Downloaded 701 times
More Related Content
Final plant layout
- 1. NATIONAL INSTITUTE OFFASHION TECHNOLOGY, CHENNAI. Plant Layout – End Term Jury Layout of a Shirt Manufacturing Unit PRESENTATION BY: NAVEEN KUMAR NILASHA TANDON PAYAL BARDAN RAVI ADITYA
- 2. Structure of theManufacturing Unit AutoCAD 2D Layout AutoCAD 3D Layout
- 3. Departments Present inthe Unit Spreading and cutting (110’ x 90’) Fabric inspection dept (100’ x 25’) Research and development dept (30’ x 25’) Human resources dept (60’ x 50’) Reception (50’ x 20’) Crèche (45’ x 15’) Locker room (50’ x 15’) Card swiping area (30’ x 15’) Toilets (30’ x 15’)
- 4. Departments Present inthe Unit Medical room (50’ x 15’) Power supply dept (80’ x 15’) Maintenance dept (80’ x 50’) Industrial engineering dept (30’ x 15’) HOD cabin (30’ x 15’) Sewing floor area (320’ x 90’) Canteen (70’ x 30’) Effluent Treatment Plant (180’ x 20’) Washing area (130’ x 30’)
- 5. Departments Present inthe Unit CAD lab (50’x25’) Finished goods warehouse (50’x80’) Finishing room (40’x90’) Packaging department (40’x90’) Fabric and trims warehouse (80’ x 30’)
- 6. Ratio ofcutting : sewing : finishing
- 7. Locational Analysis Location Village Vanj,Taluka Choryasi, District: Surat Type of SEZ Sector Specific SEZ for Apparel. Area: 56 hec. Status Notified - Functional Connectivity: Road, Rail, Air and Port Road Network: 8 km-National Highway (NH8), SEZ is on Navsari- Surat State Highway (SH) ƒ Rail Network: 20 km from Surat Railway St. ƒ Nearest Port: 30 km from Hazira port and 18 km from Magdalla port ƒ Nearest Airport: 20 km from Surat Airport
- 8. Locational Analysis Land availability &Lease Rates Plots allotted to industries @ Rs. 1500 sq. mt. Available Infrastructure Internal roads, Power, Water, Drainage system are available in the SEZ Training Facility Established by ALT Training College, an Apparel Training Centre is present in the SEZ Proposed industries All kind of apparel manufacturing industries are permitted
- 9. Locational Analysis Developer Company:Gujarat Industrial Development Corporation (GIDC) Contact Information Address: GIDC, Block No. 4, 2Floor, Udyog Bhavan, Gandhinagar-382 017 ƒ Contact Person & Designation: Mr. Nayan Raval, GM (Projects) Tel. No. +91-79-23250705 Website: www.gidc.gov.in
- 10. Assumptions Layout: Productspecific Layout Type: Prefabricated Product: Casual shirt 50% washed & 50% unwashed Available time: 480min No. of days working: 6 No. of m/c= 700 10% extra, so available m/c=640
- 11. Assumptions SAM ofthe shirt: 33.04 No. of lines in sewing floor: 8 No. of workstation req. for a shirt: 80 Output per day @ 60% efficiency:5,712 Output per day with 10% extra: 6,397 No. of days working in a month: 25 Output per month: 1,59,936
- 12. Fabric Store Length ofthe roll: 150m Width of the roll: 6ft Height of the roll: 1.5 ft Average consumption per garment: 2 m Fabric width: 60 inch Fabric consumption per day:11,424m No. of rolls req. per day: 76 rolls Inventory: 10 days Total rolls inventory: 762 Rack dimension: 6ftX 6ftX4ft No. of shelves: 3 No. of rolls stacked in a height:24 Total rolls inventory in store: 762 Calculation sheet
- 13. Fabric store Inspection m/c:9ftX7ft Average speed: 6mts/min Utilization: 90% Available time: 432min Inspection per m/c: 2592m Daily needed fabric:68,544m M/c req. =3 No. of racks required: 32 No. of shelves: 95 Area required for racks: 1,142 sq. ft. Area required for fabric store: 2500sq. ft Calculation sheet
- 14. Cutting room Available time:480 min Utilization: 75% Efficiency: 60% Average consumption: 2m Marker length: 4m Layer length: 4.008m No. of sizes in a marker: 2 No. of layer: 80 Total garment in a lay: 160 Meter spread: 320.64m No. of rolls req. :2.14=3 Bundle size: 20 No. of lays req. per day: 40 Calculation sheet
