Addis Ababa City Administration Technical, Vocational, Education And Training Agency Bole Manufacturing Collage Efficient Plant Layout Design Project For A Small Scale Garment Workshop.pdf

EFFICIENT PLANT LAYOUT DESIGN PROJECT FOR A
SMALL SCALE GARMENT WORKSHOP
Haileyesus Wondwossen
B LE
MANUFACTURING COLLAGE

Agenda Section
In this section we will understand and implement industrial
layout. Then analyzing available resources.
Garment Layout
01
In this section we will demonstrate and analyze different layouts
with relative to our area
Design Layout
02
In this section we will describe different biro layout. This is
because the organization need to change some adjustments.
Organizational Layout
03
Finally we will demonstrate our research factor and errors made
before this document.
Challenge
04

Section Break
Garment Layout
2m

Introduction to Plant Layout
Plant layout refers a systematic and efficient functional
arrangement of various machines, equipment, tools.
Layout identically involves the allocation of space
and the arrangement of equipment
Layout decisions are one of the key facts
determining the long-run efficiency of operations.
Layouts have numerous strategic implications because
they establish an organization´s competitive priorities in
regard to capacity, processes, flexibility, and cost.

Experimental Layout
Visualization

Principle of Layout
Workers and materials must pass through the shortest distance
between the processes to avoid wastage of labor and time.
Principle of minimum travel
Machineries and processes should be arranged in a sequential
order which is achieved in the product layout.
Principle of sequence
Every foot of existing space should be effectively utilized. It
includes the proper usage of space both horizontally and vertically.
Principle of usage
There should be harmonious fusion of all the related factors so that
the final layout looks well integrated and compact.
Principle of compactness
workers to ensure they are safeguarded from the occurrence of fire
and must be protected from excessive heat, dust from the raw
materials such as fabrics and the trimmings of the threads in
sewing, glare and fumes.
Principle of safety and satisfaction

Principle of Layout
The layout must allow modifications with minimum complications
and at minimum cost.
Principle of flexibility
A good layout is one that makes the materials move only in the
forward direction, towards the completion stage.
Principle of Uni-direction flow
Duplicated movements consume unnecessary materials handling,
add to costs and lead to inefficiency.
Effective use of available space
A good layout is one that makes men, machines and materials
ready and observable at all times
Maximum Visibility
A good layout is one that makes all servicing and maintenance
points readily accessible
Maximum Accessibility

Influencing Factors
START
These decide the size and type of the
machinery to be installed which, in turn,
influences the plant layout.
Machinery
Whether the product is light or heavy,
small or big, its arrangement related to
the plant location affects the plant layout.
Product
2
any industry there is a need to offer a
proper storage and movement of raw
materials, which are necessary for the
production of a product, until they are
transformed into finished products.
Materials
Worker facilities is needed like wellbeing
and related services, locker rooms and
public facilities
Worker
1 1
2
The volume of production and provision
for expansion
The extent of automation
Making or buying a particular component
Management policies
Desire of rapid delivery of goods to the
customers
Purchase policy
Personnel policies
Management policies
3 3

Benefits of Plant Layout
Secure a smooth flow of work over the shortest routes
of production
IN TERMS OF PRODUCTION
Good plant layout facilitates accurate planning and
control of production
IN TERMS OF PLANNING
Efficient utilization of machinery, material and men
IN TERMS OF 3MS
Ideal plant layout secures better utilization of available
floor space.
Well-designed plant layout economizes the space
required for production and reduces the unit cost
IN TERMS OF SPACE
GOOD PLANT LAYOUT BRINGS
ABOUT
• Economies in materials and product handling;
• Reduction in number of accidents, loss of man-hours and wastage of
equipment;
• Better utilization of available floor space;
• Cut-back in idle capacity, superfluous work and delay in operations;
• Better provision for maintenance and inspection of the production
capacity, work in process and the work completed;
• Reduction in cost of supervision; and
• improvement in personnel morale and response.

