PLANT LAYOUT
SUBMITTED TO:
SUBMITTED BY:
Mr. Pavan Godiawala
TAMANNA M.FTECH 2010-12
1
FACTORY LAYOUT
1. GROUND FLOOR a. Raw material storage department b. Cutting department c. Sampling department d. Warehouse e. Operator Canteen f. Maintenance department g. Boiler room h. Training department, utility room, medical room, executive parking, labour parking
2. FIRST FLOOR a. Director Cabin b. Administrative department & H.R department c. Production floor d. Conference Room e. I.E. Department f. Q.A. Department g. Compliance department h. Display Room i. Finishing department j. Staff Canteen
2
WORKING IN AN INDUSTRY BUYER
PRODUCT DEVELOPER
MERCHANT SAMPLING
FABRIC
TESTING MARKER PLANNING SPREADING
CUTTING
BUNDLING & TICKETING RESEARCH & DEVELOPMENT PRODUCTION WASHING 3 & PRESSING FINISHING
PACKING & FINISHING
PRODUCT DEVEVELOPEMENT
PROCESS FLOW OF INTERNAL DESIGNING MOCK OR SAMPLES WILL BE PREPARED FOR SELECTION
IF SELECTED THEN MEETING SAMPLES WILL BE MADE
COSTING AND NEGOTIATIONS
SALESMAN SAMPLE
GRADING
ORDER CONFIRMATION
FURTHER TO PD IT PASSED TO MERCHANDISING DEPT
4
EXTERNAL DESIGNING LINE ADOPTION WITH BASIC DETAILS
SAMPLES WILL BE MADE (2 Pcs)
APPROVAL/COMMENTS
BUYER SENTS A TECH PACK
THEN AGAIN PROTO SAMPLE MADE (3 Pcs)
FIT SAMPLES MADE (3 Pcs)
APPROVAL/COMMENTS
BUYER WILL SENT FIT SAMPLE SPECIFICATIONS
SIZE SET ARE MADE
APPROVAL
REVISE FIT OR SEALER SAMPLE IS MADE
5
ORDER CONFIRMATION
MERCHANDISING PROCESS FLOW OF MERCHANDISING DEPARTMENT
6
Start Obtain tech pack from buyer
Costing
Analyze fabric consumption from CAD
Sampling
Obtain general sewing data from IED
Analyze cost of trims and fabric
Develop sample as per the tech pack
Prepare cost sheet from sample
Develop proto sample
Cost sheet & sample sent to buyer for approval
Confirmation of order
Source trims & fabric from concerned dept.
Obtain PCD & details from production unit
Yes
No
Approv al
Book washing & embroidery capacity if required
Cost sheet reworked
Obtain GSD from IED
Execution of order by entering details in ERP
Prepare sample as per buyer requirements
Forward the sample to buyer for approval
Hold pre production meeting with the production unit
Execute bulk order
Yes
Follow up with production departments & update the buyer
Approv al Submit required documents to documentation dept
7
No
Comments received from buyer should be incorporated and fit sample reworked Offer garments for final inspection. Truck out
Follow up on the payments for goods
En d
SAMPLING STEPS OF SAMPLING:
PROTO TYPE SAMPLE MADE
FIT SAMPLE MADE 8
PP SAMPLE MADE SHIPPMENT TOP SIZE SAMPLE SET SAMPLE MADE MADE MADE
FABRIC SOURCING Fabric requisition from merchandiser
Order placed
Fabric receive invoice/challan
9
Unloading after checking
Tally with supplier invoice for quantity
Send bill to gate for entry
Receive fabric in store
Forward fabric for inspection
Inspection report sends to the concern merchant or sourcing dept.
After comments reentry in the system with final comments if rejected or accepted
If accepted
Relocation in store
Issue against job order
FLOW FOR ORDER PROCESSING
RECEIVE PO FROM MERCHANDISER
RECEIVE SHADE APPROVAL
PREPARE A FABRIC REQUISITION
SEND GOODS FOR DYEING
RAISE THE REQUISITION TO VENDORS
RECEIVE DYED GOODS 10
SEND SEND YARDAGE FOR INTERNAL FOR REDYEIN SUBMIT FORTESTING BUYER’S APPROVAL BULK FABRIC IN - HOUSE G, FOR COLOR AND QUALITY
SOURCE OUT THE GOODS
FINALIZE THE VENDORS NO
PLACE THE ORDER
APPROVE D
FIRST LOT IN - HOUSE
YES
LAB TESTING SUBMIT FOR APPROVAL TO MERCHANT REOR DE R
NO
READY FOR ISSUE
APPROV ED YES
LAB DIPS PREPARED AT DYEING UNIT IN NEAREST SHADE
SAND LAB DIPS FOR SHADE APPROVALBY THE BUYER
FABRIC STORE
PROCESS FLOW OF FABRIC STORE: FABRIC DISPATCHED FROM SUPPLIER FABRIC RECEIVING 11
SOLID/YARN
GRIEGE FABRIC
DYED/PRINTE D
SEND IT FOR PROCESSING BACK TO INHOUSE AFTER DYEING OR PRINTING
100 % CHECKING (4 POINT SYSTEM)
METER CHECKING BY SECURITY GUARDS LOT MAKING AND SEND IT TO THE MERCHANDISING QUALITY CHECKING FOR DEFECTS
KEPT IN STORE
FABRIC INSPECTION
12
Sta rt Receive fabrics
Conduct shrinkage test on minimum 2 bits/bale or minimum 10 bits of consignment
If No
Inform to stores and prepare goods received note (in case of imported fabric)
Verify whether quantity received match with quantity ordered
If No
If Yes
Forward one meter of each consignment for lab test
Inspection based on four points system. Match bulk with approved dye lot, width of fabric etc.
