PLANT LAYOUT OF A

GARMENT INDUSTRY
 Whole Garment Production System
When a tailor alone makes a complete garment, then it is called as make though
systems. The tailor even makes pattern (use ready-made pattern), cuts fabric and
does finishing of the garment.

• It is the traditional method of manufacture in which an operator makes right

through one garment at a time.

• It has quick throughput time and easier to supervise

• Reduce work in progress (WIP)

• But has Low productivity and high labor cost

• Highly experience operator require.

 Objective:
Preparation of a layout plan for a
hypothetical manufacturing unit.
Selection of Product
Manufacturing Unit Layout –
Men’s Casual Shirt
 Product: Men’s Casual Shirt

• Description: Half Sleeve Shirt with Double Pleated Pocket and Flap, Front Yoke,
Shoulder Tab with Loop

• Fabric: Solid
 DETAILS REQUIRED

Area 30,000 square feet

Flooring Single floor (Ground floor)
Product category Casual Shirt
Nature of Business Domestic
Rate of Production 3000pieces/day
No of shift per day 1
Hours per day 8 hours
LOCATION ANALYSIS
 Operation Breakdown Sheet
• OB Sheet
• Total SAM: 31.292
- M/c SAM – 23.001

- Manual SAM – 8.291

• Total No. of Workstations: 80

- Sewing Machines- 63

• Process Breakdown
Industrial Infrastructure and
Departments
Setting-up an industry and area calculations.
 DEPARTMENTS MANPOWER
Design 5
Fabric store 11
Sampling 27
Spreading and Cutting 15
Sewing 328
Finishing 51
Merchandising 5
Marketing 5
Maintenance 4
HR 4
Reception 1
Crèche 2
Medical room 2
 DEPARTMENTS MANPOWER
Library 1
Transport 4
Administration 1
Production Planning 4
Finance 5
IT 1
Training 1
CAD 9
IE 6
Control 3
Security 11
Canteen 13
Total 519
 BUILDING AREA
Ground coverage

• Total Plot Area = 34,000 sq. ft.

Area calculation

Required work place areas + Required temporary storage areas + aisle space +
Minimum space requirement for the plant layout
 Plant layout

A two floor factory and still to grow: Ground Floor and First Floor

Floor Area: 30,000 sq.ft

Height: 20 feet (6 meters) per floor
Total floors:
• The foundation is 9-10 feet deep with load bearing pillars as per the
soil of the land.
• Height of the building is 40 feet.
• Floors are coated CEMENT and hard for strength.
DEPARTMENTS: FABRIC STORE
• No. of shirts produced per day = 3000
• Fabric consumption for solids = 1.65m
• Total fabric required = 3000 X 1.65
= 4950m
• Roll diameter = 1ft.
• Fabric length = 6ft
• Roll length = 7 ft (Fabric length + handle length)
• Meters of fabric in one roll = 100m
• No. of rolls required per day = 4950/100
= 49.5 = 50 (approx.)
• No. of rolls required for 10 days = 500
• Height of rack = 8 ft.
• Length of rack = 20 ft.
• No. of rolls arranged vertically = 5 (excluding 3 ft. of isle space
for excessive bending and unloading space at the top)

• No. of rolls arranged along the length = 17

• Total no. of rolls in one rack = 5 X 17

= 85
• For 500 rolls,
No of racks required = 500/85
= 5.88 = 6 racks(approx)
 FABRIC STORE

Fabric Store - Layout

CUTTING ROOM
• No. of Shirts produced per day = 3,000
• Sizes- 38, 40, 42, 44
• Ratio- 1 : 2 : 2 : 1
• Fabric Consumption-
 Size 38 – 1.5m
 Size 40 – 1.6m
 Size 42 – 1.7m
 Size 44 – 1.8m
 Laying
• No. of Layers per Lay = 200

1. Marker I : Sizes- 38, 42 Ratio- 1:2

Fabric Consumption - 1.5 + 1.7*2 = 4.9
Fabric required for 1 Lay = 4.9m*200 = 980m

2. Marker II : Sizes- 40, 44 Ratio – 2:1

Fabric Consumption – 1.6*2 + 1.8 = 5
Fabric required for 1 Lay = 5m*200 = 1000m

Total Fabric required = 1980m

 Lays
• No. of Shirts from 1 Lay = 200*3 = 600
• Total no. of Shirts to be produced = 3,000
• No. of lays required = 3,000/600
=5
• No. of operators required per lay=2
• Hence, Total no. of operators required in cutting room per day
= no.of lays required per day X No.of operators required per lay
= 5X2
= 10
SEWING FLOOR
 No. of Working Hours = 8 = 480 mins
 SAM = 31.293
 Efficiency assumed to be of each operator = 75%
 No. of Garments to be produced each day = 3,000
 No. of garments produced per day by 1 operator
= (Working time X Efficiency) / SAM
= (480 X 0.75)/31.292
= 11 .61
= 11gmts (approx.)
• Since, 11 gmts are produced by each operator each day.
• Hence, 3,000 gmts would be produced by 3000/11 operators per day = 272.72
• = 273 (approx.) operators required each day to produce 3000 gmts.
FINISHING & PACKING
SECTION
 Plant Layout
• Area of Cutting room
= 70*100
= 7,000 sq. ft.
• Area of the Sewing floor
= 180*65
= 11,700 sq.ft.
• Area of Finishing Department
= 100*90
= 9,000 sq. ft.
Hence, Ratio of cutting : sewing : finishing = 1 : 1.7: 1.3
 Departments
Fabric Store

