Plant Layout Arch Brief

Architectural Brief Of A
Trouser Manufacturing Unit

Progressive Bundle System
Avanish Kumar
Janaki G Nair
Rabiba Zia
Saikat Biswas
Shruti Singh
Project description
Proposed Industry : Apparel Industry
Type of Industry : Manufacturing
Nature of Business : Export
Daily working hours : 8 hours (single shift)
Total no. of Employee : 450(Approx)
S. No. Products SAM Daily

Production
1. Men’s 22.5 5000
Trousers
Site location
Address- Sector 37
Industrial area,
Gurgaon, Haryana
Site details
Gurgaon is a leading financial and Accessibility –
industrial city of India, situated in the Availability of Airways: 23 Km
National Capital Region near the Indian Availability of Railways: 9 Km
capital New Delhi in the state of Haryana.
Located 19.9 miles (32 km) south-west of Reasons for the Selection of the site –
New Delhi, Gurgaon has a population of Easy availability of laborers
around 27 lakhs. Witnessing rapid Skilled Labor
urbanization, Gurgaon has become the city Cheap Land
with the third highest per capita income in Easy Transportation
India. Close to buying offices
Close to raw material resources
LAND COST
Total Area: 3344.509 sq m.
Cost per sq. m.: Rs. 12500
Total cost: Rs. 41,806,400
MINIMUM LABOUR COST

Skilled Labour : Rs. 10,000/month
Unskilled Labour : Rs. 7000/month
Plant layout
The manufacturing plant will spread across an area of 3344.509 sq. m. in Sec-37 Industrial
Area, Gurgaon, Haryana, India. Setbacks of width 4.5 m will run on all four sides. An
electrical substation of capacity 90kV-100kV of area 500 sq. m, boilers and pneumatic
compressor rooms occupy 250 and 170 sq. m. Respectively. The plant will open to two gates
onto main street of 12 m width. The main front gate will open to Loading and unloading area.
Floor Area Ratio (FAR) = 2.5
Structural design and construction
● Boundary wall minimum height of 2.4 m.
● Provision for underground water storage of 1,00,000 l capacity.
● Paved, bitumen roads of width 2 m circumventing the manufacturing unit.
● Structural Shed to be braced steel framed structure.
● Masonry walls.
● Cemented Floor for manufacturing unit.
● Rain water harvesting pipes affixed outside external walls.
● PBS is designed in 3-3 straight lines on the first and second floor.
● Three staircase of width 1.5m, 15 steps per flight .
● Emergency and escape routes 2 m wide.
● Wood fuel used for Boilers - Fire load density up to 50kg/m3.
The Product
Product to be manufactured is Men’s Trouser.
Production System– Progressive Bundle System

Line layout – Straight
Production per day – 5000 garments
Provision for 7 days inventory
Product styles may vary from buyer to buyer.
Type of fabrics required for production

Shell - Wool, Linen, Denim, Viscose, Poly-Wool, Poly-Viscose, Cotton, Lycra, Canvas,
Polyester, Silk, Rayon, Poly-Cotton etc.
Lining - Knee Lining, Piping etc.
Fusing - NR Fusing, Welt Fusing, Belt Fusing etc.
Pocketing - Herringbone, Stripes, Solids etc.
Industry Process flow
Product Order
Order received
merchandising confirmation
Fabrics and Pre production

