Plant Layout in Apparel Manufacturing

Front Cover
The foremost and the most important step of establishing a business is setting up a factory. While designing of a factory layout has been nowadays handed over to professional architects, the apparel manufacturers must have a basic knowledge of what a ‘good’ factory layout actually means. A good factory layout offers minimum transportation time and flexibility with no back and forth motion. This series is a one-stop solution for all the factors to be considered, apart from the checklist, and the ways to maximum optimise the factory along with case studies of apparel manufacturing plant layouts in India.
 

Contents

The definition of a good
1
Multistoried factories have been mushrooming because the land costs today
12
A smooth interdepartmental flow of man and materials greatly
19
Employee productivity does not singlehandedly depend on the skill set or the level of machinery heshe
29
A single floor factory
36
The rigid mindset of apparel manufacturers has changed from understanding the need to keeping
43

Common terms and phrases

About the author (2020)

Suresh Dureja, Plant Manager at ‘Canada-Goose’, Toronto is a mechanical engineer and a post-graduate diploma holder in Garment Manufacturing Technology from NIFT, New Delhi.

He has worked for highly progressive companies at senior management level in India like Shahi Exports Ltd., Orient Craft Ltd., Niryat- Sam Apparels India Ltd. and Pearl Global Ltd. before immigrating to Canada in 2000.


Dr. Prabir Jana is a Professor at Department of Fashion Technology at National Institute of Fashion Technology, Delhi (India). A visionary in development, application and management of technology in apparel manufacturing, he started his career with a private garment manufacturing enterprise in 1991. He is a graduate in Textile Technology from Calcutta University, postgraduate in Garment Manufacturing Technology from NIFT, New Delhi and PhD from The Nottingham Trent University, UK.


Y P Garg started his career in the garment industry with “York” shirts, way back in 1966. Since 1985 he is working as a consultant and has successfully re-engineered many factories in India. Widely travelled across India and the Far East, Mr. Garg specialises in manufacturing technology with special emphasis on sewing. He is currently involved in operator training and research on the use of lightweight fabrics.


Paul Collyer, from Leicestershire, UK, has over thirty-seven years of experience in production management, specialist consultancy and training in the garment industry. He has spent 17 years in a consultancy role, the last five as a freelancer. He has worked extensively in the garment industries of North Africa, the Middle East and with many companies throughout Sri Lanka.


Paul F. Bowes is the Managing Project Director of Performance for Business Productivity Services Ltd, a World Class Manufacturing consultancy firm operating in the U.K. and Asia, supporting the apparel industry. A professional Industrial Engineer, Project Manager and Consultant, Paul worked on the MAS “iconic” Green Factory, developing lean production systems and processes; and as National Consultant for the Sri Lankan Productivity Improvement Programme from 2005 to 2007, assisting 30 factories to improve their productivity by over 30% using lean manufacturing techniques and the methods described above. (www.leanapparelsolutions.com)


Piyush R Vyas, a graduate with Chemistry and Microbiology, holds a Diploma in Administrative Management and also International Marketing and has been in the apparel industry since 1975. Having worked with exporters, buying house and importers, he presently offers consultancy services in the apparel industry in setting up new projects, looking at existing units and suggesting corrections & gives training lectures and on job training. He has more than three decades of experience in setting up Whitefield Projects, ERP Implementation, Human Resource Management, Project Management and Supply Chain Management in the apparel industry.