If Yes
Name shade lot as ABC Send to merchant for buyer’s approval
If No
If approved
If Yes
Forward to cutting dept.
Reject lot End
13
TESTING LAB
14
Star t
Fabric Sourcing
Accessory stores
Test
Test
Count
Merchandising
Buttons
Construction
Color fastness to washing Color fastness to crocking
Lining fabrics
Carry on test on fabric and garment as per buyer requirement
On meeting buyer requirement , samples to be sent to external lab to get approval
Dimensional stability to washing Fabric Strength Fabric Weight
En d
ACC ESSO RIES STORE WORK FLOW OF ACCESSORIES STORE 15
Merchandiser prepares swatch card
Swatch card is send to the purchase dept.
Accessories purchased by purchase dept.
Accessories received by receiving dept.
Testing of accessories is done
Storing of accessories in accessory store
Issuing accessories to the sampling and production dept.
TYPES OF ACCESSORIES •
LABELS AND TAGS: Main label, size label, wash care label, price tag & hand tag
•
THREADS: Sewing threads.
•
BUTTON
•
INTERLINING AND FUSING MATERIAL: Shoulder pads paper foams etc.
•
NEEDLES
•
STATIONARY: Record books, role paper, pens etc.
16
PROCESS FLOW OF INDUSTRIAL ENGINEERING DEPARTMENT:
Receiving sketch/garment from merchant sampling dept.
construction enquiry –
Prod. Friendly solution Calculate SMV dept.
merchandising dept.
Prod. Cost Tech analysis before fit stage-suggest amendments(stamp) incorporate in sampling
PPC
prod. planning
merchandising dept.
start thinking innovation tool room Receive sample for thread consumption
Make opern bullttin & calculate T.C
merchandising. dept
Receive red tag sample
thread order
In depth style study & construction engineered way folders tool room
develop customized
(innovate)
Prepare opern bullttin
prepare R & D report
17
Update SMV & finalize reports
Factory IE discuss & collects reports
Prepare work station layout maintenance↓↓
m/c & work aid REQMT to
Line setting according to IE reports
procure from maintenance
Capacity check analysis & feedback dept
R & D analysis and feedback
IE
Prod. Studies to increase efficiency
Improve methods
rebalance
line
Achieve target
18
MACHINE MAINTENANCE
FUNCTION OF MAINTENANCE DEPARTMENT:-
•
Care of the fittings
•
Adjusting settings
•
Oil changing
•
Graph maintenance
•
Outward/inward reports
•
Needle weekly reports.
•
Machine configuration chart
•
History card
•
Needle log cards.
:
19
CAD DEPARTMENT
PROCESS FLOW OF CAD: Receive spec sheet form Receive patterns from pattern Digitize pattern to feed in Pattern correction Output to Graphtec plotter
Pattern grading Cut ratio planning
Pattern sent to merchandiser for sampling
Market planning according to the cut plan 20
Output marker to plotter
Output mini marker to printer
WORK FLOW IN CAD DEPARTMENT
Send to cutting room for cutting
Send to merchandiser for costing
WORK FLOW OF SPREADING AND CUTTING:
SPREADING
RELAXATION FOR 8 HR.
CUTTING MANUAL/AUTOMA TIC
TICKETING
FUSING
CHECKING
BUNDLING 21
TRANSFER TO PRODUCTION
SPREADING PROCESS FLOW OF SPREADING: FABRIC IS LOADED ON SPREADING MACHINE
PAPER IS SPREAD ON SPREADING TABLE
22
MANUAL SPREADING IS DONE
RELAXATION FOR 8 HR.
PROPER TENTION IS MAINTAINED WHILE
MARKER IS SPREAD OVER IT AND PASTED BY TAPE
TRANSFERRED TO THE CUTTING
\
PROCESS FLOW OF CUTTING DEPARTMENT:-
Cutting package from production manager Acquire fabric from fabric store 23
Cut sample to check Requir e Checki ng Yes
Send to CAD for Change
No
Receive changed pattern from
Cut for initial size set
Assemble and check Requir e chang NO es
Yes
No
Issue job order Cut plan Bulk cutting
Sortin g
24
Bundlin g
Issue
PRODUCTION PLANNING & CONTROL
Start On receiving the orders, allocate the same to units based on line openings and buyer’s ratings
Provide details to the respective units on PCD, order quantity & sample
Take inputs from IED on productivity based on garment analysis
Confirm the above details given to concerned units in consultation with GM & FM
Confirm in consultation with embroidery, washing departments
Confirm order plan with merchandising team
SEWING DEPARTMENT
Provide MIS report to management every fortnight
Production floor follows Assembly Line system. Following are steps to start a production line: To study the production file.
Planning follow up with factory till order execution
To study operation bulletin and set line accordingly.