Cutting dept
trims sampling
Cutting quality Sewing Sewing quality

check department check
Packaging Finishing Finishing

quality check department
Warehouse Shipment Buyer

Departments
ADMINISTRATIVE BLOCK- PRODUCTION BLOCK-
1. General Manager 9. Sampling Department
2. Human Resource Department 10. CAD Department
3. Factory Manager Cabin 11. Fabric Receipt Area
4. Production Manager Cabin 12. Fabric Store
5. PPC Department 13. Trim Store
6. Marketing & Merchandising Department 14. Spreading & Cutting Room
7. Accounts & Finance Department 15. Sewing
8. Conference Room 16. Finishing & Packaging Section
17. WareHouse
18. Quality Assurance Department
19. Industrial Engineering Department
20. Maintenance Department
21. Training Department
FACILITIES PERSONNEL BLOCK
22. Main Entrance 32. Creche
23. Security Room 33. Canteen
24. Parking 34. Water
25. Garden 35. Safety Department
26. Reception Area 36. Toilet
PHYSICAL PLANT
27. Boiler
28. Generator
29. Escalator (Lift)
30. General Maintenance
31. Store Room
Department details S.NO.
1
DESIGNATION
GENERAL MANAGER
MANPOWER
1
2 ASSISTANT GENERAL 1
1. General manager cabin MANAGER
S.NO PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)
1 CHAIR 2 4.5
2 TABLE 2 5*3 30
3 CABINETS FOR 2 3*2 12
STORAGE
4 VISITOR’S CHAIR 2 1.5*1.5 4.5
TOTAL AREA 51
ALLOWANCE(150%) 76.5
TOTAL AREA INCLUDING ALLOWANCE 127.5
2. Human Resource Department
S.NO. DESIGNATION MANPOWER
1 HR HEAD 1
2 ASSISTANT HR 3
S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

1 CHAIR 4 1.5*1.5 9
2 TABLE 4 5*3 60
STORAGE
4 VISITOR’S CHAIR 5+1(sof 1.5*1.5+6*3 29.25
a)
TOTAL AREA 116.25
3. Factory Manager Cabin
1 FACTORY MANAGER 1
2 ASSISTANT 1
FACTORY MANAGER
1 CHAIR 2 1.5*1.5 4.5

2 TABLE 2 3*5 30
3 VISITOR’S CHAIR 4 1.5*1.5 9

STORAGE
TOTAL AREA 55.5
4. Production manager cabin 1 PRODUCTION MANAGER 1
2 ASSISTANT 2
PRODUCTION MANAGER

1 CHAIR 3 1.5*1.5 6.75
2 TABLE 3 3*5 45
3 CABINET FOR 6 1.5*1.5 13.5
STORAGE
4 VISITOR’S CHAIR 3 3*2 18

5 HANGER STAND 1 10*3 30
TOTAL AREA 113.25
ALLOWANCE(150%) 16985
5. PPC department 1 PPC MANAGER 1
2 ASSISTANT PPC 2
MANAGER
3 HELPER 1
1 CHAIR 4 1.5*1.5 9
2 TABLE 3 3*5 45
3 VISITOR’S CHAIR 6 1.5*1.5 13.5
STORAGE

TOTAL AREA 109.5
6) Marketing & merchandising department
1 MARKETING HEAD 1
2 JR. MARKETING 4
EXECUTIVES
3 MERCHANDISER 1
4 JR. 4
MERCHANDISER
1 CHAIR 10 1.5*1.5 22.5
2 TABLE 6 3*5 90
3 VISITOR’S CHAIR 10 1.5*1.5 22.5

STORAGE
TOTAL AREA 147

7. Accounts & Finance department 1 ACCOUNTS MANAGER 1
2 ASSISTANT ACCOUNTS 1
MANAGER
3 DATA ENTRY OPERATOR 1
S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

.)
1 CHAIR 3 1.5*1.5 6.75
2 TABLE 3 3*5 45
3 VISITOR’S 6 1.5*1.5 13.5
CHAIR
STORAGE
TOTAL AREA 77.25
8. Conference Room S.NO. DESIGNATION MANPOWER
1 NIL NIL

