PLANT LAYOUT

SUBMITTED TO: Mr. Pavan Godiawala

SUBMITTED BY: TAMANNA

M.FTECH 2010-12

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

WORKING IN AN INDUSTRY
BUYER

PRODUCT DEVELOPER

MERCHANT SAMPLING

FABRIC

TESTING MARKER PLANNING SPREADING

CUTTING

BUNDLING & TICKETING RESEARCH & DEVELOPMENT PRODUCTION WASHING

3 FINISHING & PRESSING

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

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

ORDER CONFIRMATION

MERCHANDISING PROCESS FLOW OF MERCHANDISING DEPARTMENT

Start
Obtain tech pack from buyer

Costing

Sampling

Analyze fabric consumption from CAD

Analyze cost of trims and fabric

Obtain general sewing data from IED

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

Yes

Approv al

No

Cost sheet reworked

Obtain PCD & details from production unit

Source trims & fabric from concerned dept.

Book washing & embroidery capacity if required

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

Yes

Approv al Submit required documents to documentation dept

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

Execute bulk order

Follow up with production departments & update the buyer

En d

SAMPLING
STEPS OF SAMPLING:

PROTO TYPE SAMPLE MADE

FIT SAMPLE MADE

8

PP SAMPLE MADE SHIPPMENT SAMPLE MADE TOP SAMPLE MADE SIZE SET MADE

FABRIC SOURCING
Fabric requisition from merchandiser

Order placed

Fabric receive invoice/challan

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 PREPARE A FABRIC REQUISITION RAISE THE REQUISITION TO VENDORS
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RECEIVE SHADE APPROVAL

SEND GOODS FOR DYEING

RECEIVE DYED GOODS SEND SEND YARDAGE FOR INTERNAL FOR REDYEIN SUBMIT FORTESTING APPROVAL BUYERS BULK FABRIC IN - HOUSE G, FOR COLOR AND QUALITY

SOURCE OUT THE GOODS

FINALIZE THE VENDORS

NO

PLACE THE ORDER

APPROVE D
YES

FIRST LOT IN - HOUSE

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

GRIEGE FABRIC SEND IT FOR PROCESSING BACK TO INHOUSE AFTER DYEING OR PRINTING

SOLID/YARN DYED/PRINTE D

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

Verify whether quantity received match with quantity ordered

If Yes

Forward one meter of each consignment for lab test

Inform to stores and prepare goods received note (in case of imported fabric)

If No

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 buyers approval

If No

If approved

If Yes

Forward to cutting dept.

Reject lot End

13

TESTING LAB

14

Star t

Fabric Sourcing Test

Accessory stores Test

Merchandising Carry on test on fabric and garment as per buyer requirement

Count

Buttons

Construction

Color fastness to washing Color fastness to crocking

Lining fabrics

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. PPC

Prod. Cost Tech analysis before fit stage-suggest amendments(stamp) incorporate in sampling

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 line

rebalance

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 Pattern grading Cut ratio planning Market planning according to the cut plan
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Output to Graphtec plotter

Pattern sent to merchandiser for sampling

Output marker to plotter

WORK FLOW IN CAD DEPARTMENT

Output mini marker to printer

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

Cut for initial size set

Receive changed pattern from

Assemble and check Requir e chang NO es

No

Yes

Issue job order Cut plan Bulk cutting Sortin g Bundlin g Issue

24

PRODUCTION PLANNING & CONTROL

Start
On receiving the orders, allocate the same to units based on line openings and buyers 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. Manpower tailors and helpers. Load and feeding lines. To arrange buffer or work-in-progress. Manufacturing.

End

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 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

Washing

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
31

TOTAL NO.

TOTAL NO.

AIR

mts)

OF LIGHTS

OF FANS

CONDITION

EXCUTIVE PARKING TIME OFFICE MAIN ENTRY UNLOADING AREA STORE MANAGER TRIMS AREA REJECTED ROLLS TESTING LABS
LABOURWASH ROOMS

353.5 sq mts. 13.77 sq mts. 15 mts. 91.8 sq mts. 13.77 sq mts. 12.39 sq mts. 16.06 sq mts 23.87 sq mts. 6.88 sq mts. 17.90 sq mts. 17.9 sq mts. 35.8 sq mts. 3.67 sq mts. 18.36 sq mts. 18.36 sq mts. 28.4 sq mts. 112.02 sq mts. 48.2 sq mts 28.12 sq mts. 28.12 sq mts. 4.59 sq mts. 22.95 sq mts. 27.54 sq mts. 20.66 sq mts. 27.54 sq mts 20.66 sq mts 21.34 sq mts 27.54 sq mts
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1 halogen 1

1 -

1 1 1 1 1 1 1 1 1 1

2 1 1 1 2 1 1 1 1 1 2 3 2 1 1 1 1 2 1 1 1 1 2

3 1 1 1 2 2 1 2 1 1 1 1 1 1 1 2 1 1 1 1 1

UTILITY ROOM CRECHE LOCKERS SUPERVISOR WASTE ROOM REMENENT CAD CUT PANEL AREA PATTERN MAKING MANAGER MEDICAL EXECUTIVE WASH ROOM EXECUTIVE CANTEEN CONFERENCE RECEPTION PPC GM MD STUDIO