End
Manpower – tailors and helpers. Load and feeding lines. To arrange buffer or work-in-progress. Manufacturing. To make daily production and to achieve targets accordingly. To understand bottlenecks stage of production. Working steps of production dept: Shrinkage production pattern is issued to production floor from CAD dept. Ready patterns are made as per the requirement of production room. Cutting receives from cutting dept. Cross checking of cut panels with patterns. 25
Bundling of cut panels is done. Operation wise feeding of cut panel into the line. Inline checkpoints. Output of line. Final checkpoints. Auditing of checked pieces.
PROCESS FLOW OF PRODUCTION DEPARTMENT Star t Bulk Production Cut parts received from cutting Sewing process begins In-Line checking
Washing
Assembly End line checking & AQL audit Button & button hole/ Bar tack Rough checking Ironing Final checking Measurement checking Tagging Packing FSA Audit Auditing by buyer QA Truck out
26
En d
WASHING PROCESS FLOW:
Start Washing Normal wash N Hydro Extraction
Drying Inspection (Random) Accounting & despatch to different units
27
End
FINISHING PROCESS FLOW OF FINISHING
GARMENT COMES FROM PRODUCTION
WASHING
THREAD CUTTING
INITIAL CHECKING AND SPOTTING
ALTERATION
REIRONING FINAL CHECKING 28
PRESENTATION/FINAL IRONING
MEASUREMENT
SENT FOR PACKING
PACKAGING PROCESS FLOW OF PACKAGING GARMENTS COMES FROM INSPECTION IT IS THEN FOLDED 1 OR 2 ARE PACKED TOGETHER ALL PIECES PUT IN TO CARTONS
DETAILS ARE PASTED ON CARTON CARTON IS SEALED
LOADED INTO TRUCKS
SENT FOR SHIPMENT 29
PACKING NORMS Packages are sent under licensing rules for shipment. The rules are also specified by the individual buyer and are universal for their respective order. Some of such norms include: All garments packed in individual poly bags. Poly bag sticker on poly bags, which may be printed by the factory. Order must be completed (packed, ready for shipment) prior to bulk orders. Order must be inspected and audited by the factory 100%. Order must be of first quality, no repair or ungraded garments should be in license shipments. Order must be shipped 100% complete otherwise notified. The packed goods are now ready to be passed through the
CALCULATION FOR PLANT AREA
Given Parameter:•
Plant size = 120*100 sq. mt
•
FSI =1.2
•
G.C = 40%
•
Front margin = 5 mt
•
Side margin = 5 mt Total space = 120*100 = 12000 sq. mt FSI = 1.2*12000 = 00 sq. mt (Maximum available floor space) Ground coverage = .65*3600 = 2340 sq. mt Available floor space = (60-12) * (60-21) 30
= 48*39 sq. mt = 1872 sq. mt
SPACE ALLOCATION FOR EACH DEPARTMENT IN EACH FLOOR GROUND FLOOR : DEPARTMENTS
AREA (in sq
TOTAL NO. 31
TOTAL NO.
AIR
mts)
OF LIGHTS
OF FANS
CONDITION
EXCUTIVE PARKING
353.5 sq mts.
1 halogen
-
-
TIME OFFICE
13.77 sq mts.
1
1
-
MAIN ENTRY
15 mts.
-
-
UNLOADING AREA
91.8 sq mts.
2
3
-
STORE MANAGER
13.77 sq mts.
1
1
1
TRIMS AREA
12.39 sq mts.
1
1
-
REJECTED ROLLS
16.06 sq mts
1
1
-
TESTING LABS
23.87 sq mts.
2
2
1
LABOURWASH ROOMS
6.88 sq mts.
1
2
-
UTILITY ROOM
17.90 sq mts.
1
1
-
CRECHE
17.9 sq mts.
1
2
-
LOCKERS
35.8 sq mts.
1
-
-
SUPERVISOR
3.67 sq mts.
-
-
-
WASTE ROOM
18.36 sq mts.
1
1
-
REMENENT
18.36 sq mts.
-
1
-
CAD
28.4 sq mts.
2
1
1
CUT PANEL AREA
112.02 sq mts.
3
-
-
PATTERN MAKING
48.2 sq mts
2
-
-
MANAGER
28.12 sq mts.
1
1
1
MEDICAL
28.12 sq mts.
1
1
-
EXECUTIVE WASH ROOM
4.59 sq mts.
1
1
-
EXECUTIVE CANTEEN
22.95 sq mts.
1
1
-
CONFERENCE
27.54 sq mts.
2
2
1
RECEPTION
20.66 sq mts.
1
1
1
PPC
27.54 sq mts
1
1
1
GM
20.66 sq mts
1
1
1
MD
21.34 sq mts
1
1
1
STUDIO
27.54 sq mts
2
1
1
32
PURCHASE
20.66 sq mts
1
1
1
EXPORT
20.66 sq mts
1
1
1
ACCOUNTS
20.66 sq mts
1
1
-
MIS
20.66 sq mts
1
1
1
HR
30.99 sq mts
1
1
1
LOGISTICS
13.77 sq mts
1
1
-
MERCHANDISER
27.54 sq mts
1
1
1
SENIOR MERCHANDISER
13.77 sq mts
1
2
1
WORKER PARKING
91.5 sq mts
-
-
-
FIRST FLOOR: DEPARTMENTS
AREA (in sq mts)
TOTAL NO. OF LIGHTS
TOATAL NO. OF FANS
AIR CONDITION
SAMPLING
530.3 sq mts.
