ArchlLecLural 8rlef Lo

seL up a Llngerle
manufacLurlng planL




2011
ueeplka 8ana kunal !aln neha ?adav and valbhav Slngh
nll1
10/20/2011
Content

1) Introduct|on
2) Company rof||e
3) L|st of Departments
4) rocess I|ow of the Iactory
S) Departments
a Cff|ce area
b roduct|on area
c Storage
d Warehouse
e Ma|ntenance
f CAD
g Mach|ne Storage area
h Cther Iac|||t|es
6) Mater|a| nand||ng
7) I|oor|ng
8) L|ght|ng










@o Setup a manufactur|ng p|ant for L|nger|e

Introduct|on
Apparel manufacLurlng ls Lhe englneered process of converLlng fabrlc lnLo garmenLs 1he
apparel manufacLurlng lndusLry ls lnvolved ln Lhe deslgnlng and manufacLurlng cloLhlng and
accessorles for women men chlldren and lnfanLs ln Lhe caLegorles of casual wear acLlve
wear essenLlals formal wear and ouLer wear

As Lhe apparel manufacLurlng markeL conLlnues Lo change and grow advanced machlnery ls
used ln Lhe manufacLurlng process Lo lncrease producLlvlLy and Lhe lndusLry ls adapLlng Lo
compuLers and compuLer dependenL conLrols LhaL are able Lo help wlLh much of Lhe labor
roflLablllLy ln Lhls lndusLry ls dependenL upon several facLors as well Lhe focus glven Lo cerLaln
locaLlons speclallzaLlon of producLs and efflclency of operaLlons

Llngerle ls a Lerm for fashlonable and posslbly allurlng undergarmenLs Llngerle usually
lncorporaLes one or more flexlble sLreLchy maLerlals llke Lycra nylon (nylon LrlcoL) polyesLer
saLln lace sllk and sheer fabrlc whlch are noL Lyplcally used ln more funcLlonal baslc coLLon
undergarmenLs
A brass|ere ls an undergarmenL LhaL covers supporLs and elevaLes Lhe breasLs
1here ls a wlde range of brasslere sLyles avallable deslgned Lo maLch dlfferenL body Lypes
slLuaLlons and ouLer garmenLs 1he degree of shaplng and coverage of Lhe breasLs varles
beLween sLyles as do funcLlonallLy fashlon fabrlc and color

ant|es are a form of underwear usually llghL and snugflLLlng deslgned Lo be worn by women
or glrls ln Lhe area dlrecLly below Lhe walsL
Company rof||e

Name uknv LxporLs LLd
Cwner kunal !aln valbhav Slngh
Manag|ng D|rector neha ?adav ueeplka 8ana
nead Cff|ce Address AnanL 1ower kharghar
Iactory p|ot Area 13 acres
Workforce 730
roduct rof||e Llngerle
uant|ty output 10000 bra and 20000 panLles per day (Slngle shlfL of 8 hours)
Market uomesLlc and LxporL
roduct rof||e 8ra underwlre SLrapless 1shlrL added PalLer Wlreless
anLles Classlc brlefs PlghcuL brlefs ConLrol brlefs PlpsLer 8lklnl 8oy
shorLs 1anga 1hong CSLrlng









LIS@ CI DLAk@MLN@S

4 Dn|oad|ng
4 Storage
4 Inspect|on
4 CAD
4 Spread|ng
4 Cutt|ng
4 @|cket|ng
4 und||ng
4 Sew|ng
4 I|n|sh|ng
4 ackag|ng
4 numan kesource
4 Merchand|s|ng
4 Accounts
4 Med|c|ne koom
4 Crche
4 Canteen
4 Warehouse
4 @ra|n|ng koom
4 Conference koom
4 Ma|ntenance koom
4 enerator koom








rocess I|ow of the Iactory

Departments

Cff|ce Area (@ota| area 487S sq feet Workforce36)

O enera| Manager

4 1here wlll be an offlce for Lhe general manager
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lable and
chalrs
4 Area 200 sq feeL