1 CHAIR 30 1.5*1.5 67.5
2 TABLE 1 28*7 196
STORAGE
TOTAL AREA 275.5
9. Sampling Department

1 PATTERN MASTER 1
2 SAMPLING 1
DEPARTMENT
MANAGER
3 SUPERVISOR 1
4 CUTTING MASTER 1
5 SEWING OPERATORS 23
6 IRONING OPERATORS 1
1 PATTERN STORE RACKS 3 2*4 24
2 FABRIC SAMPLE RACKS 3 2*4 24
3 CABINETS FOR STORAGE 1 3*2 6
4 SNLS 10 3.5*2.5 87.5
5 SNLS UBT 5 3.5*2.5 43.75
6 SNCS 1 4*3 12
7 AUTO SERGER 1 5*3 15
8 BELT LOOP MACHINE 1 3*3 9
9 TANDEN NEEDLE 1 4*3 12
10 KAZ MACHINE 1 5*3 5
11 BUTTON ATTACH 1 4*3 12
MACHINE
12 BARTACK MACHINE 1 4*3 12
13 APW MACHINE 1 5*5 25
14 IRON TABLES 1 6*4 24
15 PATTERN TABLES 1 5*7 35
16 TABLES 1 3*5 15
17 OPERATOR’S CHAIR 25 1.5*1.5 56.25
TOTAL AREA 417.5
10. CAD Department
1 CAD EXECUTIVES 1
2 PATTERN MASTERS 1
3 JR. PATTERN MASTERS 1
4 PLOTTER & DIGITIZER 1

1 TABLE 2 3*2 24
2 PLOTTER 1 6*3 18
3 DIGITIZER 1 6*4 24
4 CAD MACHINE 1 8*3 24
5 CHAIR 4 1.5*1.5 9
STORAGE
TOTAL AREA 93

11. Fabric Receipt area S.NO. DESIGNATION MANPOWER
1 NIL NIL

1 TEMPORARY 1 10*5 50
FABRIC
STORAGE
TOTAL AREA 50
ALLOWANCE(150%) 75
TOTAL AREA INCLUDING ALLOWANCE 125
12. Fabric store
❖ Average Fabric Consumption Per garment -

1.5 m
❖ Per day requirement - 5000 x 1.5 = 7500m S.NO. DESIGNATION MANPOWER
❖ Per week requirement: 7500 x 7 = 1 STORE MANAGER 1
52500m 2 ASSISTANT MANAGER 2

❖ Now, assuming that 1 roll has 100m fabric. 3 HELPERS 4
Then, Total rolls to be stored for 7 days= 4 FABRIC/SHADE 3
525 rolls. INSPECTORS
❖ Given, this rack (4 shelves) will

accommodate 20 rolls at a time.
❖ Therefore, number of such racks required:
525/20 = 26.25 ~ 27 racks.
❖ The extra three shelves will be used for
storage of end bits and extra fabric after
order completion.
1 TABLE 3 5*3 45
2 RACKS 6 9*5 270
3 FABRIC 3 9*8 216
INSPECTION
MACHINE
4 INSPECTION 4 6*3 72
TABLES
5 WORKING 3 8*6 144
TABLES
6 CHAIR 6 1.5*1.5 13.5
7 EXTRA SHELVES 3 6*3 18
TOTAL AREA 535.5
13. Trim store
1 STORE MANAGER 1
2 HELPERS (ISSUERS) 1

.)
1 RACKS 6 8*6 48
2 WORKING 1 5*3 15
TABLES
3 CHAIR 2 1.5*1.5 4.5
TOTAL AREA 64.5
14. Spreading & cutting department

1 CUTTING DEPARTMENT 1
MANAGER
2 CUTTING MASTER 1
3 CUTTING OPERATORS 5
4 SPREADERS+HELPER 12
5 HELPER (TROLLEY) 2
6 NUMBERING 2
7 FUSING MANPOWER 4
8 PART CHANGE 1
9 BUNDLING 2
1 TABLES 3 5*3 45
2 STRAIGHT KNIFE 6 - -
3 END CUTTERS 2 - -
4 CUTTING TABLES 4 50*6 1200
5 NUMBERING & 2 20*6 240
BUNDLING
TABLES
6 FUSING 1 10*4 40
MACHINE
7 RACKS FOR WIP 15 5*3 225
TOTAL AREA 1750
ALLOWANCE(150%) 2625
15. Sewing Department
Area calculation and manpower requirement for sewing section
Product – Formal Trouser