5
14
-
MAINTAINENCE
123.9 sq mts.
3
4
-
IE
19.2 sq mts.
1
1
-
QUALITY ASSURANCE
1.83 sq mts
1
1
-
SEWING AREA
2107.2 sq mts
1065
59
-
COMPLIANCE
36.7 sq mts.
1
1
-
TRAINING
31.22 sq mts.
1
1
-
MANAGER ROOM
13.77 sq mts.
1
1
1
STORE
31.22 sq mts.
1
1
-
BOILER
18.36 sq mts.
1
1
-
EXECUTIVE WASH ROOMS
11.01 sq mts
1
1
--
EXECUTIVE CANTEEN
22.9 sq mts
1
2
-
WASTE ROOM
18.36 sq mts
1
1
-
33
DRINKING WATER
4.59 sq mts.
-
-
-
WASH ROOMS
4.59 sq mts.
1
-
-
RACKS
27.5 sq mts.
2
1
-
SECOND FLOOR : DEPARTMENTS
AREA (in sq mts.)
TOTAL NO. OF LIGHTS
TOTAL NO. OF FANS
AIR CONDITI ON
WASH ROOMS
9.18 sq mts.
1
-
-
EXECUTIVE CANTEEN
34.4 sq mts.
1
1
-
LABOUR CANTEEN
385.6 sq mts.
2
11
-
MEASUREMENT & INSPECTION
128.5 sq mts.
65
4
-
AUDIT AREA
80.34 sq mts.
40
2
-
PACKAGING
144.6 sq mts.
50
3
-
DISPATCH AND LOADING
96.4 sq mts.
5
4
-
CARTON STORAGE
18.36 sq mts.
2
1
-
WASHING AREA
146.9 sq mts.
10
5
-
WASHROOMS
4.59 sq mts.
1
-
-
DRINKING WATER
4.59 sq mts.
1
-
-
SUPERVISOR
2.52 sq mts.
-
-
-
WASHING MANAGER
27.5 sq mts.
1
1
1
FINISHING MANAGER
27.5 sq mts.
1
1
1
FINISHING ZONE
156.1 sq mts.
78
5
-
WORKFORCE IN DIFFERENT DEPARTMENT ADMINISTRATION DEPARTMENT:-
34
DEPARTMENT
NO. OF EMPLOYEES
Executive
2
Accounts and finance
5
Human resources
4
Purchase
3
Export and import
3
MIS
4
Logistics
2
Merchandising
5
PPC
5
IE
3
CAD
5
Maintenance
4
TOTAL
42
SAMPLING DEPARTMENT: Cutting master
3
Sampling manager
1
Sampling in charge
1
Pattern master
1
Supervisor
2
Tailors
35 35
Helpers
2
Ironer
3
checker
3
TOTAL
51
STORE DEPARTMENT:Fabric store
Store manager
1
Assistant manager
2
Checker
3
Workers/helpers
20
TOTAL
26
Store manager
2
Assistant manager
2
Workers/helpers
10
TOTAL
14
Trim store
CUTTING DEPARTMENT:
Production manager
1
Pattern master
2
Assistant pattern master
2
Cutting master
3 36
Workers/helpers
50
TOTAL
58
SEWING DEPARTMENT: Production manager
1
Supervisor
4
Quality checker
4
Workers/helpers
268
Male:female(ratio)
70:30
TOTAL
277
QUALITY ASSURANCE DEPARTMENT:
Quality manager
1
Workers/helpers
5
TOTAL
6
FINISHING DEPARTMENT:
OPERATION
WORKER
HELPER
Button holing
2
2
Button attaching
2
0
Thread cutting
25
0
37
Pressing
20
2
Initial checking
15
0
Final checking
2
0
Re final checking
2
0
Spot removal
4
0
PACKAGING DEPARTMENT
Assistant manager
1
Quality checker
3
Workers/helpers
8
Equipment details of various department
FABRIC INSPECTION MACHINE
38
Specifications of Fabric Inspection Machine for Fabric up to 3500 mm are: • • • • • • • • • • •
Speed of Machine: 30meters/minute. 2HP x 1440rpm, 415volts Electric Motor. Reverse - Stop - Forward Arrangements [From Three Sides]. Roll Compact with 5" Dia. M. S. Rubber Striped Rolls: 2 Nos. Adopter for Paper Tube as per your requirement. Revolution type Meter Counter. Batching on Operator Side. Transparent Horizontal Inspection Table with Bottom illumination. Tension Device and Guide Rolls. Cloth Inspection & Winding Unit are completely wired electrically, only main supply is to be provided.
39
Equipment details of testing lab 1. AUTOMATIC TWIST TESTER
Specifications of Automatic Twist Tester: •
Yarn test length
• • •
Range Resolution Elongation Range
•
Motor Speed
•
Clamps
•
Averaging
• •
Supply Size
: 25mm to 500 mm adjustable (metric unit) OR 1” to 20” adjustable (imperial unit). The test length is automatically taken into account for calculation and final reading is displayed directly in TPM/TPI. : Up to 9999 TPM or 99.99 TPI. : 1 TPM or 0.01 TPI. : Up to 9999 TPM or 99.99 TPI. : With tolerance of -15mm or 0.6 inch for movement in other direction. : Up to 1500 RPM : Manual control of rotation is possible by hand. : Spring loaded clamps at motor end for easy clamping of yarn. : Toggle clamp at spool end for easy, quick and continuous clamping of yarn through spool. : Reading of at least 20 samples can be stored and average TPM/TPI value is calculated and displayed. : 230 V AC, 30 Watts. : 1000mm x 150mm x 200mm (approx).