PURCHASE EXPORT ACCOUNTS MIS HR LOGISTICS MERCHANDISER SENIOR MERCHANDISER WORKER PARKING

20.66 sq mts 20.66 sq mts 20.66 sq mts 20.66 sq mts 30.99 sq mts 13.77 sq mts 27.54 sq mts 13.77 sq mts 91.5 sq mts

1 1 1 1 1 1 1 1 -

1 1 1 1 1 1 1 2 -

1 1 1 1 1 1 -

FIRST FLOOR: DEPARTMENTS AREA (in sq mts) TOTAL NO. OF LIGHTS TOATAL NO. OF FANS 14 4 1 1 59 1 1 1 1 1 1 2 1 AIR CONDITION

SAMPLING MAINTAINENCE IE QUALITY ASSURANCE SEWING AREA COMPLIANCE TRAINING MANAGER ROOM STORE BOILER EXECUTIVE WASH ROOMS EXECUTIVE CANTEEN WASTE ROOM

530.3 sq mts. 123.9 sq mts. 19.2 sq mts. 1.83 sq mts 2107.2 sq mts 36.7 sq mts. 31.22 sq mts. 13.77 sq mts. 31.22 sq mts. 18.36 sq mts. 11.01 sq mts 22.9 sq mts 18.36 sq mts
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5 3 1 1 1065 1 1 1 1 1 1 1 1

1 --

DRINKING WATER WASH ROOMS RACKS SECOND FLOOR : DEPARTMENTS

4.59 sq mts. 4.59 sq mts. 27.5 sq mts.

1 2

AREA (in sq mts.) 9.18 sq mts. 34.4 sq mts. 385.6 sq mts. 128.5 sq mts. 80.34 sq mts. 144.6 sq mts. 96.4 sq mts. 18.36 sq mts. 146.9 sq mts. 4.59 sq mts. 4.59 sq mts. 2.52 sq mts. 27.5 sq mts. 27.5 sq mts. 156.1 sq mts.

TOTAL NO. OF LIGHTS 1 1 2 65 40 50 5 2 10 1 1 1 1 78

TOTAL NO. OF FANS 1 11 4 2 3 4 1 5 1 1 5

AIR CONDITI ON 1 1 -

WASH ROOMS EXECUTIVE CANTEEN LABOUR CANTEEN MEASUREMENT & INSPECTION AUDIT AREA PACKAGING DISPATCH AND LOADING CARTON STORAGE WASHING AREA WASHROOMS DRINKING WATER SUPERVISOR WASHING MANAGER FINISHING MANAGER FINISHING ZONE

WORKFORCE IN DIFFERENT DEPARTMENT ADMINISTRATION DEPARTMENT:-

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DEPARTMENT Executive Accounts and finance Human resources Purchase Export and import MIS Logistics Merchandising PPC IE CAD Maintenance TOTAL

NO. OF EMPLOYEES 2 5 4 3 3 4 2 5 5 3 5 4 42

SAMPLING DEPARTMENT: Cutting master Sampling manager Sampling in charge Pattern master Supervisor Tailors
35

3 1 1 1 2 35

Helpers Ironer checker TOTAL

2 3 3 51

STORE DEPARTMENT:Fabric store

Store manager Assistant manager Checker Workers/helpers TOTAL

1 2 3 20 26

Trim store Store manager Assistant manager Workers/helpers TOTAL 2 2 10 14

CUTTING DEPARTMENT:

Production manager Pattern master Assistant pattern master Cutting master

36

1 2 2 3

Workers/helpers TOTAL

50 58

SEWING DEPARTMENT: Production manager Supervisor Quality checker Workers/helpers Male:female(ratio) TOTAL 1 4 4 268 70:30 277

QUALITY ASSURANCE DEPARTMENT:

Quality manager Workers/helpers TOTAL

1 5 6

FINISHING DEPARTMENT:

OPERATION Button holing Button attaching Thread cutting

WORKER 2 2 25

HELPER 2 0 0

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Pressing Initial checking Final checking Re final checking Spot removal

20 15 2 2 4

2 0 0 0 0

PACKAGING DEPARTMENT

Assistant manager Quality checker Workers/helpers

1 3 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 : 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).

Averaging Supply Size

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 975335mm

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 L760W270H240mm 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 660160mm215mm (LWH) 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 MOTOR DRIVE BLOWER STEAM CONN. CONSUMPTION ELECTRIC OVERALL DIMENSIONS NET WEIGHT : 950 X850 : 0.75 KW : 15 (0.5" BSP)50KG/HR : 18/24 KW : 1150 X 1460 X 1980 : 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

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.

5 THREAD OVERLOCK

51

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

52

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: -

MODEL POWER SUPPLY HEATER

53

AE-300 SINGLE PHASE 3 KW

MOTOR CURRENT TEMPERATURE PRESSURE BELT SPEED FUSING WIDTH

0.40 KW 17 A 200 C 1 KG/CM2 8.7 M/MIN 300 MM

2. PRESSING

MODEL

NO. OF MOTORS

POWER

DIMENSIONS(L*W*H ) INCHES

WEIGHT KG.

NX-2429

.75 HP, 1 PH/3PH

50*30*36

80

54

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
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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.)
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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
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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
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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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