throughout facility, it can 13 million kWh per year
and further reduce impact on the environment
which will be a great contribution towards the
green manufacturing and a green sustainable
building.
3.2 REDUCED HEAT ISLAND EFFECT
In order to limit the heat absorbed by the built constructions, the project has covered
its roof by high SRI Value paints and covered parking areas.
3.3 GREEN AREAS
About 20 percent of the site area has been developed as green area using native
plantation, thus considerably reducing the landscaping water demand. All the empty
and free spaces in the industry will have plantations and even in the parking area and
free spaces, we’ll have gardens which will also have a good green impact towards
the industry. Open space will be planted with trees and flowering plants and
rainwater fed pond.
3.4 CARBON NEUTRAL
By providing alternative transportation solutions to our associates in the planned
industry we will be able to reduce emissions, and planting trees to offset carbon
emissions, we will become carbon neutral in the long run. All the departments are in
the walkable distance and thus there would be no need of any fuel intensive vehicles.

4. WATER SUPPLY, DRAINAGE & SANITATION

An underground water storage of capacity 1,00,000 l for fire safety and cooling
system will be there in the planned industry. Rainwater harvesting pond of capacity
20000 l is attached with terrace pump of pumping power 900 l/min. Reservoirs and
tanks for the reception and storage of water shall be constructed of reinforced
concrete brick masonry, Ferro cement precast, mild steel, stainless steel or plastic.
Lead-based paint shall not be used in the tank. Lead-lined tanks shall not be used.
Tank/water reservoir higher than 900 mm deep shall be provided with corrosion
resistant catch rings, steps or ladders according to the depth to enable a person to
reach the bottom of the tank. Tank/water reservoir shall be provided with an
overflow pipe terminating above the ground/terrace level to act as a ‘Warning Pipe’
to indicate overflow conditions. The size of the overflow pipe shall be adequate to
accept the flow. Normally the overflow pipe size shall be one size higher than the
inlet pipe. Tank/water reservoir larger than 5000 l capacity shall be provided with
vent pipes to prevent development pressure in the tank which might result in NO
FLOW condition or inward collapse of the tank.
Adequate number of manholes for access and repair. The manholes shall be made of
corrosion resistant material (for example, cast iron, reinforced cement concrete, steel
fiber reinforced concrete, galvanized steel, high density polyethylene, fiber glass
reinforced plastic or such other materials acceptable to the Authority). Manholes
shall be provided with locking arrangement to avoid misuse and tampering.
SEPTIC TANKS
The planned layout will also have a septic tank where Effluent is infiltrated into the
ground or transported via a sewer to a (semi-)centralized treatment plant.
Accumulating faecal sludge needs to be dug out the chamber regularly and correctly
disposed. Septic systems are cost effective and have relatively low maintenance way
to treat and assist in the disposal of wastewater in the industry and is thus absolutely
necessary.
Rainwater that is collected goes for basic filter after which with the help of motor it
gets pumped and put in a filtration kit from where it goes for the domestic use. And
after getting basic filter it goes for flushing, while it’s not necessary that it is pure.
The septic tank will have a smoothing inlet which is referred as the flow calming
device to eliminate the turbulence of the incoming water. To help prevent damage,
septic tanks are fitted with low water cut-off float switch. These devices are intended
to detect the low water condition and shut down the tanks. There is a backflow
prevention device installed with the septic tank which prevents to keep wastewater
contaminants from getting into the fresh water supply. There is a pressure regulator
or actuated valve which is intended to regulate the high-pressure water that comes
in from the main supply line to ensure its pressure is reduced to a safe level.
WATER HARVESTING
Total rooftop area = 1400 sq ft. = 130. 06 m2
Catchment Coefficient = 0.85
Average rainfall = 970mm per year = 0.97 m per year
So, Total amount of rainwater collected = Total area (m2) × Catchment Coefficient
× Amount of rainfall (m) = 130.06×0.85×0.97 =107.23 m3 or 107230 liters
The equipment used for rainwater harvesting is relatively inexpensive, consisting in
most cases of valves, piping, small pumps, and tanks only. The operating costs of
these systems are generally very low. Routine maintenance and, in some cases,
electricity for the pumps, would be the major cost components. In addition to the
direct cost savings, it can reduce the capital costs of any required end-of-pipe
wastewater treatment system.
We are planning to install a rain water harvesting unit as it is beneficial in an industry
like this. The water bill is a huge expense and it is difficult to cut-back the usage of
water. Installing a rainwater harvesting system leads to 80% direct cost saving on
lengthy water bills.
It is sometimes perceived that the installation of an RWH system is an additional
expense. But when we considered its future returns, the system pays for itself over a
3 to 5 year period, majorly through cost savings on water usage.
Most of the industries have to run methods to avail freshwater, for the personnel and
industrial functional use. These methods involve filtration pumps, which are
responsible for emitting carbon into the environment. And for us by setting up a
rainwater harvesting system guarantees the availability of freshwater, thus cutting
down on one’s carbon footprints by saving the power used in freshwater processing.
Water recycling systems will also be installed in our industry and we will be extra
benefited by a rainwater harvesting system, as we will receive better quality, thereby
increasing their shelf life.
Harvested rainwater is naturally soft and is found in its purest form. This leaves your
storage tanks with high-quality water, having a minimal requirement for filtration.
This will be one of our main green and sustainable practice followed at our planned
industry.