40
2. FABRIC ABRASION TESTER
Specifications of fabric abrasion tester: •
Standards: GB/T4802.2, GB8690, ASTMD4966, ASTMD4970, ISO12945.2
•
Friction head: 8 pcs
•
Sample clip diameter: diameter 38mm and diamter90mm
•
Diameter grinding platform: diamter 120mm
•
38mm Sample clip and guide rod total weight: (200 ± 1) g
•
Hammer: 395g ± 2g, 594g ± 2g
•
Counter counting range: 1-65535 times preset
•
Test speed (grinding speed): 50 ± 2r.p.m
•
Power: 380V ± 5%, 50Hz, three-phase four-wire
•
Dimensions: 850mm × 600mm × 350mm
•
Weight: about 80kg 3. FABRIC PILLING TESTER:
41
Specifications of fabric pilling tester: •
Model: YG502B
•
Standard: GB/T4802.1-1997
•
Main technical data: trajectory diameter 40, circular orbit
•
Brush Height 2-12mm adjustable
•
Dimensions 520x280x360
•
Weight 45kg
•
Power AC220V
4. FABRIC PICK COUNTER
Specification for fabric pick counter: •
Y511B Fabric pick counter
•
Standard: GB/T4668, ISO7211
•
Magnification 10, 20
•
Figured scale travel 0~50mm
•
Dimensions 97×53×35mm
42
5. WASHING COLOR FASTNESS TESTER
Specification for washing color fastness •
Reciprocating travel 100mm
•
Rubbing finger pressure 60Times/min
•
Rubbing finger pressure 9N
•
Reciprocating times 10 times (automatic stop)
•
Rubbing head size Circular diameter 16mm
•
External Dimensions L760×W270×H240mm
•
Weight 20kg
•
Power- AC220 50Hz 40W
•
Manual
•
Applicable standards: Built according with: AATCC
•
Features: It applies for AATCC standard.
•
Model Y571M
•
Testing Times 1-99999
43
•
Rubbing Travel 105mm (Can be adjusted)
•
Rubbing Speed Manual
•
Rubbing Pressure 9N
•
Rubbing Head diameter: 16mm
•
External Dimensions 660×160mm×215mm (L×W×H)
•
Power Source :NO 6. COLOR ASSESSMENT CABINET
Specification of color assessment cabinet •
Brand: JAG
•
Model: JAG60
•
Configuration: D65, TL84, F, UV (4 light sources)
•
Weight: 25Kg
•
Cabinet dimensions (W x D x H): 710x420x570 mm
•
Packing dimensions (L x W x H): 750x600x350mm
•
Light Tube Length: 600mm (24")
44
7. SINGLE FIBER TESTER
Specification of single fiber tester:
•
Electronic single fiber strength tester
•
Testing breaking strength; break elongation rate, fixed elongation, etc. of fibers, or thin metal wires.
•
Standard: GB/T14337, ISO5079, 11566, ASTM D3822, BS4029, AATCC, etc.
•
Unit: N, CN, KG, LB, IN etc.
•
Max Strength Range: 100cN, 200cN, 300cN, 500cN.
•
Scale limits: 2-120%
•
Scale value: 0.01N
•
Accuracy: <± 0.5%
•
Sensor Accuracy: <±0.05%FS
•
Resolution 0.01cN
•
Minim clamp distance: 10mm Digital setting, automatic fixing
•
Drawing speed: 2-200mm/min. Scale value: 1 mm/min. Accuracy: 1% 45
•
Return speed: 2- 200mm/min. Scale value: 1 mm/min. Accuracy: 1%
•
Work motion: 100mm. Elongation resolution: 0.01mm
•
Maximum elongation: 150mm
•
Host size: L370 × W300 × H550mm
•
Weight: 85KG
WASHING MACHINE FABCARE WASHING MACHINE specifications: •
Fabcare 'Washing Machines' are designed for all types of Laundry Jobs, Technical and Enzyme Washings.
•
Machines are available with different types and size to cater the need of different Fabrics such as Denim, Cotton, Rayon, Knitted, Woolen Garments.
•
Automatic, Auto timed, Auto reverse, Auto Digital temperature control.
•
Front plate/Inner Basket/Outer Drum all in SS Heavy duty fabrication.
•
Heating system available in Electric/Steam Direct Injection/Indirect steam through Seamless pipe of SS 316 quality Coils/Thermic Heat Transfer Fluids, Oil/Gas fired heated.
•
Available in 20, 35, 70, 140 Kg. Dry weight per charge capacity.