Daily production - 5000 pcs
Per line -900 pcs
Efficiency – 64 % (assumed)
SAM: 22.5 mins
Daily working hours - 8
Total SAM needed per day = 5000x22.5 mins
= 112500 mins
Actual minutes req per day = 112500/0.64
= 175781.25 mins
Number of workstations/line= 37
Actual mins/line = 37 x 8 x 60= 17760
Thus, no. of lines required = 112500/17760 = 6.33 ~6 lines
OPERATION MACHINE SMV NO OF MACHINES
REQUIRED
BACK
pocket hemming APH .07 1
pocket overlock 3T O/L .3 1
pocket creasing ADPC .4 6
POCKET ATTACHING
(VARIATIONS)
patch pocket APS .74 12
welt pocket and flap pocket AUTOMATIC
WELTING
M/C
Second stitch@ back pocket SNLS .65 11
BACK YOKE ATTACH
( variations)
without yoke
with yoke FOA .41 7
back rise join FOA .24 4
size label attach SNLS .2 3
FRONT SECTION
COIN POCKET HEMMING
(variations)
with coin pocket APH . 1
015
without coin pocket
coin pocket attach @ jet piece SNLS .2 3
POCKET BAG ATTACH WITH 5T O/L .42 7
JET PIECE
POCKET VARIATIONS
slant pocket AUTOMATIC
WELTING M/C
vertical pocket SNLS
frogmouth pocket SNLS
curved pockets with coin pocket SNLS
overlock @ pocket bag 3T o/l .68 12
top stitch @ pocket bag SNLS .4 7
FLY (variations)
with zipper
with drawstring (no fly) 4 needle elastic
sewing m/c
with buttons
overlock @ zipper fly 4T O/L .3 5
front panel overlock 3T O/L .26 4
zipper attach @ left fly DNLS .32 5
left fly attach @ front panel SNLS .34 6
J- stitch @ left fly APJ .58 9
front pocket mouth hemming DNFPH .3 5
pocket bag stitch to front panel SNLS .46 7
right fly attach with zipper and SNLS .25 4
crotch join
ASSEMBLY SECTION
loop preparation 3T F/L .15 2
main label attach @ waistband & SNLS .3 5
w/b joining in chain
top stitch@inseam FOA .55 9
side seam join (attach front & 5T O/L .65 11
back panels)
top stitch @ side seam SNLS .38 6
waistband stitch WBAM .38 6
waistband corner finish SNLS .72 12
loop attach ABLA .65 11
bottom hemming BHM .33 5
button attachment ABAM .41 6
buttonholing BUTTON .32 5
HOLE M/C
SNO PARTICULARS NO DIMENSIONS (ft) AREA(sq ft)
1 Auto pocket 1 5*4 20
hemming
creasing m/c
stitching m/c
4 SNLS 64 3.5*2.5 560
5 FOA 20 3.5*2.5 175
6 3T O/L 17 4*3 204
7 4TO/L 5 4*3 60
8 5T O/L 18 4*3 216
9 DNLS 5 3.5*2.5 43.75
10 3T F/L 2 4*3 24
11 Auto J making 9 4*3 108
12 Double needle front 5 4*3 60
pocket hemming
13 Waist band attach 6 3.5*2.5 52.5
14 Auto loop attach 11 3.5*2.5 96.25
15 Bottom hemming 5 3.5*2.5 43.75
16 Auto welting m/c 1 5*5 25

