Plant Jury

7/30/2019 Plant Jury

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LAYOWom

Top(ca

manufactuInd

By: Ankur (03) Dayal (05) Kunal (09)Shashank (20)


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INTRODUCTION

VARIANT:Casual of woven fabric (twill -cotton and polyster blend.)Casual on knit fabric

CAPACITY OF THE PLANT:Daily production: 3000 pcs

BUSINESS TYPE:For Domestic Market.

PLOT AREA : 20000 sq. ft.


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DEPARTMENT

H.R. DepartmentAccountsMerchandisingSamplingI.T Department

CAD/ CAMSpreading & cuttingSewingQuality and AuditFinishingWarehouseStores


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FACILITY:

Estimates assumed:Product - Garment- Casual Shirts

Style details:Casual top with epaulette and pocket flap.Casual top with epaulette.Casual top with front yoke.Full sleeve and half sleeve top.


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Plant efficiency: 60%Target per day-=3,000 piecesType of production system : Progressive Bundle systemTotal no of machines in one line = 15(Approx.)Total no of machines in sewing section= 160(Approx.)

So, total no. of lines required = 140/15 = 11Total production per day= 3,000No of shifts per day=1Working hours per shift= 8 hours


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LAYOUT (Ground floor )

The plant has 3 floors. The ground floor has the security near theentrance. The generator is on the back side of the security.

There is a pathway for the container form main gate to warehouse

There is parking on the both side, one is opposite to security roomanother is near to the generator.

Building is surrounded by the fence and has two entrance one whleads to the sampling and another to the office area.


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LAYOUT

The building has the lift and stares too.The adjoining room is a meeting and show room and near to that Operations cabin.Opposite to that there is merchandising office which has passage between.Every floor has toilets.And the boiler is on the terrace.


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FIRST AND SECOND FLOOR

first floor has cutting room , fabric and trim store.Fabric store contains fabric checking m/c.Also there is electric panel room and fusing m/c.Second floor is completely for sewing and finishing.On the floor there is cabin for production manager and floor mana


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AREA CALCULATION, MANPOWREQUIREMENT, FURNITURE AN

EQUIPMENT DETAILS FOR VARIO

DEPARTMENTS


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DEPT. TOTAL

AREA

MAN-

POWER

COMPUTE

R TABLE

CHAIR

H. R. 300 sq. ft. 06 06 08

ACCOUNTS

300 sq. ft. 08 08 05

MERCHAN

DISING

400 sq. ft. 05 05 12

SAMPLING

600 sq. ft. 12 -- 04

I. E. 200 sq. ft. 04 04 10


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CUTTING SPREADING DEPT.

AREA

500 + 140 + 74sq. ft.

TICKETING TABLE (dimensions of table= 5x3) x4

BAND KNIFE (5 x 4) x2

RACK (10x3) x2

FUSING M/C (4 x 3) x2

BUNDLE TABLE (5x 5) x2

SRAIGHT KNIFE 4


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FABRIC STOREAREA 738 sq. ft.RACK (20 x 4 x3.5) x12

Fabric inspection (6 X 5 X 2) X2

INSPECTION TABLE (8 x 6) x4

TRIMS STOREAREA 360 sq. ft.RACK (10 x 8 ) x6


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CUTTING DEPARTMENT AREAMANPOWER CALCULATIONDaily production: 3000 garmentsDaily working hours: 8Let 1 lay consist of 100 plies with 4 way markerThus, no. of garments = 100x4 = 400SPREADING:

Spreading time of 1 lay= 120 minSo, SAM = 120/400 = 0.3Now, total SAM req. per day= 3000x0.3 = 900 minThus, total no. of tables req.= 900/480 = 1.85 = 2Manpower req. per lay (spreading) = 3 (2 operator + 1 helper)Thus, total manpower req. = 2*3

= 6 (4 operator + 2 helper)


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Cutting:

Cutting time of 1 garment= 22.5 min (approx.)So, Cutting time for 4-way marker = 22.5x4 = 90mins

SAM = 90/400 = 0.225Now, total SAM req. per day= 3000x0.225 = 675 minThus, total no. of tables req.= 675/480 = 1.40 = 2

Straight knife -4Manpower req. per lay (cutting) = 3 (2 operator + 1 helper)

Thus, total manpower req. = 2*3 = 6(4opr + 2 helper)

Band knifeManpower req. = 2 (1 operator + 1 helper)Machine requirement = 4 straight knife + 1 band knife m/c


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Fusing

It is found that 1 m/pcs are capable of handling fusing required peAssuming 3 persons per m/c,Manpower required for fusing = 31 supervisor1 cutting head4 helpers


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Ticketing

Ticketing time per garment = 10sTime required per day = 3000x0.16 = 480minsMachine requirement = 480/480 = 1Manpower requirement = 1No. of tables required = 1


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TOTAL MANPOWER IN CUTTING = 6+6+2+1+3+2+4=24

Now, the cutting room should have the capacity to store inventorydays.