• The distance between the departments must be as small
as possible to minimize the material movement.
• The machines that are similar are grouped in one section/
department.
• It must be convenient for supervision and inspection.
Requirement
01
• There is greater flexibility in the production.
• Better supervision is achievable through
specialization.
• This layout provides better use of men and
machines.
Advantage
02
• Movement of materials is difficult.
• Requires more floor space.
• The WIP accumulates at different
places.
Disadvantage
03
Process layout
The process arrangement is meant by the grouping together of similar machines
based upon their uniqueness.

The process starts at one side of the line and the
assembled product is delivered at another side of the line.
In between, partly finished goods move automatically or
manually from one machine to another
Definition
01
• Reduction in materials handling cost
• Better production control
• Less floor space per unit of production
Advantage
02
• Expensive and inflexible layout.
• Supervision is difficult.
• Expansion is difficult
Disadvantage
03
Product layout
The machines are generally arranged in a series based on the process sequence
required for manufacturing the garment.

men and machine have to move toward it which is desirable
as the cost of moving them is lower than the cost of moving
the product.
Definition
01
• Men and machines can be utilized for
numerous kinds of operations
manufacturing different products.
• The investment on layout is less.
• The costs of transportation for a bulky
product are avoided.
Advantage
02
Fixed position layout
The product remains stationary in a fixed location

Every cell in this design is shaped to produce single parts,
all with common attributes, which typically means they
necessitate the same machines and have similar machine
settings.
Definition
01
• Reduced material handling costs.
• Flow time of materials is less in production
planning.
• Improved visual control of process which
enables quicker set ups.
Advantage
02
• Manufacturing flexibility.
• Reduced machine stoppage time.
Disadvantage
03
Cellular
Manufacturing layout
The machines are generally assembled into cells which function fairly like a
product layout within a process layout.

Combined and service layout
Combined layout
It is a mixture of the product and process
layouts, which could be observed in many of
the apparel units.
Service facility layout
The major distinction between the service
facility and manufacturing facility layouts is
that many service facilities exist to bring
collectively customers and services together.
Each process is situated as a single unit and a number of such
units is arranged in a product layout. It is feasible to have both
types of layout in a capably combined form if the products
manufactured are fairly similar and not complex.
Some of the requirements of service facility layouts are
large, well organized and amply lighted parking areas
and well-designed walkways to and from parking areas.

Garment production process
Laying of paper pattern helps one to plan the
placement of the pattern pieces in a tentative
manner.
Laying
Relaxing refers to the process that allows the
material to relax and contract prior to being
manufactured.
Fabric Relaxing
Spreading, Form Layout, and Cutting
allow operators to identify fabric defects;
control the tension and slack of the fabric during
cutting; and
ensure each ply is accurately aligned on top of
the others.
Receiving Fabrics
Garment factories receive fabric from overseas
textile manufacturers in large bolts with cardboard
or plastic center tubes or in piles or bags.
Preparation

Process
Marking
Cutting
Embroidery
and Screen
Printing
Sewing
Checking
marker planner uses
full-size patterns and
arranges them in an
economical manner
on marker paper.
Of all the operations in
the cutting room, this
is the most decisive,
because once the
fabric has been cut,
very little can be done
to rectify serious
defects.
These processes are
commonly
subcontracted to off-
site facilities
Garments are sewn in
an assembly line, with
the garment becoming
complete as it
progresses down the
sewing line.
Spot Cleaning and
Laundry
Fusing and Pressing
Packaging and
Shipping

MACHINES IN GARMENT WORKSHOP
This area is used to define
the work area on a computer,
each individual can make his
own storage area. A storage
area is used to group related
work, such as pattern pieces
and a marker for a particular
style.
CAD SOFTWARE
DIGITIZING BOARD
PLOTTER MACHINE

Modern embroidery
machines are mostly
computer controlled and
exclusively designed for
embroidery.
DIGITAL EMBROIDERY
MACHINE

It has a drive motor and end
switches that allow the
machine to automatically
drive itself from beginning to
the end of the table and back.
FABRIC SPREADER
MACHINE

It may have rails fixed on the
top of a spreading table to
guide and control the
spreader as it moves along
the length of the table.
CUTTING TABLE

