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 Sampling

Analyze fabric Obtain general Develop sample as

Analyze cost of
consumption from sewing data from per the tech pack
trims and fabric
CAD IED

Prepare cost sheet Develop proto

from sample sample

Cost sheet & sample sent to buyer for approval

Confirmation Yes Approv No Cost sheet

of order al reworked

Obtain PCD & Source trims & Book washing &

Obtain GSD
details from fabric from embroidery capacity if
from IED
production unit concerned dept. required

Execution of order by entering details in ERP

Prepare sample as per buyer requirements

Forward the sample to buyer for approval

Hold pre production Comments received from buyer

Yes Approv No
meeting with the should be incorporated and fit
al
production unit sample reworked

Follow up with Submit required Offer garments Follow up

Execute production documents to for final on the En
bulk order departments & documentation inspection. payments d
update the buyer dept Truck out for goods

7
 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
RECEIVE SHADE APPROVAL
MERCHANDISER

PREPARE A FABRIC
SEND GOODS FOR DYEING
REQUISITION

RAISE THE REQUISITION TO

RECEIVE DYED GOODS
VENDORS
SEND
10
SEND YARDAGE FOR INTERNAL FOR
SUBMIT FORTESTING REDYEIN
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 READY FOR ISSUE
RE-
OR APPROV
NO
DE
ED
R 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 Verify whether Forward one

test on minimum 2 quantity received If meter of each
If No
match with quantity Yes consignment for
bits/bale or
minimum 10 bits ordered lab test
of consignment

Inform to stores and Inspection based on If

If No
prepare goods received four points system. Yes
note (in case of imported Match bulk with
fabric) approved dye lot,
width of fabric etc.

Name shade lot as

ABC

Send to merchant for

buyer’s approval

If Forward to
If No If Yes
approved cutting dept.

Reject lot

End

13
TESTING LAB

14
 Star
t

Fabric Accessory
Merchandising
Sourcing stores

Carry on
Test Test
test on
fabric and
garment as
Count Buttons per buyer
requirement

Construction
On meeting
buyer
Color requirement
fastness to , samples to
washing be sent to
external lab
to get
Color
Lining approval
fastness to
crocking fabrics

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 construction enquiry –

sampling dept.

Prod. Friendly solution

Calculate SMV merchandising dept. PPC

dept.

Prod. Cost prod. planning

Tech analysis before fit stage-suggest amendments(stamp) merchandising dept.

incorporate in sampling

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 develop customized

folders tool room

(innovate)

Prepare opern bullttin prepare R & D report

17
 Update SMV & finalize reports

Factory IE discuss & collects reports

Prepare work station layout m/c & work aid REQMT to

maintenance↓↓

Line setting according to IE reports procure from maintenance

Capacity check analysis & feedback R & D analysis and feedback IE

dept

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
Pattern
Graphtec
grading
plotter

Cut ratio
planning Pattern sent
to
Market merchandiser
planning for sampling
according to
the cut plan

20
 Output Output mini
marker to marker to
WORK FLOW
plotter IN CAD printer
DEPARTMENT

Send to Send to
cutting room merchandiser
for cutting 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
Cut for initial
changed
size set
pattern from

Assemble and
check

Requir
Yes
e
chang
NO
es
No

Issue job
order
Cut plan

Bulk cutting Sortin Bundlin Issue

g g

24
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 Confirm in

Confirm the above details
IED on productivity consultation with
given to concerned units in
based on garment embroidery, washing
consultation with GM & FM
analysis 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:
Planning follow up with factory till
order execution
To study the production file.

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

Assembly
In-Line
checking
End line checking & AQL
audit
Button & button hole/ Bar
tack
Washing
Rough checking

Ironing

Final checking

Measurement
checking

Tagging

Packing

FSA Audit

Auditing by buyer
QA

Truck out En
26 d
 WASHING
PROCESS FLOW:

Start

Washing Normal wash

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. TOTAL NO. AIR

31
 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 4.59 sq mts. 1 1 -
ROOM
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 TOTAL NO. TOATAL AIR

mts) OF LIGHTS NO. OF CONDITION
FANS

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 11.01 sq mts 1 1 --
ROOMS
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 TOTAL NO. TOTAL NO. AIR

(in sq mts.) OF LIGHTS OF FANS 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 & 128.5 sq mts. 65 4 -
INSPECTION
AUDIT AREA 80.34 sq mts. 40 2 -
PACKAGING 144.6 sq mts. 50 3 -
DISPATCH AND 96.4 sq mts. 5 4 -
LOADING
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

Trim store

Store manager 2

Assistant manager 2

Workers/helpers 10

TOTAL 14

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:

: 25mm to 500 mm adjustable (metric unit) OR 1” to 20” adjustable (imperial

• Yarn test length unit). The test length is automatically taken into account for calculation and
final reading is displayed directly in TPM/TPI.
• Range : Up to 9999 TPM or 99.99 TPI.
• Resolution : 1 TPM or 0.01 TPI.
• Elongation
: Up to 9999 TPM or 99.99 TPI.
Range
: With tolerance of -15mm or 0.6 inch for movement in other direction.
• Motor Speed : Up to 1500 RPM
: Manual control of rotation is possible by hand.
• Clamps : 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
• Averaging
calculated and displayed.
• Supply : 230 V AC, 30 Watts.
• Size : 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 :SDS 30

• CAPACITY DRY WTPEPCHARGE : 30 KG 1:24

• BASKET SIZE : Ø950 X850

• MOTOR DRIVE BLOWER : 0.75 KW

• STEAM CONN. : Ø15 (0.5" BSP)50KG/HR

CONSUMPTION

• ELECTRIC : 18/24 KW

• OVERALL DIMENSIONS : 1150 X 1460 X 1980

• NET WEIGHT : 560 KG

48
 CUTTING ROOM MACHINE DETAILS
TYPES OF MACHINES USED & THEIR SPECIFICATIONS:-

1. BAND KNIFE MACHINES-

LF-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

50
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 ;

• 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.

3 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
SINGLE PHASE
POWER SUPPLY
HEATER 3 KW

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 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

NO. OF DIMENSIONS(L*W*H
MODEL POWER WEIGHT KG.
MOTORS ) INCHES

NX-2429 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’

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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

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 =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)
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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)
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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

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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
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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
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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

66