Inventory to be stored= 3000 x 3 = 9000

A rack of (5 x 3) can store 1000 garment pieces.

Hence 9 racks required to keep the inventory.

Total area covered by the racks= (5 x 3) x 9=135 sq.fts

C f S


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Area Calculation for Store Room

Total yardage = 120 mRoll diameter = 7 inchesRoll height = 60 inchesSo, Total number of rolls =36,000 /120 = 300 rolls

Rack:Length = 6m approx 20 ft

Breadth = 1m approx 3.5 ftHeight = 1 m approx 3.5 ftArea of rack: 70 sq ft1 rack can store 25 rollsTherefore for 300 rolls aprox 12 racks (keeping one rack on anothSo we need 6 colums for keeping 12 racks

70*6= 420 sq ft


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Other equipment's in a store are:

Fabric inspection m/c = 2 (6 feet x 5 feet x 2) =60sq ftFabric inspection table = 4 (8 feet x 6 feet) = 192 sq ftOffice = 1 (100 sq ft)Main gangway = 13 ftGangway between racks = 10 ftSo, space requirement for racks and machines = 738 sq f t

Accessories Storage Area (Thread Storage, Button Storage No. of Racks: 6Length: 10 ftWidth: 8 ftArea: (10*8)*6=480 ftFree space: 40 sq ft

Total area for trims: 360 sq ft


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SEWING FLOOR

SNLS JUKI MACHINE:Length: 42 inWidth: 21 in.Area: approx 6 sq feet120 m/c: 120*6= 720 sq ft

DNLS Machine:Length: 42 in

Width: 21 in.Area: approx 6 sq feet

Over lock machine:Length: 41 in

Width: 21 inArea: approx 6 sq ft

Iron table:Length: 51 in

Width: 32inArea: approx 11 sq ft

Button ho

Length: 47W

Area: appr


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SEWING FLOOR

Number of machines = 160Total area required for machinery = 1500 square feetTotal number of ironing tables in sewing floor = 8Area required for each = 12 square feetTotal area for ironing tables = 12 X 8 =96 approx 100 square feetTotal number of inspection tables/bundle table= 12

Area required for each = 8 square feetTotal area for inspection tables = 12 X 8 = 96 approx 100 square fTotal chairs =180Area required for each chair: 3 sq ftTotal area for chair: 540 sq ftTotal area for machines: 2250 sq ft


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SEWING FLOOR

Production Manager Cabin: 100 sq ftFree space between m/c lines: 600 sq ftTotal Area for Sewing Floor (excluding the aisle space) =approx 3square feetFree space required: 800 sq ft

TOTAL AREA REQUIRED FOR SEWING DEPARTMENT: 4200 s


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WAREHOUSE AREA CALCULATION

Dimension of a carton = 60 cm x 40 cm x 30 cmPeak Total Inventory = 30 daysTotal production per day = 600So,Total number of Casual top in a day = 3000 casual topIn the carton considered, 10 casual tops can be stored.So,Number of cartons in warehouse at a time = 18,000 /10 = 1800 caCartons will be stored on racks.


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WAREHOUSE AREA CALCULATIONRacks dimension:

Length = 6m approx 20 ftBreadth = 1m approx 3.5 ftHeight = 1 mSo, In this way, Total of 300 cartons can be stored on a single racStacking one rack on another we can store 600 cartons on two raneed 1800/ 600 = 3such racksIn a single column, 2 such racks would be there with a storage ca600 cartons.We will have 3 such columns.Total rack area: 20*3.5= 70 sq ft3 racks: 70*3=210 sq ftFree space required: 190 sq ftTotal area re uired = 400 s ft


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FINISHING AREA CALCULATION

No. of m/c Dim Area per unit Total AChecking table 10 6ft*4ft 24 240

Iron table 10 5ft*3ft 15 150Stain removal 5 5ft*3ft 15 75Thread sucker 2 4ft*3ft 12 48

Needle detector

2

2.5ftx4ft

10

20Table (packing) 4 15ft*5ft 75 300

total 833

Area required for machines = 833Sq. feetFree space required: 867 sq ftTotal space required: 1700 sq ft


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CRCHE

The place where the workers children are properly taken care , wthere parents are in shift for productios a small play center

Area required for one child = 1 square metre = 10 square feetTherefore, area required for 30 children = 30 X 10 = 300 square f

CANTEEN:

Its is the place for having lunch during the lunch timeKitchen area = 300 square feetDining area = 700 square feetSeating capacity = 150TOTAL AREA: 1000 sq ft

DEPT LIGHT FAN


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DEPT. LIGHT FAN

H. R. 300 lux x1 1 fan per 50 sq ft (total 6fans)

ACCOUNTS 300 lux x1 1 fan per 50 sq ft (total 6fans)

MERCHANDISING

300 lux x4 1 fan per 50 sq ft (total 8fans)

SAMPLING 400 lux x12 1 fan per 50 sq ft (total 5fans)

I. E. 300 lux x4 1 fan per 50 sq ft (total 4

fans)


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STITCHING MAN POWER STATUSS. NO. WORK TYPE REQUIRED

1

MANAGER

2 EXECUTIVE

3 OPERATOR 1

4 HAND OPERATOR 3

5 IN LINE CHECKER

6 FINAL CHECKER

7 S.P.I. CHECKER

8 Q.C.

9 DESPATCHER

10 PRODUCTION WRITER


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STITCHING MAN POWER STATUS(I.E.)