Creating patterns for clothing
production is a skilled
practice. The detail and
technique behind each
pattern ensure that garments
are made to specification
with a minimal margin of
error.
PATTERN MAKING
TABLE

is an often-articulated doll
used by artists, tailors,
dressmakers, window
dressers and others specially
to display or fit clothing
MANNEQUIN

It is the most useful cutting
instrument in apparel cutting
STRAIGHT KNIFE
CUTTER

This machine is small in size,
flexible & used for small
production. It is also a
popular cutting machine.
ROUND KNIFE
CUTTING MACHINE

a hot drill is used which will
slightly scorch or fuse the
edges of the hole. A
hypodermic drill may be used
which leaves a small deposit
of paint on each ply of fabric.
If it is important that no mark
remains on the fabric
DRILLING MACHINE

While layering fabric on the
cutting table, cutting
allowance is taken at both
ends of the ply. The
allowance of fabric in length
is called end loss. End loss
can be also defined as length
of fabric of a lay that doesn’t
get covered by a marker.
END CUTTER

Iron which is known
commonly as iron box has
been in existence for a very
long time with the traditional
one being used with heat
generated using charcoal.
IRONING MACHINE

high-speed lockstitch sewing
machine is the best common
mechanical system stitch
made by the sewing machine.
The term of single needle
stitching often found on dress
shirt labels, referring to
lockstitch machine.
HIGH SPEED LOCKSTITCH
SEWING MACHINE

Single needle lock stitch
machines are used for joining
two or multiple fabric plies
together. The machine is
used to sew lightweight,
medium weight and heavy
materials.
HIGH SPEED
COMPUTERIZED
LOCKSTITCH SEWING
MACHINE

A double needle lockstitch
machine works on the same
principle as the single needle
machine by using two
needles and two bobbins
thus resulting in two parallel
rows of lockstitch.
HIGH SPEED DOUBLE
NEEDLE LOCKSTITCH
SEWING MACHINE

Industrial zig-zag sewing
machine stitch moves from
side to side instead of
creating a straight stitch.
HIGH SPEED ZIG ZAG
LOCKSTITCH SEWING
MACHINE

Overlock machine also
known as serge, over edge
sewing machine and
interlock sewing machine.
HIGH SPEED 4 THREAD
OVER LOCK LOCKSTITCH
SEWING MACHINE

Overlock machine also
known as serge, over edge
sewing machine and
interlock sewing machine.
HIGH SPEED 5 THREAD
OVER LOCK LOCKSTITCH
SEWING MACHINE

these machines resemble
traditional sewing machines
in that the arm and needle
extend over the flat base of
the machine.
HIGH SPEED FLATBED
INTERLOCK SEWING
MACHINE

Chain stitch is formed by two
or more sets of threads
named needle thread and
looper thread.
HIGH SPEED
CYLINDERBED
INTERLOCK CHAIN STICH
SEWING MACHINE

It is a very expensive
machine and is used for
mainly sewing Jeans,
Grabidding goods & Double
stitching pants.
FEED OFF THE ARM
INTERLOCK SEWING
MACHINE

These cylinders bed shape
multi needle machine ensure,
with speed and ease, firm
and beautiful inserting
(attaching) of elastic tape.
MULTI NEEDLE CHAIN
STICH INTERLOCK
SEWING MACHINE

during pressing switch after
sewing one complete button
hole the machine will stop.
HIGH SPEED LOCKSTITCH
BUTTON HOLE SEWING
MACHINE

button sewing machine is
used to sew the button in the
garment without damaging it.
HIGH SPEED CHAIN
STITCH BUTTON SEWING
MACHINE

The bar tack machine is used
for sewing dense tack around
the open end of the
buttonhole.
HIGH SPEED ELECTRONIC
LOCK STITCH BAR
TRACKING SEWING
MACHINE

Button and buttonhole play
an important role in any kind
of apparel for easiness in
wearing and final
presentation.
BUTTON MACHINE

movable whiteboard is
double sided and magnetic to
be a versatile fixture for your
office or classroom.
MOVABLE WHITE BORD