17 4 needle elastic 1 4*3 12
sewing m/c
18 Auto button attach 6 4*3 72
19 BUTTON HOLE 5 3.5*2.5 43.75
M/C
20 BARTACK M/C 5 4*3 60
21 TABLES 21 5*4 420
22 IRON TABLES 7 3*4 84
23 RACKS 6 5*4 120
24 Operators chair 260 1.5*1.5 585
TOTAL AREA 3301
ALLOWANCE(150% 4951.5
)
AREA INCLUDING 8252.5
ALLOWANCE
SNO DESIGNATION NO OF MANPOWER
1 Sewing Department Manager 1
2 Supervisor 7
3 Inspectors 5
4 Sewing Operators 260
5 Helper 22
16. Finishing and packaging department
1 FINISHING 1
SUPERVISOR
2 CHECKING 7
3 IRONING/PRESSING 15
4 TAG ATTACHMENT 12
5 FOLDING 10
6 PACKING 2
7 HELPER 4
8 TRIMMING 1
9 THREAD SUCKING 2
10 STAIN REMOVAL 1
1 TABLES 2 5*3 30
2 IRONING TABLES 15 3*5 225
3 TAG ATTACHMENT MACHINE 4 3*5 60
4 PRESSING 15 5*5 375
5 THREAD CUTTING TABLES 3 3*3 27
6 THREAD SUCTION MACHINE 2 4*3 24
7 NEEDLE DETECTION MACHINE 2 5*3 30
8 TROLLEY 4 4*3 48
9 INSPECTION TABLES 6 8*6 288
10 PACKING TABLES 2 3*5 30
11 TAG ATTACHMENT TABLE 4 5*3 60
12 FOLDING TABLE 2 6*6 72
TOTAL AREA 1269

17. Quality assurance department S.NO. DESIGNATION MANPOWER
1 QA MANAGER 1
2 QA SUPERVISOR 3

1 TABLE 3 3*5 45
2 CHAIR 6 1.5*1.5 13.5
3 INSPECTION 1 3*8 24
TABLE
STORAGE
TOTAL AREA 124.5
18. Industrial engineering department 1 INDUSTRIAL 1
ENGINEER MANAGER
2 ASSISTANT IE 3
S.N PARTICULA QTY DIMENSIO AREA(sq. ft.) MANAGER
O. RS NS(ft.)
3 HELPER 3
1 CHAIR 5 1.5*1.5 11.25
2 TABLE 3 3*5 45
3 CABINETS 2 3*2 12
FOR
STORAGE
4 VISITOR’S 3 1.5*1.5 6.75
CHAIR
5 HANGER 1 10*3 30
STAND
TOTAL AREA 105
19. Maintenance department

1 MAINTENANCE 1
MANAGER
2 ASSISTANT 1
MAINTENANCE
MANAGER
3 HELPER 1
4 MECHANIC 5
5 ISSUER 1
S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq.
ft.)
1 CHAIR 5 1.5*1.5 11.25
2 WORK TABLE 3 3*4 36
STORAGE
4 SHELVES FOR 2 2*5 20
STORAGE
TOTAL AREA 99.25
20. Training department S.NO. DESIGNATION MANPOWER
1 TRAINING INCHARGE 1

.)
1 SEWING 20 4*3 240
MACHINES
2 OPERATOR’S 20 1.5*1.5 45
CHAIR
3 TABLE 1 5*3 15
4 CHAIR 1 1.5*1.5 2.25
TOTAL AREA 302.25
21. Security department S.NO. DESIGNATION MANPOWER
1 SECURITY HEAD 1
2 SECURITY GUARDS 8

.)
1 TABLE 2 5*3 30
2 STOOL 9 1*1 9
3 PUNCHING 5 1*0.5 2.5
MACHINE
4 PARKING AREA 1 83*10 830
TOTAL AREA 871.5
ALLOWANCE(150%) 1307.25
22. Garden
1 GARDENER 1

.)
1 GARDEN NIL 35*10 350
TOTAL AREA 350
ALLOWANCE(150%) -
23. Reception area S.NO. DESIGNATION MANPOWER
1 RECEPTIONIST 1