5. ELECTRICITY
The capital investment (excluding the land required) in a solar power project range
from Rs. 60 lakhs to Rs. 1.5 crore for a 100 KW capacity solar power project.
Moreover, about 10 square metres of land is required per KW for a solar power plant.
The total sq ft. that we need for 100 KW is 10,763 sq ft (Production block+
administrative block+ creche) and we have 12,000 sq. ft of land for setting a solar
power plant, so we can set up a solar plant of 100 KW in our industry.
We will be using 200 sewing machines which will require almost 500 KW/h and the
industry uses energy for the production of garments, thermal and visual comfort of
the factory occupants, as well as maintenance purposes and office equipment such
as computers, printers, and photocopy machines. So, in total the energy consumed
is nearly 1000 KW/h. Also, the solar panels that we are using is on grid. We will be
having a connection from the electric department and will be using that if there is a
less power in the system.
While on really sunny days or the days when we won’t require much energy, extra
energy will be sent to the electrical department so they can store it for the later use.
This will also help us to avoid installing batteries as it would be too expensive and
space taking at the same time.
The energy consumed by the apparel production division consists of large numbers
of small-sized companies and their employees in the overall industry, is not
necessarily low compared to other sub-sectors, but the share percentage of energy
cost to the total cost (personnel cost + energy cost + material cost) is relatively low.

Clothing production stages, including laying up, cutting, sewing, cleaning with air
suction, ironing, and transporting processes, mostly consume electric energy. Only
finishing processes (heating and ironing) might require both steam or hot air and
electricity.

6. AIR AND STEAM REQUIREMENTS

In finishing department, the processes require both steam or hot air. The ironing
tables needs steam to complete its process. And we have shown pipelines of steam
in our layout for the same. We have boiler lines and pneumatic air flow throughout
the industry wherever it is needed. Boiler lines produces steam which is being used
in irons. While pneumatic air flow is used to blow the threads or fibers in the
finishing department, and also to remove fray from the fabric in the overlock
machines in sewing department.
 Lift
Fire extingusher
Boiler pipelines

Solar panels

Solar Panel rails

Energy flow from Inverter

to generator room

Electricity Supply
to Blocks

Rainwater Flow

Rainwater pipelines
Ground floor of Production Block 1st floor of Production Block 2nd floor of Production Block
60'-8"
Lift
General Manager
Cabin
Human Resource
Department
Factory Manager
Cabin
General Manager
Cabin
Human Resource
Department
Factory Manager
Cabin
General Manager
Cabin
Human Resource
Department
Factory Manager
Cabin
Fire extingusher
Parking
Creche Creche Creche
Toilets

Parking
Toilets

Parking
Toilets

Boiler pipelines
Production Manager Production Manager Production Manager
PPC Department
Cabin 52'-7" PPC Department
Cabin
PPC Department
Cabin
Security Room
Security Room
Conference Room

Conference Room

Conference Room
Security Room

Solar panels
Accounts Marketing and Accounts Marketing and Accounts Marketing and
department merchandising department merchandising department merchandising
department Septic Tank department Septic Tank department Septic Tank
Toilets Toilets Toilets

96'-8"
Solar Panel rails
Ware house
receipt

Energy flow from Inverter

Fabric

area

Toilet
Toilets
CAD Department
Quality assurance
Sampling Department

IE Department
180' Trims store Maintenance
Department to generator room
Parking Parking
Parking

Electricity Supply
Finishing Department
to Blocks
Spreading and cutting
Department

96'-8"

Generator Generator
Sewing Department
Generator Rainwater Flow

Training Department

Boilers Boilers Boilers

Rainwater pipelines
Toilets

170'

3rd floor of Production Block 4th floor of Production Block Terrace of all blocks The septic tank
13 12 13
1 11
2
15 10
Parking Factory Manager Factory Manager
General Manager Human Resource General Manager Human Resource
Cabin Department
Cabin
Cabin Department
Cabin 5
Parking Parking