• Congestion reduction
• Elimination of unnecessary occupied areas
• Reduction of administrative and indirect work
• Improvement on control and supervision
• Better adjustment of changing directions
• Better utilization of the workforce, equipment and services
• Reduction of material handling activities and stock in
process
• Reduction on parts and quality risks
• Reduction on health risks and increase on workers safety
• Ensuring that workers satisfaction is increased
• Reduction on delays and manufacturing time as well as
production capacity
Contents Title
SPECIFIC OBJECTIVE
The principal objective of a proper plant layout is to maximize the
production at the minimum of the costs. This objective should keep in
mind while designing a layout for a new plant as well as while making
the necessary changes in the existing layout in response to changes in
management policies and processes and techniques of teaching with
analyzing and providing a good working environment on specified
space for Garment workshop.
OBJECTIVE OF THE STUDY

Procedures and Principles of plant
layout
85%
Objectives
70%
Information gathering
65%
Production and flow analysis
40%
Support services
Implementation and evaluation.
55%
Compilation of overall plan
Integration
Content A
Minimum distance
Content B
Maximum space utilization
Content C
Maximum flexibility
Content D
Minimum material handling
Content E

Model One
First design
Rough potation
MODEL ONE
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
Sewing Machine 226.8
316.4
685.13
Chair 61.6
Pattern Table 111.84 ------------
Spreading
Machine
98.82 79.47
Cutting Table 41.94 28
Total 541 423.87 1650

Model Two
Regular design
MODEL TWO
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
144.64
1013.45
Chair 28.16
Pattern Table 111.84 ------------
Spreading
Machine
98.82 79.47
Total 384.44 252.11 1650

Model Three
Regular design
MODEL THREE
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
177.184
909.302
Chair 34.496
Pattern Table 153.78 ------------
Spreading Machine 98.82 79.47
Total 456.004 284.654 1650

Model Four
Regular design
MODEL FOUR
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
177.184
945.65
Chair 34.496
Pattern Table 117.432 ------------
Spreading
Machine
98.82 79.47
Total 419.696 284.654 1650

Model Five
Regular design
MODEL FIVE
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
177.184
962.426
Chair 34.496
Pattern Table 100.656 ------------
Spreading
Machine
98.82 79.47
Total 402.92 284.654 1650

Model Six
Regular design
MODEL SIX
Machine Area
(m2)
Working Area
(m2)
Walking Area
(m2)
177.184
962.426
Chair 34.496
Pattern Table 100.656 ------------
Spreading
Machine
98.82 79.47
Total 402.92 284.654 1650

Final
Result
This action need to done
Maximizing efficiency with available resource
No Trial activity
Sewing
Qty
Pattern
Qty
Spreader
Qty
Cutting
Qty
Machine
Area
Working
Area
Walking
Area
1 Model one 350 40 0 0 541 424 685
2 Model two 160 40 9 3 385 252 1013
3 Model three 196 55 9 3 456 285 910
4 Model four 196 42 9 3 420 285 945
5 Model five 196 36 9 3 403 285 962
6 Model six 196 36 9 3 403 285 962

Section Break
Design Layout
2m

r e c e n t
P l a n t l a y o u t
Some modifications must be done for the sake of
collage efficiency
Bole Manufacturing collage Three
identical shop layouts with Error
Designer
Unknown

Sewing Machine = 180
Pattern Table = 84
Spreader Machine = 9
Cutting Table = 3
Total Number of Machineries and Equipment's
Total Area = 1560
Utilized Space (all measurement in m2)
Over utilized space and remaining machineries
Sound problem and merged space
Complicated to implement for 4 levels education
Electrical installation and Room Partitioning is needed
There is group pattern area
Layout Challenge
Store available
2 CAD, 2 class, 2 dressing, 2 toilet room available
7 biros available
Improvement
Sewing Machine = 14
Pattern Table = 12
Cutting Table = 0
Remaining Number of Equipment's

