UNIT

03
PREPARED BY
PRIYANKA GADE
Basics of Apparel Plant
and Sewing Machines
Layout

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The definition of a good layout might differ from person to person but there are certain

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basics that are must for any apparel factory layout.

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A good factory layout is directly associated with good workflow, right from material

receiving till the finished goods go out of the factory. Whatever type of plant layout a

firm develops, it should be designed to optimise quality, throughput time and flexibility.

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Plant layout is the spatial arrangement and configuration of departments, work stations,

machinery and equipment used in the conversion

A process. Layout of an apparel

production plant directs the flow of materials and work-in-process from start till its

completion and integrates material handling and equipment.

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An efficient layout has the flexibility to be changed to meet requirements of the product

line, delivery schedules, and anticipated volume. Safety is a major consideration in plant
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layout. Fire and safety codes, emergency and accessible exits, open traffic areas, etc.

must all be a part of layout plans.

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The following factors should be taken into consideration while planning a layout:
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• Minimization of manufacturing cost,

• Feeding the materials and parts at highest possible speed and in one direction without
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any backtracking or overlapping flow of products,

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• Minimization of work transfer among the processes from acceptance of raw materials

till delivery of finished product with properly defined spaces for each process, and
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• Provision of future expansion plans.

The layout planning should be done based on factory site selection and arrangement of

building and machines.

Layout of the Plant

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

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assembly may be configured with a line arrangement for final assembly.

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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

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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

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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.

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General Steps for Making a Plant Layout
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Make a scaled drawing of factory/shop floorMake models of machines/equipments

Draw immovable facilities/equipments

• Entrances, exits/stairs
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• Washrooms, corridors

• Pillars, partitions
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• Air conditioning ducts, steam, air and vacuum lines

• Power outlets, electrical lines for feed to machines,electrical panelsArrange the main
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flow process in a straight line regardlessof available spaceArrange the main flow process

in the available spaceIf it is necessary to change the direction of main flow process
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change it for worker who is in charge of an iron or a special purpose machineArrange the

additional divisions in the remaining space

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Make a final drawing based on completed machine layout

Other factors that need attention before laying out the factory plan include ceiling height

(3-3.5 metres from floor), lighting (large windows of 2 or 3 stages) and illuminance

levels (600 Lux for production and 800 Lux for inspection areas) besides ventilation.

Also, the workplace should have sufficient number of men’s and women’s toilets and

drinking water outlets in the vicinity.

 FOUR MAIN TYPES OF
PLANT LAYOUT

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Keeping in view the type of industry and volume of production, the type

of layout to be selected is to be decided from the following:

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1. Product or Line Layout

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2. Process or Functional Layout.

3. Fixed Position Layout.

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4. Combination type of Layout.
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1. Product or Line Layout:

If all the processing equipment and machines are arranged according to the sequence of

operations of the product, the layout is called product type of layout. In this type of

layout, only one product of one type of products is produced in an operating area. This

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product must be standardized and produced in large quantities in order to justify the

product layout.The raw material is supplied at one end of the line and goes from one

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operation to the next quite rapidly with a minimum work in process, storage and material

handling. Fig. 8.3 shows product layout for two types of products A and B.

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Advantages offered by Product Layout:

(i) Lowers total material handling cost.

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(ii) There is less work in processes.

(iii) Better utilization of men and machines,

(iv) Less floor area is occupied by material in transit and for temporary storages.
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(v) Greater simplicity of production control.

(vi) Total production time is also minimized.

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Limitations of Product Layout:

(i) No flexibility which is generally required is obtained in this layout.

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(ii) The manufacturing cost increases with a fall in volume of production.

(iii) If one or two lines are running light, there is a considerable machine idleness.
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(iv) A single machine break down may shut down the whole production line.

(v) Specialized and strict supervision is essential.