46
47
DRYING TUMBLER
•
MODEL CAPACITY
•
CAPACITY DRY WTPEPCHARGE : 30 KG 1:24
•
BASKET SIZE
•
MOTOR DRIVE BLOWER
•
STEAM CONN. CONSUMPTION
•
ELECTRIC
: 18/24 KW
•
OVERALL DIMENSIONS
: 1150 X 1460 X 1980
•
NET WEIGHT
:SDS 30
: Ø950 X850 : 0.75 KW : Ø15 (0.5" BSP)50KG/HR
: 560 KG
48
CUTTING ROOM MACHINE DETAILS TYPES OF MACHINES USED & THEIR SPECIFICATIONS:1. BAND KNIFE MACHINESLF-BK-00850 MODEL EC-700 220V,50/60 HZ,1PH,3AMP KNIFE SIZE 3500 mm.
2. END CUTTER MODE EC-3 LF –EC-00900 220 V,50HZ,1 PH,0.5AMP EASTMAN M/C CO. NEW YORK,US 3. STRAIGHT KNIFE
49
Motors 110v, 1ph: Weight 34 lbs. (15.4kg) Horsepower .65hp Blade Size (inches): 5" (cm): 12.7cm Cutting Capacity (inches):3.5" (cm):8.89cm Stroke Size (inches):1.125" (cm): 2.86cm
SEWING MACHINES DETAILS TYPES OF MACHINES USED – 1. SINGLE NEEDLE LOCK STITCH
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Specifications : Bed dimensions: • Length: 18 3/4" (477 mm) Width: 7" (178 mm) Space to right of needle: 10 5/16" (262 mm) • Outside diameter of machine pulley: 2 61/64” (75 mm) effective diameter for V-belt • Regular machine: Singer® clutch motor high speed 1/2 H.P. • Under bed thread trimmer (U.T.T): Singer® AC servo motor/EC (N.P.) motor • Including the operation panel C-30 • Needle bar Stroke: For 200A: 1 3/16 " (30 mm) For 300A: 1 3/18" (35 mm) • Clearance under presser foot: By hand 7/32 " (5.5 mm) By knee 1/2" (13 mm) 2.DOUBLE NEEDLE LOCKSTITCH :
SPECIFICATIONS ; • • • • • • • • •
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Max sewing speed -3000rpm Max. stitch length-5mm Needle bar stroke-33.4mm Needle-DPX5 #14. Bed size-517mm*478mm Weight of machine-43kgs Power required- single phase 100,420V,200. Three phase 200,240V/650VA. With automatic UBT.
5 THREAD OVERLOCK
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SPECIFICATIONS : • • • • • • • • • • • •
Brand: Juki Application: For light-weight materials Feed Dog: 4-Row Feed System: Bottom-Feed Max. Sewing Speed: 7000 rpm/spm Max. Stitch length: 1.5~4mm Needle Bar Stroke: 24.5mm Needle System (at time of delivery): DC X 27 Lubrication: Automatic Lubricating Oil: Juki New Defrix Oil #2(Equivalent to ISO VG32) Lift of Presser Foot by Hand: 7 mm Number of Threads: 2/3/4/5 Threads
3. BUTTON STITCHING MACHINE :
SPECIFICATIONS : • • • •
Max. sewing speed- 1500 spm. Number of stitches-8, ,16 and 32. Applicable buttons- round shaped ,flat(2 holed,4 holed),shank/snap/metal. Needle bar stroke-48.6 mm • Needle size -TQ x 7 #18 ~#20TQ x 1 # 14~#18. • Button clamp lifting height / system- >9mm/Automatic System. 3. BUTTON HOLE SEWING MACHINES –
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• • • • • •
Max. SewingSpeed -3,000 spm Number ofStitches -83~225 (by gear change method). Max lift of work clamp-12 mm (15/32”) Needle bar stroke -34.6 mm Length ofbottom holes -6.4-38.0 mm Needle Size -DP x 5 # 11~ 16
FINISHING MACHINES DETAIL 1. FUSING MACHINE
Specifications: - CONTINOUS FUSING MACHINE: -
AE-300
MODEL POWER SUPPLY HEATER 53
SINGLE PHASE 3 KW
MOTOR
0.40 KW
CURRENT
17 A
TEMPERATURE
200’ C
PRESSURE
1 KG/CM2
BELT SPEED
8.7 M/MIN
FUSING WIDTH
300 MM
2. PRESSING
MODEL
NX-2429
NO. OF MOTORS
POWER
DIMENSIONS(L*W*H ) INCHES
WEIGHT KG.
1
.75 HP, 1 PH/3PH
50*30*36
80
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RAW MATERIAL STORE DEPARTMENT
CALCULATION:Total area=390 sq mt Rack size=7’*6’ Fabric Gsm=220 Fabric weight-100 kg Fabric width =56” Capacity of 1 rack=1800 kg. Fabric diameter=2.5’ 55
Total no. of racks=28racks Total capacity of racks=28*1800 = 50400 kg.