Sewing Machine = 60
Pattern Table = 28
Cutting Table = 1
Machine Area = 175
Working Area + Walking Area = 1385
Electrical installation is needed
Room Partitioning is needed
Layout Challenge
Store available
7 biros available
Improvement
Pattern Table = 56
Cutting Table = 2

Pattern Table = 40
Cutting Table = 0
Machine Area = 541
Working Area = 424
Walking Area = 685
Electrical installation is needed
Room Partitioning is needed
Layout Challenge
Store available
7 biros available
Improvement
Sewing Machine = -156
Pattern Table = 44
Cutting Table = 3

Pattern Table = 40
Cutting Table = 3
Machine Area = 385
Working Area = 252
Walking Area = 1013
There is no group pattern area
Layout Challenge
Store available
7 biros available
Improvement
Sewing Machine = 34
Pattern Table = 44
Cutting Table = 0

Pattern Table = 55
Cutting Table = 3
Machine Area = 456
Working Area = 285
Walking Area = 910
Layout Challenge
Store available
7 biros available
Improvement
Sewing Machine = -2
Pattern Table = 29
Cutting Table = 0

Pattern Table = 42
Cutting Table = 3
Machine Area = 420
Working Area = 285
Walking Area = 945
Layout Challenge
Store available
7 biros available
Improvement
Sewing Machine = -2
Pattern Table = 42
Cutting Table = 0

Pattern Table = 36
Cutting Table = 3
Machine Area = 403
Working Area = 285
Walking Area = 962
Layout Challenge
Store available
7 biros available
Improvement
Sewing Machine = -2
Pattern Table = 48
Cutting Table = 0

Section Break
Organizational Layout
2m

Adjustments
New Room
Adjustments
Efficient work
Old building organizational layout adjustments

Mrs. Beza Assefa
Main building
challenge
Garment challenge
Solution
Organizational
challenge
Every challenge

EXECUTIVE SUMMERY
One of the most common industrial problem is proper use of man, material and machines
properly.
So, I begin to solve this illusion by
reduction of three garment workshop
into two workshop and free the
remaining workshop. In methodology
part there is a calculation based on
every machinery manuals and ISO
standard specification, some of the data
also count from literatures. But finally
using the requirements I found that the
plant need to place one workshop for
garment only so other departments can
use remaining. This is a great
opportunity for the collage to increase its
efficiency. Also, from my sample point
yearly graduating class is very minimum
like 24.6% only in garment this telling us
the collage must change its policy by
adding more department depending on
customer needs. Finally, I will
recommend to deeply analyze every
system for future better work and to fulfill
the components or materials need to
build the facility
Contents B
Contents A
Some organization are thriving to solve
this problem even educational institutes.
The key idea of this project is proper use
or efficient use of resources with
available area. So this project begin with
analyzing the total area used by a
collage and I have found that the collage
have 31,719.685 m2 area, from this
much amount of space building 8562 m2,
road 5149 m2, green area 5900 m2 is
used, so by roughly calculation the
collage will have 12,108.685m2 space
but the collage need much more space
than this because students need a
playground for football, there is no
entertainment center even tv room,
there is no lab workshop building area
for maximizing collage aim finally there
is 2 building this to be planted with this
area. This calculation will give us the
collage must maximizing its efficiency
with minimum requirements and
available resources.

ACKNOWLE
DGMENT
I wish to express my deep gratitude to Ms. Beza, Mr. Yared, Mr. Sisay, Mr.
Eyob, Mr. Endale and Mr. Negese for support and some of them help me
for the field measurement process. I also appreciate their consideration
and understanding towards my effort. Next, I would like to thank garment
workshop assistances for their encouragement, sharing materials and
ideas with interview, and those who share materials like Mr. wendu with me
for what I am going to do,
academically support and guidance revealed and offered from the initiation to the very last time
at which our design has come true.
Finally, I wish to be thankful for all the people who aren’t mentioned by their
name for their support presented in a straight line, in some way
academically. Lastly, I wish to appreciate the encouragement and
sympathetic by my families for the duration of every part of my enjoyable
and dreadful moment.
Thank you

THANK YOU
With a great power comes a great responsibility!

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