O roduct|on Managers

4 1here wlll be a producLlon manager for each producLlon hall
4 no of people 4
4 Lach one wlll have a separaLe cublcal
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables
and chalrs
4 Area 400 sq feeL


O Merchand|s|ng] Market|ng

4 lL lncludes dlrecLlng and overseelng Lhe developmenL of producL llne from sLarL
Lo flnlsh
4 1here wlll be Lwo Leams of merchandlsers for domesLlc and exporL markeL
respecLlvely
4 no of people6
4 Lach one wlll have a separaLe cublcal
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables and
chalrs
4 Area 480 sq leeL



O Accounts

4 no of people 2
4 Lach one wlll have a separaLe cublcal
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables and
chalrs
4 Area 160 sq feeL

O numan kesources

4 no of people3
4 1wo P8 personnel and 1 welfare offlcer
4 Lach one wlll have a separaLe cublcal
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables and
chalrs
4 Area 160 sq feeL


O ua||ty Assurance

4 no of people 4
4 Lach one wlll have a separaLe cublcal
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables and
chalrs
4 Area 200 sq feeL


O Conference kooms

4 1here wlll be 3 conference rooms
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers whlLe board
pro[ecLors round Lables and chalrs
4 Area
8oom 1 400 sq feeL
8oom 2 300 sq feeL
8oom 3 300 sq feeL


O @ra|n|ng koom

4 1here wlll be a Lralnlng room for workers
4 Speclal requlremenLs ro[ecLor whlLe board
4 Area 400 sq feeL

roduct|on Area (@ota| area 24 063sq feet Workforce6S4)
1here wlll be four producLlon halls
roduct|on ha|| 1
4 CapaclLy 3000 bra
4 uomesLlc markeL
4 Area 3378 sq feeL
4 Workforce 167

roduct|on ha|| 2
4 CapaclLy 3000 bra
4 LxporL markeL
4 Area 3378 sq feeL
4 Workforce 167


roduct|on ha|| 3
4 CapaclLy 10000 panLles
4 uomesLlc markeL
4 Area 4806 sq feeL
4 Workforce 142

roduct|on ha|| 4
4 CapaclLy 10000 panLles
4 LxporL markeL
4 Area 4806 sq feeL
4 Workforce 142







@he act|v|t|es performed |n each ha|| w||| be
O Cutt|ng Department

Spread|ng and Cutt|ng
4 ,anual
4 1here wlll be 1 spreadlng and cuLLlng Lable
4 LqulpmenL sclssors SLralghL knlfe blns band knlfe gloves mask
4 no of people 3 persons/ Lable
4 8lns for sLorage of cuLparLs
4 1here wlll be one Lable for recuLLlng wlLh Lwo people

und||ng and @|cket|ng
4 1here wlll be Lwo Lables for bundllng and LlckeLlng each
4 1lckeLlng ls done manually wlLh Lhe help of LlckeLlng guns
4 8undles of 30 pleces each wlll be made
4 8lns wlll be used for sLorage of Lhe bundles
4 1here wlll be Lwo palrlng Lables wlLh Lwo people on each Lable

O Sew|ng

4 1hls deparLmenL ls responslble for Lhe converslon of cuL panels lnLo acLual garmenLs
4 We are followlng a modular producLlon sysLem whereln we have dlvlded module based
on operaLlons as such one operaLlon would be compleLed ln one module
4 1hls Lype of producLlon sysLem wlll help us ln lncreaslng our efflclency and aL Lhe same
Llme we can run dlfferenL sLyles slmulLaneously
4 1he labour requlremenL for such sysLem wlll be semlskllled operaLors and supervlsor
wlll be responslble for one operaLlon
4 1here wlll be 1 supervlsor for every 2 modules
4 10 floaLers and helpers are added Lo Lhe LoLal workforce ln sewlng deparLmenL