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2. Process or Functional Layout:

The process layout is particularly useful where low volume of production is needed. If the

products are not standardized, the process layout is more low desirable, because it has

creator process flexibility than other. In this type of layout, the machines and not arranged

according to the sequence of operations but are arranged according to the nature or type of

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the operations. This layout is commonly suitable for non repetitive jobs.

Same type of operation facilities are grouped together such as lathes will be placed at one

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place, all the drill machines are at another place and so on. See Fig. 8.4 for process layout.

Therefore, the process carried out in that area is according to the machine available in that

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area.

Advantages of Process Layout:

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(i) There will be less duplication of machines. Thus, total investment in equipment

purchase will be reduced.

(ii) It offers better and more efficient supervision through specialization at various levels.
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(iii) There is a greater flexibility in equipment and man power thus load distribution is

easily controlled.
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(iv) Better utilization of equipment available is possible.

(v) Break down of equipment can be easily handled by transferring work to another
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machine/work station.

(vi) There will be better control of complicated or precision processes, especially where

much inspection is required.

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Limitations of Process Layout:

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(i) There are long material flow lines and hence the expensive handling is required.

(ii) Total production cycle time is more owing to long distances and waiting at various
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points.

(iii) Since more work is in queue and waiting for further operation hence bottle necks
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occur.

(iv) Generally, more floor area is required.

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(v) Since work does not flow through definite lines, counting and scheduling is more

tedious.

(vi) Specialization creates monotony and there will be difficult for the laid workers to find

job in other industries.

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Process or Functional Layout

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3. Fixed Position Layout:

This type of layout is the least important for today’s manufacturing industries. In this

type of layout the major component remain in a fixed location, other materials, parts,

tools, machinery, man power and other supporting equipment’s are brought to this

location.

The major component or body of the product remain in a fixed position because it is too

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heavy or too big and as such it is economical and convenient to bring the necessary

tools and equipment’s to work place along with the man power. This type of layout is

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used in the manufacture of boilers, hydraulic and steam turbines and ships etc.

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Advantages Offered by Fixed Position Layout:

(i) Material movement is reduced

(ii) Capital investment is minimized.

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(iii) The task is usually done by gang of operators, hence continuity of operations is

ensured

(iv) Production centers are independent of each other. Hence, effective planning and
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loading can be made. Thus total production cost will be reduced.

(v) It offers greater flexibility and allows change in product design, product mix and
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production volume.

Limitations of Fixed Position Layout:

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(i) Highly skilled man power is required.

(ii) Movement of machines equipment’s to production centre may be time consuming.

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(iii) Complicated fixtures may be required for positioning of jobs and tools.

This may increase the cost of production.

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4. Combination Type of Layout:

Now a days in pure state any one form of layouts discussed above is rarely found.

Therefore, generally the layouts used in industries are the compromise of the above

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mentioned layouts. Every layout has got certain advantages and limitations. Therefore,

industries would to like use any type of layout as such.Flexibility is a very important

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factory, so layout should be such which can be molded according to the requirements

of industry, without much investment. If the good features of all types of layouts are

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connected, a compromise solution can be obtained which will be more economical and

flexible.

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 THE LOGISTICS
MANAGEMENT IN
TEXTILE & GARMENT
INDUSTRY

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Logistics is the management of the flow of goods and services between the point of

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origin and the point of use in order to meet the requirements of customers or

corporations. Logistics involves the integration of information, transportation, inventory,

warehousing, material handling, and packaging, and even security. Logistics is a channel

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of the supply chain which adds the value of time and place utility. Today the complexity

of production logistics can be modeled, analyzed, visualized and optimized by plant

simulation software, but is constantly changing. In Textile Industry where so many

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stages are need to pass from Raw materials to finished goods and then to reach at

customers end within stipulated time frame , the logistics management plays a vital role
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in satisfying customers need and brings delighters in business circle.