- 15. Cutting room Spreading tablelength: 5.508m No. of spreading table req.:7 No. of spreader req. :11 No. of spreader allotted:6 No. of spreading team: 6 No. of req. cutter: 5 No. of cutter allotted : 3 No. of allotted cutter: 2 M/c area: 2898 sq ft OP. space area: 1416 sq ft Total area : 4314 sq ft Total area req. :9900 Calculation sheet
- 16. Sewing Room SAMof the shirt: 33.04 No. of workstation: 80 No. of sewing line: 8 Total m/c: 640 M/c area per line: 1063sq ft Op space area per line:447.5 sq ft Total area required: 3398.625 sq ft Calculation sheet
- 17. Washing room 50%washed and 50% unwashed Washing machine Tumble Drier Drier M/c area:1290 sq ft Op space area: 300 sq ft Total area req. 3900 sq ft. Calculation sheet
- 18. Finishing Room FinishingSAM = 4.45 Minutes Thread Sucker Press Fold Spotting M/C Checking tables Sub Total Space = 1585 Sq. ft. Allowance (125%) = 1981.25 Sq. ft. Total Required Area 3566.25 Sq. ft. Calculation sheet
- 19. Canteen No. ofemployees: 900 Canteen is without cooking So area req. per employee is 12 sq ft So the canteen area is 2100 sq ft Two floor canteen Occupies 350 employees at a time. So there will be three shifts for employees Calculation sheet
- 20. Sustainable Factory OBJECTIVES Efficientmanagement of energy and water resources Management of material resources and waste Restoration and protection of environmental quality Enhancement and protection of health and indoor environmental quality Reinforcement of natural systems Analysis of the life cycle costs and benefits of materials and methods Integration of the design decision-making process
- 21. Renewable Sources ofEnergy in Gujarat Wind power (capacity=3,187 MW) Solar power (capacity=856.81 MW)
- 22. SUSTAINABLE CONSTRUCTION Adoptionof materials and products in buildings and construction that will require less use of natural resources and increase the reusability of such materials. Sustainable construction also enhances the resilience of the industry as such materials are readily available in the world market. Steel, other metals, glass and prefabricated parts using combinations of these, as well as recyclable substitutes for concrete are examples of sustainable materials and products.
- 23. SUSTAINABLE RAW MATERIALFOR CONSTRUCTION To reduce the non-renewable energy (energy expended to process and transport materials) in the building, the main walls are made of compressed stabilized-earth block manufactured forty kilometres from the site. The machine moulded blocks are made of local soil, sand, and locally manufactured cement. The large size of the blocks minimizes mortar joints. The walls require no plaster finish; they are simply sealed with varnish on the interior and exterior. Polycarbonate sheets on roof. Glass strips, running continuously across the breadth of the roof at regular intervals.
- 24. SUSTAINABLE RAW MATERIALFOR CONSTRUCTION Windows use imported plate glass and aluminium frames. Floor finishes include polished concrete tile, rendered and cut concrete, tile, and wood. Bamboo is used for window blinds and various forms of sunscreen. Nonhazardous finishes and materials are used throughout the building, ensuring good indoor air quality, which is enhanced by high airexchange rates. Stabilizing plants, silt traps, and stormwatercollection ponds were used to prevent soil erosion during construction. Special mechanisms to recycle construction waste, which reduced the amount of waste that went into landfills.