.)
1 TABLE 1 5*3 15
2 SOFA 3 4*6 72
3 CHAIRS 1 1.5*1.5 2.25
TOTAL AREA 89.25
24. Boiler

1 NIL NIL

.)
1 BOILER - 40*10 400
TOTAL AREA 400
ALLOWANCE(150%) -
25. Generator

1 NIL NIL

.)
1 GENERATOR 3 15*5 225
TOTAL AREA 225
ALLOWANCE(150%) -
26. Escalator (lift)

1 NIL NIL

.)
1 LIFT( 4 floors) 1 13*8 416
TOTAL AREA 416
ALLOWANCE(150%) -
27. General maintenance
1 HOUSEKEEPING 1
INCHARGE
2 HOUSEKEEPING STAFF 12

.)
1 HOUSEKEEPING 2 2*4 16
STUFF
2 RACKS 4 1.5*5 30
TOTAL AREA 46
ALLOWANCE(150%) 69
28. Store room

1 STORE ROOM INCHARGE 1

.)
1 RACKS 2 2*8 32
2 IDLE MACHINE 25 2.5*3.5 218.75
AREA
3 OTHER STUFF - 8*5 40
TOTAL AREA 290.75
29. Creche
1 CRECHE INCHARGE 1

.)
1 WASHROOM 1 5*4 20
2 SLEEPING AREA 1 20*11 220
3 PLAYING AREA 1 20*15 300
4 KITCHEN 1 6*4 24
5 ALMIRAH 2 1.5*3 9
TOTAL AREA 573
30. Canteen
1 CANTEEN SUPERVISOR 1
2 COOKS 4
3 HELPERS 10

.)
1 TABLES 25 10*4 1000
2 CHAIRS 250 1.5*1.5 562.5
3 COOKING ROOM 1 15*12 180
TOTAL AREA 1742.5
ALLOWANCE(150%) 2613.75
31. Safety department 1 NURSE 1
2 SUPERVISOR 2

.)
1 BED 2 5*6 60
2 STRETCHER 1 3*7 21
3 CHAIR 1 1.5*1.5 2.25
TOTAL AREA 83.25
34. Toilet S.NO. DESIGNATION MANPOWER
As per standard 50 Female = 1 Toilet
As per standard 40 Males = 1 Toilet 1 NIL NIL

.)
1 LADIES - 23*11.5 264.5
WASHROOM
2 GENTS - 15*11.5 172.5
WASHROOM
TOTAL AREA 437
ALLOWANCE(150%) -
Machinery list
MACHINE MAKE MODEL POWER(watt) COST
CUTTING &
SPREADING
Automatic Gerber SY 251 11000 531249
spreading
machine
Band knife msk BK-700A 1000 75000
Straight knife Eastman 629X 800 15131
CAM cutting m/c Gerber GT 5250 8000 5618745
Continuous BX BX 1000 3000 374687
fusing machine
SEWING
APH Euromac EM-6011-c 2200 194700
ADPC Epa EPM 202 1800 197000
APS Durkopp 906-CNC 2200 876735
SNLS Juki DDL8100s 100 50000
FOA Jack JKT9280-2PL 130 281249
3T O/L Piano PA757DDH 110 30,449
4TO/L juki MO67145 150 50,760
5T O/L Pegasus W1562N 200 86,980
DNLS JUKI LH-3568A 150 121659
3T F/L Duma 600D-01/UT 550 50,000
APJ Juki ANS221ENHS 1100 109199
DNFPH Euromac EM 8054 346319
WBAM Kansai fbx-1104pr 120 71,887
ABLA Juki MOL-254 1000 197000
BHM Kansai NM1001J 120 53167
Auto welting m/c JUKI APW196N 1100 284872
4 needle elastic mild steel jx 1404 PMD 600 1,54,000