11 COMPUTER OPERATOR 3

12 Jr. I.E. 2

13 SUPERVISOR 11

14 LINE INCHARGE 11

15 FLOOR INCHARGE 2

16 WRITER 1

17 FEEDSWRRRRRRR 7

18 NEEDLE STOCK 1

19 MECHANIC 2

20 ELECTRICIAN 2

21 MEDICAL 1


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COSTING

DIRECT LABOUR

Category of Workers No. of workers Salary perworker

To

R

SNLS m/c operator 70 52004th O/L m/c operator 40 52005th O/L m/c operator 20 52003th F/L m/c operator 30 5600

Button hole/Button m/c operator 4 5600Fusing m/c operators 2 5500Cutting m/c operators 10 5500

Ironers 30 5000


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Packers 30 5500Garment checkers 50 5900

Fabric checkers skilled 5 5800Fabric checker semi-skilled 4 5500

Helpers 80 4900

Store keepers

2

8000

Mechanics 2 9000Electrician 2 8500Office boys 2 4800

Watch and Ward 12 7500Sweepers 12 4800

Total Direct Labour cost per month

Additional Benefits @ 15%

Total Direct Labour cost per month including Benefits

Total Direct Labour cost per Annum including Benefits

Total Direct Labour cost per Annum including Benefits =302.716 lakhs


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FACTORY SUPERVISION

Category of Staffs

No. of staffs

Salary T

per staff

Senior ppc manager1

55000

Production Manager 1 45000Floor incharge 2 28000I.E 1 25000Cutting Manager 1 25000Quality Manager 1 32000


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Supervisor 16 9000Factory Supervision cost per month

Additional Benefits @15%

Total cost of Factory Supervision per month

Total cost of Factory Supervision per Annum

Total cost of Factory Supervision per Annum = 52.71 lakhs


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OFFICE /ADMINISTRATIONCategory of Staffs No. of Salary

staffs per staff

Accounts/Admn Manager 1 23,000.00Assistants 2 23,000.00

Export/Import Manager 1 28,000.00Office Assistants 2 15,000.00

Fabric Merchandisers 2 30,000.00Garment Merchandisers 2 22,000.00

Additional Benefits @ 15%Total Salaries per month including Benefits

Total Salaries per Annum including Benefits

Total Salaries per Annum including Benefits = 31.878lakhs


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MachineryEstimation of Machinery Required and Cost Estimate

Details of Machine

Quantity

Cost per

M/c in US$

Single Needle Lock Stitching m/c 50 320

[Juki DDL-5530N]Double Needle Lock Stitching m/c 20 1850.00

[Juki LH-3168SF]Overlock Machine 50 900.00

[Juki Mo-3316E DE4-40H]flat lock Machine 15 1,450

cover seamflat lock Machine 15 2270

bottom seamButton Holing Machine 2 2700.00


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Button Sewing Machine 2 3850.00[Juki LK-1903SS/304/MC-590-3K]

Fusing Machine 2 16365

[Hashima HP-400CS]Edge Cutter [Eastman EC-3] 2 450.00Straight Knife Cutter 4 1000

[Eastman 629 X 8BS-11]Banned Knife Cutter [Wastema] 3 12000.00

Total value in us dollars

Total Value in Indian Rupees @ Rs.55 per dollar


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Details of Machine Quantity cost per m/c in Rs.

Needle detector Equipments 1 set 450000Ironing Table Set-ups [Ramsons] 10 sets 25900.00

Fabric CAD with Scanner/printer 1 set 75000.00

Hand Scissors 20 Nos 300.00

Total Cost for Machinery in Indian Rupees = [7.90] lakhs]

Cutting Table/Assorting Table/Checking Tables

Other Furniture

Total Cost for Furniture etc in Indian Rupees = Rs 98000


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Needle cost per month = 30 X 160 X 6= Rs 28800

Needle cost per annum = 12 X 28800 =Rs 345600

Total Raw Materials Costs per Annum =

Debtors- Direct Labours = 302.716 lakhs- Factory Supervision = 52.71 lakhs- Admn Salary = 31.878 lakhs

-----------------Total Debtors = 387.29 lakhs


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Expenses

Machinery = 140.19 lakhs

Furniture = Rs 98000

Needle = Rs345600

Total expenses = 144.26 lakhs

Total cost = 387.29 + 144.26 = 531.916 lakhs


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Thank you !!!

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