CUTTING DEPARTMENT
CALCULATION Total area=694 sq mt No of pieces cut per day=2000 3% extra=2000*3*2060/100 pcs/day Avg consumption/t-shirt=0.9 mtr Avg consumption /t-shirt=220*100/.9*56*2.5=1.4 kg Marker way=10 way Total no. of layers=100 Total garments/cut=10*100=100 pcs/cut For one cut (assumption) Spreading: One lay spreading time=35 sec=30/60=0.50 min Total spreading for 100 layers=0.50*100 =50 min Lay preparation time=10 min Total spreading time for one cut=50+10 =60 min Total cutting for one lay or cut=100 min Total required time for one cut finishing=100+60 =160 min Total no. of cuts/ day=480/160=3 cut From 3 cut=3*1000 =3000 pcs Production of cutting department=4*3000 56
=12000pcs/day 9000 pcs issued to sewing department In sewing department=4 line 1 line capacity=2000 pcs 4 line capacity=2000*4 =8000 pcs Thus WIP in cutting department=12000-8000 =4000 pcs/day Total fabric required per day in cutting room =9000*1.4 =12600 kg
COMPLIANCE ISSUES FOLLOWED IN THE INDUSTRY: Displays Factory Act Abstract Minimum Wages Abstract The Payment of Wages Abstract The Payment of Gratuity Abstract The Maternity Benefit Act Abstract The Payment of Bonus Abstract ESI Abstract EPF Abstract Form 11 Weekly Holiday Notice Notice Nearest Hospital, Fire Station, Police Station etc. Notice Important Officials Phone Numbers Form V (National & Festival Holiday) 57
Standing Order (Tamil & English) Needle Control Policy Voluntary Work Policy Sexual Harrassment Policy Health and Safety Policy Child labour abolition policy Anti discrimination policy Urgent Business need policy Zero abusement policy Working hours policy Broken needle policy Sexual harrassment policy Hiring / Recruitment policy Environmental policy Security policy Buyers code of conduct Workmen Committee Members Photo with Name Health & Safety Committee Members Photo with Name Canteen Members Photo with Name Transport Committee Members Photo with Name Harrassment & Discrimination committee Members Photo with Name Unit Work Flow Organisation Chart with manpower details Weekly Holiday Announcement Excise Certificate
Building Name Sign to All Rooms / Area Indicators / Direction from Security Gate onwards Storage above Storage limit Carton Box etc. Aisle marking Aisle width minimum 112 cm. Indicators Arrows in the passage Aisle without block Health Drinking Water At least4.5 Litres water provided per day per employee Water Testing Certificate Drinking water not in plastic pot Drinking Water, Cup availability Drinking Water centre (one place to every 150 employees upto 500) 58
Drinking Water centre (one place to every 500 employees above 500) Water Cooler / Heater available at every canteen, dining hall, rest room etc. Drinking Water Signage in English and Tamil Locate from 20 feet away from toilet Locate maximum 50 meteres distance from work spot Drinking Water vessale cleaned at least once in a day Water Reservoir or Tank Cleaned at least once in a week Water centre cleaning condition Water Vessal Cleaning log sheet Water Centre Incharge person with cleanliness Suggessation Box Register
Toilets Toilet Seat to Every 20 Women Toilet Seat to Every 20 men upto 100 Toilet Seat to Every 50 men beyond 100 All toilet seat with proper privacy and lock facility Urinal Accomodation Min. 61 cm for every 50 employees upto first 500 Urnial Accomodation Min. 61 cm for every 100 employees for above 500 Effective water Sewage system Soap/ Towel Bathroom Lock Water tap Dust Bins Buckets with mug at toilets Toilet White Washed once in every four month Tiles/Mosaic floors washed with Detergent or disinfectant once in four month Daily Cleaning Log sheet provided Adeaquate Water Tabs No smoking Sign in Gents Toilet 59
Awareness Quotes in Toilets Ladies / Gents Toilet Name Sign in Dual Language and Picture Spittoons Adequate Spittoons Sipittoons filled by Sand or Suitable disinfectant Spittoons covered by bleaching powder layer Spittoons scrapped or cleaned at least once in every day Others 500 Cubic feet for every employees Disposal of Wastes and effluents Room Temperature Lighting facility Trees on factory campus
Safety Guards Metal Glows on good Condition Rubber Mat to ironers Rubber Glows to ironers Ironers wearing slipper Motar Guard Needle Guard Eye Guard Sharp Tools Paddle Mat Scissors and trimmers are tied Sharp Boxes Mask Needle disposal once in six month Broken Needle Register Human resources Dining Hall 60
Dining Hall with sufficient Space Dining Hall with Sufficient Chair/Table Water Facility Ambulance Room Doctor Visit Nurse Medicines Medicines Issueing Record Creach Sufficient Space Creach Attender Creach Children Detail Daily Register Cradle Toys Postures Wash Room Facility Toilet Milk Eatables Available Drinking Water Ventilation Chairs for mothers Shady plaground for older children First Aid First Aid Boxes with All medicines First Aid Boxes Location List First Aid Box Daily Checklist First Aid Training employees (20 %) First Aid Trainer Name & Photo List First Box once for 150 employees First Aid Stations Fire Sufficient Fire Extinguisher Fire Extinguisher all in good Condition Fire Extinguisher Location List Fire Extinguisher Service Checklist Access area without hindarance Fire Extinguisher kept in 3 feet Fire Signage in Tamil & English Usage Guide in dual language Fire Extinguisher Colour Background Marking Space beneath marked Space beneath kept empty Refilling Service Done Fire Certified persons photo Evacuation Drill (External) Every Six Month 61