sewing m/c
ABAM JUKI MEB-3810 590 421780
BUTTON HOLE JUKI UN-B7811 2000 53167
M/C
BARTACK M/C JUKI LK-1901B 500 197000
FINISHING
Thread Sucking Pagani TSM 77 2200 65000
Ironing Machine starfish EVT 1 1100 18000
needle detection Paramount i2 100 190000

machine
tagging gun joytitude 200 500
total 42,120 10,713,935

Electrical and allied installation
DEPARTMENT EQUIPMENTS POWER COST
General manager 1fan,1 light,1 ac 315 28000
cabin
HR department 3 computer system, 1 1860 127,000
ac,4 fan, 4light
Factory manager 1fan,1 light,1 ac 315 28000
cabin
Production manager 1fan,1 light,1 ac 315 28000
cabin
PPC department 2 fan, 2 light 230 6000
Marketing and 1 ac, 3 computer 1330 121000
merchandising system,2 light, 2 fan
department
Conference room 5 ac,10 lights,1 led 1800 185000
Accounts and finance 1 ac, 2 computer 1145 94000
department system,3 lights,3
fans
Sampling department 2 computer system, 910 68000
2 fan,4 light
CAD 3 computer system, 1 2455 171000
plotter, 1 xerox,2
fan,2 light
Fabric receipt area 2fan,2 light, 2 830 66000
computer system
Fabric store 2 fabric inspection 1830 166000
m/c,2 light,2fan
Trim store 2 light 80 2000
Spreading and 40 lights,2 computer 2280 100800
cutting system,8 exhaust fan
Sewing 50 fan,50 light,2 6420 210080
computer system,8
exhaust
Finishing and 10 lights,7 fans,2 3525 140000
packaging computer system, 1
bar code reader, 2
m/c for packaging
Warehouse 15 lights,10 fans 1350 35000
Quality assurance 2 fans,1 light 190 5000
department
IE department 1 fan,1 light 115 3000
Maintenance 2fan, 3 light,1 570 37000

department computer system
Training 5 light,3 fans,2 1025 71000
computer system
Security department 2 fan,2 light,1 530 36000
computer system
Reception 1 fan, 2 light,1 455 34000
computer system
General maintenance 2 fan,3 light,1 570 37000
computer system
Store room 2 fan,2 light 230 6000
Canteen 14 lights,10 fans 1310 34000
Safety department 5 light,3 fan 425 11000
Creche 3 light,2 fan 270 7000
Boiler room 2 boiler 800 1068000
Generator 3 generators 200 kw each 105000
total 33480w 3,029,880 rs

VENTILATION & TEMPERATURE CONTROL
● Horizontal cooling tower power by terrace pump pressure 900 l/min, fed by rainwater
pond of capacity 20000 l
● Exhaust ventilation system in storage and finishing departments
● 200 roof vents (1/100th of total area) having lightweight metal frames and housing with
hinged dampers, of 4x7 feet. Depth from roof -- 3 m
● Machine rooms shall be ventilated. They shall be such that the motors and equipment as
well as electric cables etc, are protected as far as possible from dust, harmful dust and
humidity. The ambient temperature in the machine room shall be maintained between 5°C
and 40°C.
● Roof made of insulated sheet in U-shape with an opening in the middle for hot air to pass
by in the environment.
WATER SUPPLY, DRAINAGE & SANITATION
● An underground water storage of capacity 1,00,000 l for fire safety and cooling system.
● Rainwater harvesting pond of capacity 20000 l 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, ferrocement 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 900mm 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.
FIRE & LIFE SAFETY
● Water and Foam Fire extinguishers for fires in ordinary combustibles such as wood,
paper, cloth, trash, and plastics.
● Carbon Dioxide Fire extinguishers for fires in flammable liquids such as gasoline,
petroleum oil and paint or fires involving energized electrical equipment .
OTHER FACILITIES
● All departments are to be connected via Inter communication lines.

