PLANT

LAYOUT
ASSIGNMENT 1

SUBMITTED BY-

SHAILJA SUNDARAM
VISHAL KUMAR RAJAK
 Ladies skirt

The term "tailored skirt" typically refers to a design or style of skirt which is fitted through the hips and
thighs in a simple, slender silhouette. The hemline can vary from ankle length to mini.
Variations

A – Line Skirt

An A-line skirt is a skirt that is fitted at the hips and

gradually widens towards the hem, giving the
impression of the shape of a capital letter A.

Circular Skirt

The circular skirt, sometimes known as the

skater skirt, is cut in a circle. The fabric is
attached to a waistband that sits exactly on the
wearer’s waist. The skirt forms a circle when it
is laid flat.
 Gathered Skirt

The gathered skirt is a very straightforward

style to follow. These types of skirts are
gathered onto the waistband. The fullness of
the skirt is determined by the amount of fabric
in the skirt part of the pattern and the gathers
pulled up to fit onto the waistband.

High Waist Skirt

The main feature of this skirt is a high

waistband. The fullness of the skirt is attached
to this band and it is usually a decorative part
of this style. High waist skirts can be created
with elastic or flat bands like the photo on the

Miniskirt

An iconic skirt associated with the 1960s, and

as the name implies, it is a very short skirt.
Production system

Progressive Bundle System (PBS)

The progressive bundle system is a traditional production system that has been widely used in the
apparel industries for many decades and still is today. In this system bundles of garments parts are
moved in sequence from one sewing machine operator to the next. Each worker receives a bundle of
unfinished garments and performs a single operation on each garment in the bundle. After finished of
his/her work on a bundle, they are re-tied the bundle and passed on to the next operator. Each PBS task
is given a target time or “SAM” (Standard Allowed Minutes). Time study engineers calculate the SAM for
an entire garment for an experienced worker as the sum of the number of minutes required for each
operation in the production process, including allowances for worker fatigue, rest periods, personal time
and so on. The success of PBS depends on how the production system is set up and used in a plant.

Distribution

Deciding whether to export fashion product offshore or

domestically goes beyond the reasons of cost and number of
units you will need to produce.

As a matter of fact it's a decision that will impact how your

business is set up and operates to best fit that scenario, re;
what kind of people/services you should hire and even the
details of your designs. The development and production
process are quite different.
 SPEC SHEET
ABCD CLOTHING

Style# - S18 – 4472 Product type – Skirt

Factory/country – India Size range - S TO
XL
Season – summer – winter Division – Women’s
Description:
Brand - UCB
Fabric : Calico – 100% cotton
LANDMARK MEASUREMENT DERCRIPTION CM TOLERANCES
A FRONT WAIST 36 4mm
B FRONT WAIST FINISHED WIDTH 2.9 4mm
C SIDE SEAM LENGTH – FROM BELOW WAISTBAND 59.3 4mm
TO FINISHED HEM

D FRONT HIP WIDTH – TAKEN FROM BELOW WAIST 50.5 4mm

TO 20CM DOWN

E CENTRE FRONT LENGTH – TAKEN FROM BELOW 58 4mm

WAISTBAND TO FINISHED HEM LINE

F DEPTH OF HEM 3.1 4mm

G FRONT HEM WIDTH – TAKEN FROM S/S TO S/S 46.6 4mm

BACK SKIRT
H BACK WAIST WIDTH WITH BUTTON FASTENED 36 4mm
I LENGTH OF ZIP OPENING 20 2mm
J HIP BACK OF SKIRT – TAKEN FROM BELOW WAIST 50.5 4mm
TO 20CM DOWN

K SPILT OPENING LENGTH 19.4 4mm

L HEM BACK WIDTH WITH SPLIT CLOSED 46.4 4mm

ADDITIONAL MEASUREMENTS
WAIST TOTAL MEASUREMENT 72 ±12mm
HIPS TOTAL MEASUREMENT 101 ±12mm
HEM TOTAL MEASUREMENT 93 ±12mm
 SMV OF SKIRT
S.No Body Part Operation Resource SMV

1 Front Part Bottom binding n trims Flat Bed 0.33

2 Assembly Front n back part match Assistant Operator 0.26

3 Assembly Side seam 4T OL Auto 0.45

Binding at one side to another around n
4 Assembly Flat Bed 0.9
trim
5 Assembly Mark and side seam topstitch SNL Auto 1

6 Waist Belt Elastic press,measure & cut Sewing Iron 0.2

7 Waist Belt Waistband join as a circle n mark SNDL Edge Cutter 0.3
DNL Lock Switch
8 Waist Belt Elastic join as a circle & mark 0.3
Auto
9 Waist Belt Mark n form hole at waistband Snap 0.28