The word logistics has its origin in the French verb loger to lodge or to quarter. Its
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original use was to describe the science of movement, supplying & maintenance of

military forces in the field. Later on it was used to describe the management of materials
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flow through an organization, from raw materials through to finished goods. It means for

giving inputs which ultimately work for the final consumer or to delivery.
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According to the Council of Logistics Management, logistics contains the integrated

planning, control, realization and monitoring of all internal and network-wide material,
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part- and product flow including the necessary information flow in industrial and trading
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companies along the complete value-added chain (and product life cycle) for the purpose

of confirming to customer requirements.

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It can be divided in Performance and cost related to fulfil the target. For the viewpoints,

the inbound logistics concentrates on purchasing to manufacturing or assembly plants.

Out bound logistics are related to storage to the end user with information flow.
The main fields are:

* Procurement Logistics

* Production Logistics

* Distribution Logistics

* After sales Logistics

* Disposal Logistics

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Procurement Logistics consists of activities such as market research, requirements

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planning, make or buy decisions, supplier management, ordering, and order controlling.

The targets in procurement logistics might be contradictory - maximize the efficiency by

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concentrating on core competences, outsourcing while maintaining the autonomy of the

company, and minimization of procurement costs while maximizing the security within

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the supply process.

Production logistics
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The term production logistics is used to describe logistic processes within The Textile

industry. The purpose of production logistics is to ensure that each machine and
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workstation is being fed with the right product in the right quantity and quality at the

right time. The concern is not the transportation itself, but to streamline and control the
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flow through value-adding processes and eliminate nonvalue-adding ones. Production

logistics can be applied to existing as well as new plants. Manufacturing in an existing

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plant is a constantly changing process. Machines are exchanged and new ones added,

which gives the opportunity to improve the production logistics system accordingly.

Production logistics provides the means to achieve customer response and capital
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efficiency. Production logistics is becoming more important with decreasing batch sizes.

In many Textile industries a batch size of one is the short-term aim, allowing even a
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single customer's demand to be fulfilled efficiently. Track and tracing, which is an

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essential part of production logisticsdue to product safety and product reliability issuesis

also gaining importance, especially in the automotive and medical industries.

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Distribution Logistics has, as main tasks, the delivery of the finished products to the

customer. It consists of order processing, warehousing, and transportation. Distribution

logistics is necessary because the time, place, and quantity of production differ with the

time, place, and quantity of consumption.

Disposal Logistics main function is to reduce logistics cost(s), enhance service(s), and

save natural resources.

Business logistics can be defined as "having the right item in the right quantity at the

right time at the right place for the right price in the right condition to the right

customer", and is the science of process and incorporates all industry sectors. The goal of

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logistics work is to manage the fruition of project life cycles, supply chains and resultant

efficiencies.Logistics management is that part of the supply chain which plans,

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implements and controls the efficient, effective forward and reverse flow and storage of

goods, services and related information between the point of origin and the point of

consumption in order to meet customer and legal requirements. A professional working

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in the field of logistics management is called a logistician.

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Logistics management is known by many names, the most common are as follows:

* Materials Management

* Channel Management A
* Distribution (or Physical Distribution)

* Business or Logistics Management or

* Supply Chain Management

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Third-party logistics:
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According to this definition, third-party logistics includes any form of outsourcing of

logistics activities previously performed in-house. If, for example, a company with its
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own warehousing facilities decides to employ external transportation, this would be an

example of third-party logistics. Logistics is an emerging business area in many

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countries.

Fourth-Party Logistics (4PL) targets management of the entire process. Some have
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described a 4PL as a general contractor who manages other 3PLs, truckers, forwarders,
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custom house agents, and others, essentially taking responsibility of a complete process

for the customer.

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There is Emergency Logistics which means to move goods or objects rapidly in the

event of any emergency which could be due to production delay or communication

failure.The Professional logistics are known as Shipping, Airport, and freight forwarder.

It is:
Cargo

Document automation in supply chain management & logistics

Inventory

Inventory management software

Performance-based logistics

Returns management system

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Reverse logistics* Sales territory

Supply chain management

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