● Wiring to be done in a concealed manner through conduits.
● Parking space of area 750 sq. m. for operators and employees
● Crèche for welfare of children of operators and employees
● Canteen spread over an area of 1000 sq. m., providing hygienic and healthy food twice a
day.
● Medical room for accidents and unforeseen emergencies.
● Training centre for new operators and workers.
OUTDOOR SIGNS & LANDSCAPING
● Open space to be planted with trees and flowering plants and rainwater fed pond.
● A board of dimensions 6 x 8 feet, displaying the company’s name shall be fixed on the
boundary wall facing the street.
● The logo of the company is to be fixed under the canopy of the roof, overlooking the front
gate.
Cost estimation
1.Cost of Plot for Manufacturing unit:
Area given = 36,000 sq. ft.

= 3344.509 sq. m.
At cost of Rs 12,500 per sq. m.,

cost of land = Rs. 41,806,400
2. Cost of total machinery= Rs. 42,773,724
3.Cost of electrical appliances= Rs. 3,029,880

4. Other costs:
PRICE QUANTITY TOTAL

REQUIREMENTS
Anti-fatigue mats 2000 20 40000
Chair for workers 800 625 5000000
Chair for cabins and 1500 98 147000

visitors
Tables 2800 136 380800
Racks/cabinets 2200 85 187000
Water coolers 7000 27 189000
Total 5,943,800
TOTAL STARTUP COST = Rs. 4,18,06,400+ Rs. 4,27,73,724+ Rs.
30,29,880+ Rs. 59,43,800
=Rs. 9,35,53,804(approx.)
THANK YOU!

Plant Layout Arch Brief

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Architectural Brief Of A

Trouser Manufacturing Unit

S. No. Products SAM Daily

MINIMUM LABOUR COST

Production System– Progressive Bundle System

Type of fabrics required for production

Fabrics and Pre production

Cutting quality Sewing Sewing quality

Packaging Finishing Finishing

Warehouse Shipment Buyer

S.NO PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

1 CHAIR 2 1.5*1.5 4.5

4 CABINETS FOR 2 3*2 12

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

4 VISITOR’S CHAIR 3 3*2 18

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

5 HANGER STAND 1 10*3 30

S.NO. DESIGNATION MANPOWER

1 CHAIR 10 1.5*1.5 22.5

3 VISITOR’S CHAIR 10 1.5*1.5 22.5

4 CABINETS FOR 2 3*2 12

TOTAL AREA 147

TOTAL AREA INCLUDING ALLOWANCE 367.5

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

S.NO. DESIGNATION MANPOWER

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

TOTAL AREA INCLUDING ALLOWANCE 232.5

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

❖ Average Fabric Consumption Per garment -

❖ Per week requirement: 7500 x 7 = 1 STORE MANAGER 1

52500m 2 ASSISTANT MANAGER 2

❖ Given, this rack (4 shelves) will

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

S.NO. DESIGNATION MANPOWER

Product – Formal Trouser

16 Auto welting m/c 1 5*5 25

2 IRONING TABLES 15 3*5 225

3 TAG ATTACHMENT MACHINE 4 3*5 60

4 PRESSING 15 5*5 375

5 THREAD CUTTING TABLES 3 3*3 27

6 THREAD SUCTION MACHINE 2 4*3 24

7 NEEDLE DETECTION MACHINE 2 5*3 30

9 INSPECTION TABLES 6 8*6 288

10 PACKING TABLES 2 3*5 30

11 TAG ATTACHMENT TABLE 4 5*3 60

12 FOLDING TABLE 2 6*6 72

TOTAL AREA 1269

TOTAL AREA INCLUDING ALLOWANCE 3172.5

S.NO. PARTICULARS QTY DIMENSIONS(ft.) AREA(sq. ft.)

S.NO. DESIGNATION MANPOWER

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)

S.NO. PARTICULARS QTY DIMENSIONS(ft AREA(sq. ft.)