O I|n|sh|ng

4 ln Lhls secLlon Lhe overall look of Lhe garmenL ls seen and a measuremenL audlL ls done
4 lor Lhe purpose of removal of sLalns deLecLed durlng Lhls sLage each Lable ls provlded
wlLh a spoL washlng sLaln removal gun
4 Also each Lable ls provlded wlLh Lhread cllpper Lo cuL Lhe uncuL Lhreads All Lhe
defecLlve pleces are senL for alLeraLlon and necessary correcLlons
4 lronlng and Lagglng are also done here
Load fabrlc roll (maual
loadlng)
oslLlon Lhe roll accordlng
Lo sLarL selvedge
Speclfy Lhe no of rolls Lo
be lald
,anual Laylng
CuLLlng by sLralghL knlfe
1lckeLlng
8undllng
O ackag|ng

4 1he producL ls polypacked and senL Lo Lhe warehouse ln Lrolleys

rocess f|ow of Spread|ng and cutt|ng
















rocess f|ow of Sew|ng








8undles recleved
from feedlng Lable
8undles fed lnLo
Lhe modules
SLlLchlng of
llngerle
lnllne lnspecLlon
SLlLched llngerle
senL Lo flnlshlng
rocess f|ow of I|n|sh|ng






Llngerle recelved
from modules
1hread Lrlmmlng
SpoLLlng
lronlng
llnall lnspecLlon
1agglng
oly packed
S@CkAL
O kaw mater|a| storage

4 When Lhe fabrlc and Lrlms are sourced and broughL Lo Lhe company Lhey are sLored ln
Lhe facLory's sLorage area and lL ls Lhe responslblllLy of fabrlc sLores deparLmenL
4 1he fabrlc and Lrlms are sLored ln racks
4 8olls of fabrlc LhaL are of slmllar shade are kepL LogeLher
4 SLorage area for 23000 m fabrlc ls requlred (keeplng lnvenLory of 7 days)

O Iabr|c Inspect|on

4 100 fabrlc lnspecLlon wlll be done afLer lL ls recelved
4 1 lnspecLlon machlne
4 2 lnspecLlon Lables are requlred for shade sorLlng


O @r|ms Inspect|on

4 1rlms lnspecLlon wlll be done afLer lL ls recelved












rocess f|ow of Storage








,aLerlal recelved
,aLerlal sLored aL
approprlaLe place
8ecelpL of
requlremenL
,aLerlal ouL accordlng
Lo lssue order
,aLerlal senL aL
respecLlve deparLmenL
8ecelve poly packed
from producLlon hall
,eLal deLecLlon
acked ln box
acked ln carLons
I|n|shed goods storage (Warehouse)

4 1he exporL lLems wlll go Lhrough meLal deLecLlon ln Lhe warehouse lLself
4 1he poly packed lLems wlll be packed ln carLons
4 1here wlll be a separaLe deslgnaLed place for exporL and domesLlc producLs
4 1here wlll be a person responslble for record keeplng and helpers for loadlng and
unloadlng

rocess f|ow of Warehouse



















Ma|ntenance

4 no of people 3
4 Speclal requlremenLs approprlaLe Lools wooden Lable for malnLenance work


CAD

4 1here wlll be a 4 paLLern maklng Lables 1 dlglLlzlng machlne 4 compuLers and 1 marker
prlnLlng machlne ln Lhe CAu room
4 no of people 14
4 Speclal requlremenLs Alr condlLloned wooden flnlshes compuLers Lables and chalrs

Mach|ne Storage koom
4 ulfferenL sewlng machlnes wlll be sLored here for use on laLer sLage or sLyle change
4 no of people 2
4 Speclal requlremenLs 1ables Chalrs and Cupboards