10 Assembly button attach Snap BA 0.35

11 Waist Belt Sandwich elastic with waistband & tack SNL Auto 0.4

12 Waist Belt Waistband topstitch form channel Snls 0.5

13 Waist Belt Waist Band lower edges close & Mark SNL [Chain STS] 0.45

14 Waist Belt Attach waistband to the body 4T OL Auto 0.5

15 Label Care label make SNL Auto 0.24

16 Label Label attach at WB SNL Auto 0.35

17 Assembly Assistant Operator 0.26

Drawsting insert through the waist
18 Assembly Assistant Operator 0.3
channel
19 Assembly Drawsting secure at CB waistband Snls 0.18

20 Assembly Thread trims Assistant Operator 0.35

– – – Total 7.9
 SMV Summary of Skirt

Sewing Helper 1.37

Sewing Machine 6.53

Sewing QI 0.00

Finishing I/M 0.00

Finishing QI 0.00

Poly Helper 0.00

Packing 0.00

Hand Tag 0.00

Total 7.90
SMV by sewing machine:
 SNLS M/C – 3.42
 Flat bed – 1.23
 4T OL – 0.95
 DNLS – 0.30
 Snap BA – 0.63

 2 lakh target of skirt

 25 days per month
 8000 pieces per day

SAM = 6.53

 Efficiency = 70%
 Total time = 480 min

So,

Total skirt/mc in a day = 73

Total Machine required in factory = 109

We consider adding 10% increase in production in coming years

So,

We will have to keep provision for 11 more machines on the sewing floor

 SNLS Machine
Time taken on SNLS machine = 3.42

So, one SNLS machine will produce = 140 skirt per day

57 SNLS m/c will be required of 109 m/c

Its 61 % of total machine

So 61% of 11 will be = 7 m/c

  Flat Bed machine
SAM of flat bed machine = 1.23

So, one Flat bed m/c will produce = 390 skirt per day

So 21 flat bed machine will be needed.

So its 17% of total machine

So 17% of 11 will be = 2 m/c

 4T OL Machine
SAM of 4T OL machine = 0.95

So one 4T OL m/c will produce = 505 Skirt per day

So 16 4T OL machine will be needed

Its 14.68% of total machine

14.68% of 11 is 1.61 = 2 m/c

 DNLS machine
SAM = 0.30

one DNLS machine will produce = 1600 skirt per day

So 5 Flat bed m/c will be needed.

Its 4.59 % of total machine

4.59% of 11 is 0.4 = 0

 Snap Button attaching machine

SAM = 0.63

One Snap BA m/c will produce = 762 Skirt per day

So 10 Snap BA machine will be needed

Its 9.17 % of total machine

9.17 % of 11 is 1 m/c
PLANNING OF LAY OUT

Aisle

One of the most important factors in the allocation of space is a very careful consideration of aisle
location and width. One authority has stated that a typical layout may show 1.2 sq ft of aisle for every
1.0 sq ft of manufacturing and storage space.

Aisles are primarily used for:

 Material handling
 Personnel movement
 Finished product handling
 Scrap and waste removal
 Equipment relocation and replacement

We should consider on macro level before getting into details of each section:-

1. Whole covered area should have two aisles:

a) Primary – It should be 6ft wide.
b) Secondary – It should be 4ft wide.

STARTING WITH LAYOUT

1. Sewing
Now for the detailed setting of each department, let us assume that we are planning to start a m/c 109
basic women’s skirt factory with daily production of 8000 skirts

Now the first step will be calculation of area, we know for setting one sewing machine:-

Area required is 20sqft, so for m/c total area required will be 20*120= 2,400 sqft.
2. FABRIC STORE:

It should have access from outside as well as inside the factory. For store layout it is very
necessary to know the form in which we’ll receive the raw material.

If it is in form of rolls then the dimensions like Roll Diameter And Roll Length will play crucial
roll in deciding the storage system, usually racks, and hence the layout.

Now daily production = 8000 skirt / day

Fabric consumption for solids = 1.65mt, checks = 2.2mt

Total fabric required will be = 8000*2(avg.) = 16000mts.

* no. of days of inventory planned (10) = 1, 60,000mts

Now roll diameter = 1ft, roll length (fabric width + handle) = 7 ft

Meters of fabric on roll = (average = 100)

So, total rolls required per day is = 160, total rolls required for 10 days = 1600

Volume available on truck = 960 cu.mts. (approx.)

Total trucks required to bring required rolls (1600) = 10. This means at least one truck will be
there in the factory each day.

So, proper space should be there outside the store for movement of at least two trucks
simultaneously.

And entry to store should be big for easy unloading of raw material through trucks directly and
proper unloading system should be in place like slides, trolleys etc.