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Facility Layout Presentation

The document outlines a comprehensive facility layout for a shirt manufacturing plant in Bangalore, India, aimed at producing 5,000 shirts per day. Key objectives include optimizing material flow, enhancing production efficiency, and incorporating sustainability features, such as solar energy and eco-friendly materials. The facility is designed with employee amenities and future scalability in mind, ensuring optimal workflow and adherence to industry standards.

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snigdha narayan
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7 views21 pages

Facility Layout Presentation

The document outlines a comprehensive facility layout for a shirt manufacturing plant in Bangalore, India, aimed at producing 5,000 shirts per day. Key objectives include optimizing material flow, enhancing production efficiency, and incorporating sustainability features, such as solar energy and eco-friendly materials. The facility is designed with employee amenities and future scalability in mind, ensuring optimal workflow and adherence to industry standards.

Uploaded by

snigdha narayan
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Comprehensive Facility Layout

for Shirt Manufacturing


Optimizing Workflow, Efficiency, and
Sustainability
Introduction
• Plant layout is the systematic arrangement of
machinery and resources to maximize
efficiency. This project focuses on a layout
designed to produce 5,000 shirts per day on a
2-acre site in Bangalore, India.
Objectives
• 1. Optimize material flow.
• 2. Enhance production efficiency.
• 3. Include employee-friendly amenities.
• 4. Design for future scalability.
Location and Site Selection
• • Location: Bellandur, Bangalore.
• • Proximity to markets and suppliers.
• • Strong infrastructure and skilled workforce
availability.
• • Government incentives for industry.
Factory Overview
• • Production capacity: 5,000 shirts/day.
• • Facility: 3-story building with basement.
• • Features: Progressive layout, ergonomic
stations, and eco-friendly design.
Basement Plan
• • Fabric and trim store: 6,045 sq. ft.
• • Equipment: Inspection machines, racks,
relaxation machines.
• • Parking: Designated vehicle storage area.
Ground Floor Plan
• • Cutting, washing, and finishing departments.
• • HR and administrative offices.
• • Loading/unloading and chemical storage
areas.
First Floor Plan
• • Sewing department: 11,833 sq. ft.
• • R&D and conference rooms.
• • Quality control and IE department cabins.
Second Floor Plan
• • Canteen and kitchen for employees.
• • Solar panels: 4,840.8 sq. ft.
• • Storage area for supplies.
Fabric Store Calculations
• • Daily fabric requirement: 6,250 meters.
• • Storage: 7 days' capacity (422 rolls).
• • Button and thread storage for 7 days.
Cutting Department
• • Equipment: Automatic cutting machines,
band knives.
• • Spreading tables: 4.
• • Daily capacity: 6,250 meters of fabric.
Sewing Department
• • Production lines: 8.
• • Machines: 288 sewing stations.
• • Output: 5,000 shirts/day at 70% efficiency.
Finishing and Packaging
• • Equipment: Ironing tables, inspection tables,
tagging machines.
• • Tasks: Quality checks, packaging, and
branding.
Warehouse and Storage
• • Area: 2,487.5 sq. ft.
• • Features: Racks and designated sorting
areas.
• • Function: Inventory and dispatch
management.
Sustainability Features
• • Solar energy generation.
• • Sewage and effluent treatment plants.
• • Natural ventilation and eco-friendly
materials.
Employee Amenities
• • Facilities: Canteen, restrooms, crèche.
• • Safety: Emergency exits, fire extinguishers.
• • Recreation: Break rooms and wellness
initiatives.
Training and Sampling
• • Training rooms: Theoretical and hands-on
skill development.
• • Sampling: Pre-production prototyping for
quality assurance.
Key Features
• • Modular production systems.
• • Ergonomic workstations.
• • Streamlined operations with automated
systems.
Architectural Overview
• • Multi-story building with RCC and CC
structures.
• • Standardized heights: 12-16 ft depending on
zones.
• • Climate-controlled areas for precision work.
Hierarchical Structure
• • Plant Manager oversees operations.
• • Departmental heads for cutting, sewing, and
finishing.
• • Support teams: HR, maintenance, and
quality control.
Conclusion
• The facility layout ensures optimal workflow,
sustainability, and scalability. Designed for
efficiency, it aligns with industry standards and
is prepared for future expansions.

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