No. of Rolls: 50 Approximately (Storage)

Weight of one roll: 50 kg
Total Weight: 2500 kg
Sampling Department

 No. of Machines: 120

 Weight of one machine: 50 kg Approximately
 Total Weight: 6000 kg
 Entrance Gate
Width: 4 feet
Height: 7 feet
Windows

 On Ground floor, for ventilation windows are provided on ceiling edge on

two sides.
 Window Dimension = 1 feet x 1 feet
 On First Floor, Balcony and windows are there.
 Other Departments
Human Resource Department - (60 X 50) inches
 Administration – (50 X 50) inches
 R&D - (30 X 25) inches
 Training Room – (45 X 20) inches
 Reception - (45X 30) inches
 Locker Room - (50 X 15) inches
 Canteen - (70 X 30) inches
Crèche - (50 X 25) inches
 Security Room - (15 X 15) inches
Maintenance Department - (45 X 65) inches
PLANT LAYOUT
Ground Floor
First Floor
Sustainable Measures
 Ventilation
In an average workplace, the air needs to be changed between 8 - 12
times per hour and there should be at least 10 cubic mtrs of air per worker.

Try to ensure that any “hot” processes such as the ironing section is sited
next to the “down wind” wall so that the heat is extracted directly outside.

• Local exhaust ventilation systems.

• Ventilation systems like suction, ducts, tubes.
• Standing fans only in Warehouse and windows in the Production Dept.
• Air conditioners in the office area.
• Average water requirement (drinking+ sanitation)= 6liters/ person.
 Noise

Noise is probably one of the most widespread and underestimated of

industrial hazards.

International standards refer to 85 dBA over an 8 hour working day. If

workers are exposed to higher noise levels without any form of hearing
protection, the exposure time must be reduced, either by rotating
workers or providing longer rest periods.
From the workers’ perspective, poor lighting at work can lead to eye
strain, fatigue, headaches, stress and accidents. On the other hand, too
much light can also cause health and safety problems such as “glare”
headaches and stress. Both can lead to mistakes at work, poor quality and
low productivity.
It is also essential that lights are positioned in the correct place so that
workers do not have to adopt poor working postures to see the task in
hand.
 Lighting
These give recommendations for the amount of light that should be
available for the type of work – for example:

Machine shopfloor
• rough work and assembly 300 lux
• medium bench and machine work 500 lux
• fine bench and machine work 1000 lux

Office work or in a garment factory

• general tasks 500 lux
• more detailed work 750 lux
• very fine work 1000 lux
• Office area: 200 lux (Fluorescent tube lights).
• Fabric store: 200 lux (normal) - 900 lux(inspection).
• Spreading & Cutting area: 300 lux (0.6 lights/sq.ft.)
• Each sewing workstation has an attached lamp.
• Sewing floor: 500-700 lux (0.6 lights/sq. ft.)
• Walls and ceilings painted with light, pale and matt colors to avoid
reflection.
 Toilets
Toilets for each sex should be constructed and situated in such a way as
to ensure privacy for the persons using them.

Access should not be through changing facilities used by members of the

opposite sex.

They should be readily accessible, well-lit and ventilated, and protected

from the weather.

Toilets should not open directly into workrooms, dining rooms, or rooms
where food is prepared.
Provision to wash and dry hands is required, including hot and cold water,
soap and clean towels or other effective means of drying.

Suitable construction materials include impervious lining materials and

floors that can be easily cleaned and maintained to provide hygienic
conditions.

Toilet paper should be provided and a means to hang clothing.

Where females are engaged or employed, there should be suitable
provision for the disposal of sanitary towels.
 Electrical Installation safety

All electrical equipment, fittings, tools and wiring used in connection

with any work carried on in any place of work should comply with the
requirements of the Electricity Act 1992 and Regulations.

Occupiers should ensure that they obtain certificates of compliance on

completion of electrical wiring work.
Long Term Goals of the Industry
• Identifying Consumer Trends
• Maintaining Profit
• Finding Distributors
• Gaining Brand Recognition
• Expansion of Factory
• Employee Appreciation Goals
• Sunstainable working conditions
• Increasing clients
COSTING
• Fabric consumption.
• Gross weight of other components of garment.
• Fabric cost per kg.
• Fabric cost per garment.
• Other charges (print, embroidery, etc).
• Cost of trims (labels, tags, badges, twill tapes, buttons, bows, etc).
• CMT charges.
• Cost of accessories (hangers, inner boards, polybags, cartons, etc).
• Cost of a garment.
• Price of a garment.
 Consumption of Fabric
The quantity ratio or assortment can be any one of the following approximate
ratio.