Cther Iac|||t|es (@ota| area 222S2sq feet Workforce40)
LnLrance/LxlL
4 1here wlll be Lhree enLrances one for workers one for sLaff and one for loadlng and
unloadlng of maLerlal
4 LnLry/LxlL for offlce sLaff wlll be 23fL wlde
4 LnLry/LxlL for workers wlll be 13fL wlde
4 LnLry/LxlL for loadlng and unloadlng of maLerlal wlll be 30fL
4 AL loadlng and unloadlng polnL porch wlll be made of 40fL wlde and 30fL lengLh

arklng
4 1here wlll be a speclfled area for Lwowheeler and fourwheeler parklng
4 lour wheeler parklng wlll have capaclLy of 20 cars
4 1wo wheeler parklng wlll have capaclLy of 100











SecurlLy
4 1here wlll be 2 securlLy personnel aL each gaLe who work for a shlfL of 8 hours each
4 Also Lhere wlll be a securlLy head aL each gaLe
4 SecurlLy cabln wlll of Lhe dlmenslons 13fL x 10fL



Loadlng/ unloadlng
4 1hls wlll be done aL Lhe back gaLe 1here wlll be a person responslble for record keeplng

,edlcal 8oom
4 uocLors and nurslng asslsLanLs wlll be avallable ln Lhe medlcal room
4 Also Lhere wlll be varlous medlcal boxes placed aL dlfferenL locaLlons ln Lhe unlL lL lsvery
useful as Lhere are varlous small accldenLs happenlng ln Lhe lndusLry every now and
Lhen
4 1hese boxes are properly malnLalned and lf some medlclne ls uLlllzed lL ls qulckly
replaced

CanLeen
4 1here wlll be Lwo separaLe canLeens one for workers and Lhe oLher for offlce sLaff
4 1he capaclLy of workers canLeen wlll be 200 aL a Llme and 30 for sLaff canLeen
4 1he furnlLure of boLh Lhe canLeens wlll vary Cooklng area of boLh Lhe canLeens wlll be
common

Creche laclllLy
4 Creche wlll Lake care of food learnlng and healLh of Lhe chlldren of Lhe women workers

CeneraLor 8oom
4 lL wlll house Lwo 130 kW generaLor seL of dlmenslon 22fL x 10fL

LlfL
4 1here wlll be llfL for Lhe easy movemenL of maLerlal
4 1he maxlmum welghL for Lhe llfL wlll be 730kg
4 1he dlmenslon ls 12fL x 12fL

8ecepLlon
4 1here wlll be Lwo people aL Lhe recepLlon
4 1here wlll be a small walLlng area for Lhe vlslLors

urlnklng laclllLy
4 There will be 2 water coolers in each hall and 2 in the oIIice area.

Washrooms
4 Lach producLlon hall wlll have one washroom for ladles and one for genLs
4 1he offlce area wlll also have one washroom for ladles and genLs each
4 Lach washroom wlll have 6 urlnals
















Mater|a| nand||ng
4 ln offlce area flles and folders wlll be sLored ln racks
4 ln producLlon halls blns wlll be used for movemenL of cuL parLs and componenLs
4 ln sLorage and warehouse racks and Lrolleys wlll be used for maLerlal handllng

L|ght|ng
4 ArLlflclal llghLlng wlll be used ln producLlon halls and fabrlc lnspecLlon area
4 naLural and ArLlflclal llghLlng wlll be used ln offlce area and oLher faclllLles

I|oor|ng
4 ConcreLe floorlng wlll be used ln Lhe producLlon halls sLorage and warehouse
4 vlnyl lloorlng wlll be used ln Lhe offlce area and oLher faclllLles

ower Consumpt|on
Power Consumption

Equipments Quantity Power requirements (Watt) Total (Watt)
Sewing Nachines 276 0.S222 144.1272
Straight Knife 8 0.481 3.848
End Cutter 8 1.48 11.84
Band Knife 4 1.1632 4.6768
Steam !rons 16 1.11 17.76
Light S2230*1.S 7834S
Fan 7S0 80 60000
AC 30 1600 48000
Lift 1 10000 10000
Computers 40 400 16000
Digitizer 1 1000 1000
Plotter 1 800 800
Printer/Copier 2 800 1600
Netal Detector 1 1S00 1S00
Fabric !nspection 1 3S00 3S00

Total (!n
KW) 220.3272S2