Creche Creche
Toilets Toilets
9
3 16

Production Manager Production Manager

PPC Department PPC Department
Cabin Cabin 6 7
Security Room
Conference Room

Conference Room

Security Room Security Room

Accounts Marketing and Accounts Marketing and

department merchandising department merchandising
department Septic Tank department Septic Tank Septic Tank 4
Toilets Toilets
Grade

1 Rainwater collection point (roof drains, 6 Low water cut off float switch 12 Pressure regulator or actuated valve
gutters, etc).
7 Pump 13 Pressure gauge
2 Water filter
8 Pitch overflow 14 Level indicator (on pump control panel)
3 Rainwater first goes in Flushing Devices
Maintenance

Safety
Department Cooking Area 15 Vent (sized as required)
General

9 Septic Tank
4 Smoothing Inlet - "flow-calming" device to 16 Drinking water filtration – sediment, UV,
Storage
eliminate turbulence of the incoming water 10 Domestic water supply and carbon for potable applications

11 Backflow prevention device

Parking Parking Parking
5 Cistern

Eaing Area

Water tank

Fabric Store

Generator Generator Generator

Hand wash

Boilers Boilers Boilers

Toilets
 Terrace of all blocks
Parking

Security Room

Septic Tank

Parking

Generator

Boilers
Ground floor of Production Block
60'-8"

Factory Manager
General Manager Human Resource
Cabin
Cabin Department

Parking
Creche
Toilets

Production Manager
PPC Department
Cabin 52'-7"
Security Room Conference Room

Accounts Marketing and

department merchandising
department Septic Tank
Toilets

96'-8"

receipt
Ware house

Fabric

area
Toilet

Quality assurance

180'

Parking

Finishing Department

96'-8"

Generator

Training Department

Boilers

170'
1st floor of Production Block
Factory Manager
General Manager Human Resource
Cabin
Cabin Department

Creche
Toilets

Parking

PPC Department Production Manager

Cabin
Conference Room

Security Room

Accounts Marketing and

department merchandising
department Septic Tank
Toilets

IE Department
Trims store Maintenance
Department

Parking

Generator
Sewing Department

Boilers

Toilets
2nd floor of Production Block
Factory Manager
General Manager Human Resource Cabin
Cabin Department

Creche
Toilets

Parking

PPC Department Production Manager

Cabin
Security Room
Conference Room

Accounts Marketing and

department merchandising
department Septic Tank
Toilets

Toilets
CAD Department
Sampling Department

Parking

Spreading and cutting

Department

Generator

Boilers
3rd floor of Production Block
Parking Factory Manager
General Manager Human Resource
Cabin
Cabin Department

Creche
Toilets

PPC Department Production Manager

Cabin
Security Room
Conference Room

Accounts Marketing and

department merchandising
department Septic Tank
Toilets

Parking

Fabric Store

Generator

Boilers
4th floor of Production Block
Factory Manager
General Manager Human Resource Cabin
Cabin Department
Parking

Creche
Toilets

PPC Department Production Manager

Cabin
Conference Room

Security Room

Accounts Marketing and

department merchandising
department Septic Tank
Toilets
Maintenance

Safety
Department Cooking Area
General

Storage

Parking

Eaing Area

Water tank

Generator
Hand wash

Boilers

Toilets
 The septic tank
13 12 13
1 11
2
15 10

9
3 16

6 7

Grade

1 Rainwater collection point (roof drains,
gutters, etc).
2 Water filter
3 Rainwater first goes in Flushing Devices
4 Smoothing Inlet - "flow-calming" device to
eliminate turbulence of the incoming water
6 Low water cut off float switch 12 Pressure regulator or actuated valve
7 Pump 13 Pressure gauge
8 Pitch overflow 14 Level indicator (on pump control panel)
15 Vent (sized as required)
9 Septic Tank
16 Drinking water filtration – sediment, UV,
10 Domestic water supply and carbon for potable applications

11 Backflow prevention device

5 Cistern
 7. CONCLUSION
The manufacturing companies are Green pioneers and green manufacturing is core
to their competitive strategies these days as people have become more conscious
regarding the necessity of green and sustainable production. The transformation
journey to green manufacturing has just started and thus simple steps like the ones
that we have suggested in our layout like solar powered roofs, water harvesting units,
a proper effluent treating system or the septic tank are something all the
manufacturing garment units can adopt to create a sustainable and green future.
While there are a few early adopters, the garment industry at large needs to develop
comprehensive plans to address all three areas — Green energy, Green products and
Green processes. The first step to make is the processes green as well as green energy
which all the industry can do. The statistics shared in our document says how
industries that run with solar energy and also has water harvesting system benefits
in the long run. The prize for these small steps towards green manufacturing is
enormous for both individual manufacturing companies and the country as a whole.
And it is high time to adopt the measures in all the apparel manufacturing industries.