- 25. Understanding the LightingRequirement
- 26. Light Source UpgradeAlternatives Lamp Type Rated Life Hours Full-size fluorescent (T5, high-performance T8) 20,000 to 30,000 - Lumen maintenance % - 92 to 93 General area lighting of all kinds, including open and closed offices, training classrooms, and high-bay areas. – Sewing, Finishing, Washing Section Compact fluorescent 6,000 to 12,000 Lumen Maintenance - 86 (%) Incandescent replacements in table and floor lamps, cans, wall washers, and sconces Quartz pulse-start metal halide 20,000 Lumen Maintenance – 65 to 75 (%) Outdoor lighting, high-bay lighting, and remote-source Lighting - Landscape Ceramic pulse-start metal halide 20,000 Lumen Maintenance - 80 (%) Where color is critical- example cutting section Induction 100,000 hours Lumen Maintenance 70 at 60,000 hours; 55 at 100,000 hours Where maintenance costs are high like parking, roadways and ware house. LED 50,000 Lumen Maintenance - 70 (%) In color-based applications such as exit signs, niche applications such as outdoor signage, task lamps.
- 27. Use of DayLight and Automatic Control Light A mix of top- and side-lighting, light shelves, highreflectance ceilings. Automatically Control Lighting.
- 28. LIGHTING Over time,all lighting systems become gradually less efficient. Other efficiency losses include improperly functioning controls, dirt accumulation on fixture lenses and lumen depreciation. How to control this ?? Follow a strategic lighting maintenance plan of scheduled group re lamping and fixture cleaning.
- 29. Indoor thermal comfort Cross- ventilation . Cooling is achieved at the plant primarily by passive design and secondarily by active systems. Passive design measures include the orientation and massing of building volumes, controlled fenestration and ventilation, shading of the building and its surroundings, and thermal mass and solar reflectivity of the facades and roofs. The massing of the building volumes and the positioning and sizing of windows permit daylight to enter as natural illumination without causing substantial heat gain Thermal roof load, the largest contributor to heat gain and indoor discomfort in the tropics, is controlled by a combination of photovoltaic roofs, and cool roofs.
- 30. IAQ(Indoor Air Quality) Production spaces and offices are ventilated and cooled by evaporative cooling units. These units draw in fresh air, filter it, and add moisture to lower the dry-bulb temperature. Indoor air is not recirculated, but extracted by suitably sized exhaust fans to ensure effective moisture and heat removal. Humidistat in each cooling unit keep the indoor relative humidity at or below 80 percent.
- 31. Window Heat Flow Infiltration Airleaks around the frame, around the sash, and through gaps in movable window parts. Infiltration is foiled by careful design and installation. Convection Pockets of high-temperature, low-density gas rise, setting up a circular movement pattern. Convection occurs within multiple-layer windows and on either side of the window. Radiation Radiation is energy that passes directly through air from a warmer surface to a cooler one. Radiation is controlled with low-emissivity films or coatings. Conduction Conduction occurs as adjacent molecules of gases or solids pass thermal energy between them. Conduction is minimized by adding layers to trap air spaces, and putting low-conductivity gases in those spaces.
- 32. Window Films Window filmsreduce heat gain due to solar radiation and provide low cost cooling load reduction. Buildings in sunny areas can benefit from a variety of shading techniques. Bamboo sheet shade screens reduce heat gain up to 80 % compared to normal glass.
- 33. Fan System Centrifugalfans (A) are the most common fans used. They are often cheaper but usually less efficient than axial fans (B).
- 34. COOLING The heat-islandeffect around the building is controlled by shading, by covering parking areas, by using lighter, reflective paving around the building instead of dark, heat absorbent paving, and by shading the courtyards between the building volumes. The combination of the many passive cooling measures reduces the thermal load to a level that can be handled by environmentally efficient cooling systems instead of power hungry conventional systems
- 35. Light intensity levelsfor different departments ACTIVITY REQUIRED LUX LEVEL Preparation of cloth 200-300-500 Cutting 500-750-1000 Matching 500-750-1000 Sewing 750-1000-1500 Pressing 300-500-750 Inspection Hand tailoring 1000-1500-2000 1000-1500-2000
- 36.