Evacuation Drill (External) File Evacuation Drill (Internal) Every Three Month Evacuation Drill (Internal) File Sufficient Fire Safety trained employees Fire safety trained employees name & Photo List Fire Buckets to Diesel Storage Area with Water and Sand Fire Buckets to Boiler Room with Water and Sand Fire Buckets to Genset room with Water and Sand Fire Buckets to E.B. Panal Board with Water and Sand Fire Buckets to Motor Room with Water and Sand Fire Buckets to Appropriate place. Fire Tray with sand Diesel Storage area floor filled by sand Evacuation Plan in all Floor / Area Emergency Exit Emergency Exit on Open Emergency Exit Signage Emergency Exit with outside open facility Emergency Exit Board Light with UPS Connection Emergency Light to All room / Area Adequate Emergency Light to All staircase Emergency Light to All Exit & Emergency Exit Emergency Light daily On/Off Log Sheet Emergency Light Location List Emergency Light kept on 6 feet hight Sufficient Spare Emergency Light in stock Emergency Electricity Switch off System (floorwise) Signage Emergency Electricity Switch Off No Hindrance Emergency Switch off Access Area Chemical Users Awareness Medical Certificate to Canteen employees Committees Workmen Committee Workmen Committee Meeting Workmen Committee Meeting File (with Circular, Agenda, Minutes, etc.) Workmen Committee Meeting Photos Health & Safety Committee Health & Safety Committee Meeting Health & Safety Committee Meeting File (with Circular, Agenda, Minutes, etc.) Health & Safety Committee Meeting Photos Canteen Committee Canteen Committee Meeting Canteen Committee Meeting File (with Circular, Agenda, Minutes, etc.) Canteen Committee Meeting Photos Transport Committee Transport Committee Meeting Transport Committee Meeting File (with Circular, Agenda, Minutes, etc.) 62
Transport Committee Meeting Photos Harrassment & Discrimination Committee H & D Committee Meeting H & D Committee Meeting File (with Circular, Agenda, Minutes, etc.) H & D Committee Meeting Photos Documents Personnel File to All Application Form Passport Size Photo Educational Qualification Certificate Age Proof I.D. Proof Address Proof Technical Certificate Previous Company Experience/Relieving order Old Salary Slip ESI Nomination Form 1 PF Nomination Form 2 Gratuity Nomination Form F Factory Act Nomination Form 34 Track Record Appointment Order Insurance NDA with Signature Employee Manual I.d. Card to All Adequate Swiping machine Punching Card to All ESI Card to All PF Slip to All Awareness Programme Stress Relieve Counselling Meetings Performance appraisal Leave Card Full & Final Settlement Exit Interview Gratuity Bonus Salary Breakup Salary on Date Induction Programme Induction Register 63
Manpower Manpower Departmentwise Male/Female Strength Report Presentism Report Late Report Absentism Report Daily Staff In-Out Register Is there Under Age Contract Employees Punch report Leave card to each employee MIR (Material Issue Register) Salary Salary date before 7 every month Bank Salary Account to all Salary Registers with employees signature monthwise Minimum Wages Basic D.A. Other Salary Breakups Over Time Double Salary to Over Time Any unwanted deduction for employee Unpaid salary are reversed Pay Cover Availability Security Adequate Securities Lady Guards Staff Movement Register Visitors Note Others In-Out Register Material Inward Register Material Outward Register Vehicle Movement Register Visitor Pass Visitor Slip Guards Knowledge about their Roles & Responsibilities Securities Personnel File Securities Uniform/Cap/Shoe/Belt etc. Securities Knowledge about Fire Evacuation & Fire Safety Security Agreement file (If outsourced) Security Salary register file (If outsourced) Security ESI, PF Challan (If Outsourced) Housekeeping
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Adequate Housekeeping Employees Lady Housekeeping employees Gents Housekeeping employees Housekeeping Supervisor Areawise work allocation Housekeeping Time Schedule Toilet Cleaning Log Sheet Brooms Availability Broom Stick Availability Water Mop Availability Thread Mop Availability Buckets Availability Phenoil Availability Harpic Availability Soap on All toilet & Bathroom Towel on All toilet & Bathroom Tissues & Hand Wash Shampoo Availability on Visitor Restroom Daily Cleaning Schedule MSDS for apropriate place. Maintenance E.B. E.B. Service Card Electricity Board Cardonned off from work place E.B. Meter Reading Register E.B. File Rubber Mat to E.B. Panel Board Rubber Mat to All swtich Board Authorized Persons Photo Display on E.B. related Rooms Caution board and danger signal on Electricity related Rooms Electrecians File C or B license certificates of Electrecian Rubber Glows to all Electrecian Safety instructions Displayed on E.B. Related Rooms Broken Wire Loose Wire Broken Switch Boiler room Boiler room cardonned off from work place Fire Safety Instruments availability Authorized persons Photo list Genset Genset Running Note Genset File AMC to Genset Gloves Safety shoes 65
Ear Muff Tray of Sand Machinary Machinary Detail Machinary File (Machinarywise) with purchase, service etc detail. AMC to all machinary Machinary Service Card Material Safety Data Sheet (MSDS) Personal Productivity Equipment (PPE) Issue Register PPE Awareness Logistics All Staff Bus/Van R.C. Book Copy All Staff Bus/Van Insurance Copy All Drivers Licence Copy Transport In - Out Time Register Transport Travellers Name List Transport Committee Transport Agreement Copy Load Van R.C.Book/Insurance Copy Company Drivers Licence Copy Company Van Trip Sheet Book General Fixed Asset Stock Register Diesel Consume Register White Petrol Consume Register Gen Set Usage Note Gen Set AMC Electrical Plan AMC to Computers AMC to Swiping Machines
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