• S: M: L: XL: XXL - 1:2:2:2:1

• S: M: L: XL: XXL - 1:2:1:2:1
• S: M: L: XL: XXL - 1:2:3:2:2
Price is the same for all these sizes of garments.
Measurements in cm: (Finished garment)

• Size: L
• Chest - 60 cm
• Length - 78 cm
• Sleeve length - 24 cm
• Neck rib width - 3 cm
• Hem – 3 cm
• ((Body Length + Sleeve Length + Allowance) x (Chest + Allowance) x 2 x
GSM) / 10000

• ((70 + 24 + 12) * (60 + 3) * 2 * 140) / 10000 = 187 grams

• Now cost of the fabric is calculated by taking into account the cost of yarn,
knitting charges, dyeing charges, compacting charge, fabric wastage,

fabric consumptions per garment in terms of gross weight.

 Cost of trims
• Labels: Woven main label (2.5 cm width x 7 cm length): Rs 0.35.
Polyester printed wash care label: Single colour print: Rs 0.10.

• Hang tag: Rs 0.40

• So the total cost of trims is Rs 0.85 per garment.
• Cost of accessories: Polybags: Normal - Rs 0.30 per garment.
Master Polybag: Rs 2 per master polybags to contain 8 garments - Rs 0.25
per garment.

• Export carton: Normal: Rs 40 per carton to contain 48 garments - Rs 0.80

per garment.
 Cost of trims

• So the total cost of accessories is Rs 1.35 per garment.

 Shipping charges

• For men's basic T-shirt, the delivery terms in the buyer enquiry as 'FOB'.

• So sea freight charges is not added.

• But the local transport with the cost of garment has to be added.
 Other Essential Costs
Labour Cost
• In Bangladesh the average monthly salary for garments workers is only around Rs 5000 to
Rs 7000.

• Rent for factory space : Rs.70,000

• Rent for storage space : Rs.30,000

• Electricity Charges : Rs 9 per unit

This is a variable cost as it depends on hours of usage of machines.
SWOT ANALYSIS
 STRENGTHS

• Advantage over China and Pakistan

• Adequate supply of labor force of both sexes, attributed with less attitudes problem (less
absenteeism and, aptitude for learning, and loyal) and high morale
• Cheaper labor cost
• Low cost of captive power generation using gas as fuel
 WEAKNESSES

• Bangladesh produce mostly basic products- which are low cost items; the share of fashion products i.e.,
high value added product is very low.
• Bangladesh does not produce the basic raw materials (only a negligible quantity of cotton but no
manufactured fiber) and as such has to depend totally on sensitive global market.
• Because of inadequate backward linkage, lead-time happens to be long, nearly 3 months.
• Public power supply is erratic.
• Bank interest rate is still high enough, particularly of private sector bank, for investment of export oriented
high value project.
• HRD facility, productivity and quality support, testing and accreditation support, design support and
compliances are yet to be enhanced.
• Cost of doing business is high because of under table money
 OPPORTUNITY
• Bangladesh has now a scope to go for more fashion oriented products deserving high price in
the global market.
• With the help of further increase of productivity & quality and design support, Bangladesh can
minimize cost and maximize profit and export value.
• Bangladesh, as a proven experienced RMG & Textile manufacturer, can expand share in the
existing market (USA, EU, Australia, Canada, etc.) and can also explore opportunity in Japan &
CIS countries.
• In the long run, Bangladesh has a scope to target huge populated country like China and India-
where demand as well as cost of manufacturing will be wider.
 THREAT

• Unless new strong market is explored in home or abroad, any non-cooperation from USA & EU may
jeopardize the whole Bangladesh RMG export business and consequently the textile
manufacturing.
• Sudden price hike of cotton and yarn in the global market may push Bangladesh to a very
awkward situation to devastate the business.
• The type of labor and political anarchies of the recent days if prevails in the future, Bangladesh
may lose the business in the way Sri Lanka has lost.
• Growing terrorism, or its false/amplified propaganda, is also a big threat.
• The poor political culture and violence is one of the most important threats.
 Bibliography
Links
 http://en.wikipedia.org/wiki/Architectural_plan

http://epf.eclipse.org/wikis/openup/core.tech.common.extend_supp/guida
nces/concepts/arch_views_viewpoints_7A6CD31.html

http://pubs.opengroup.org/architecture/togaf8-doc/arch/chap31.html

http://www.mif.vu.lt/~donatas/PSArchitekturaProjektavimas/slides/Softwar
eArchitecture/02%20-%20Intro-Viewpoints.pdf

Books:
- International Labor Office Handbook 2011
- Occupational Health & Safety Manual (pdf Files
THANK YOU