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SOP for Sewing Operator Recruitment and Training

SOP for Sewing Operator Recruitment and Training

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Published by: ChodathKulangareth BhagavathiTemple on Jun 29, 2011
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I. Procedure for Setting up of Sewing Training Section in factory II. Procedure for Recruitment of Trainee Operators (Tentative) III. Training Syllabus for Trainee Operators

Scientific Approach to “NEED BASED TRAINING” in 2 simple Steps 1. Primary Training: Basic Sewing & Machine Control Training 2. Secondary Training: Adding on Skills to Existing Operators & Improving the Efficiency of Low Performing Operators I. Procedure for Setting up of Sewing Training Section in factory A. Analysis to be made before setting up of the Training Section 1. The Output capacity of training section needs to be determined before setting up of a training section in the factory. 2. To determine the Output of the training section following factors need to be considered: a. Present Operator Strength in the Factory & Grade wise % contributing to the strength. b. Line wise, Grade wise Operators % available in every line c. % Labour Turnover in the factory & Grade Wise % Split in the total Turn Over d. % Absenteeism in Factory (Should also be analysed line wise) & Grade wise % Split in the overall Absenteeism

Complexity of styles running in the factory & Operation wise Skill Set requirement for the style needs to be analysed.e. II. Ball &tube test . Training Instructors need to be recruited depending on the size of the training section and the trained operator output planned out of the training section. Analysis of most frequently running styles in the factory & Operation wise Skill Set requirement for the style. One is training section instructor who will train the trainees within the training section and the other instructor will render ON JOB TRAINING instructor who will train the existing operator or the newly trained operator. There will be two categories of instructors required in training of the operators. Selection tests: 1. This would tell use what should be the ideal mix of Skill Set that needs to be allocated to the line g. Personal interview: Discuss & fill the relevant information in the Trainee Operator Recruitment Slip by HR Department 2. Peg board tests 2. This would tell use what should be the ideal mix of Skill Set that needs to be allocated to the line f. the factory IE has to co-ordinate with the training B. Needs to be analysed. Planned Strategy: 1. 2. supervisor in Style/Operation training Specific Skill of set availability Operators Considering the above said factors. Pin board test 3. Procedure for Selection of Trainee Operators (Tentative) 1.

86Sec). Two Hand Co-ordination Apparatus Reqd: Peg Board. we can assess the ability of applicant’s Hand & Arm movements. Metal pegs (120) one end painted red. these basic skills are very Important for making successful Sewing Operators). Metal pegs (120).4. Grade 4(83-90 Sec). Colour Perception test Objective: Assessment of Basic Skills for making successful Sewing Operators These tests are very important for assessment of basic Skills such as Manual dexterity (Speed of Hand Movements). Grade 4(76-80 Sec). Target: 75 seconds Note: 1 Being Least & 5 Being Highest B. Grade 2(101-105 sec). Finger Dexterity (Speed of hand movements). Apparatus Reqd: Peg Board. Peg Board Dexterity Test A (PBDA): In this test. Grade3 (91-100Sec). & two hand CoOrdination. Stopwatch Grade: 1to 5 (Grade 5(75 sec). Grade1 (Above 105 sec) . and Hand Eye Co-ordination & Sewing tests (Only for experienced operator. Grade 2(87-90sec) Grade1 (Above 90 sec). & Stopwatch Grade: 1to5 (Grade 5(82 sec). 1. Grade3 (81. Visual Accuracy test 5. PEG BOARD DEXTERITY TESTS: A. Peg Board Dexterity Test B (PBDB): In this test we can assess the ability of finger movements.

BALL & TUBE TESTS (BTT): In this test. we can measure the visual Accuracy & Speed Apparatus Reqd: Visual forms. accurately & sensitivity. & Stopwatch. Target: 90 seconds Test: Right Hand & Left Hand Note: 1 Being Least & 5 Being Highest 4. PIN BOARD TEST (PBT): In these tests. 135 pins. Target: 48 Seconds . & Stopwatch. It tests the ability to make rapid finger movements. Apparatus Reqd: Standard Pin board. we can measure the main manual Co-ordination together with the Finger dexterity Apparatus Reqd: Ball tube Stand & Boxes with one lid. VISUAL ACCURACY TEST (VAT): In this test. we can tests the ability to do the fine work with the fingers. neatly. 25 balls & Stopwatch Target: 25 Seconds Test: Right Hand & Left Hand 5. pencils.Target: 82 seconds Note: 1 Being Least & 5 Being Highest 3.

Peg Boards – 1 No & Metal Pegs – 120 Nos . Grade 2(7-9). Single Needle Lock Stitch – 10 Nos b. Grade3 (10-12). Grade 4(13-16). We also can give them some cones of thread of different colours and blocks of same or nearly same colours and asked to match the thread to the block of colours. Flat Lock Machine – 3Thd .Grade: 1to5 (Grade 5(17-20). Measuring Tape – 5 8. Permanent Marker – 1. After passing of above tests by trainees. In this test operators are asked to differentiate and rank different shades of the same colour in Ascending Order. Soft Board – 4X4 – 1 No 6.1. Grade1(less than 7)) Note: 1 Being Least & 5 Being Highest 6. then only they are eligible for to entering the training department Resources Required: 1. White Board Marker – 4. Sewing Machines a. COLOUR PERCEPTION TEST (CPT): This test is conducted to analyze the colour sensitivity of the operator. Cupboard of Documentation – 1 No 5. Over Lock Machine – 3Thd – 1 No d. Continuous Availability of Fabric. Over Lock Machine – 5Thd – 1 No e.1 No 2. Stop Clock – 2 Nos 9. Duster . Thread & Needle for Sewing Training 4. Manpower – Sewing Instructor – 1 Person 3. Double Needle Lock Stitch – 1 No c. While Board – 4X4 – 1 No 7.

F/L. 4. Needle up & Needle down. Different types of Sewing Machines 3. Treadle Control PART-I a. Treadle movement. Full speed & stop at stop points. e. 2.10. Training Syllabus for Trainee Operators STEP 1: Approx Duration: 1 Day Theory: 1. Running the machine at very low speed.Ball & Tube Stand – 1 No & Marble Balls – 25 Nos III. Running the machine at high Speed b.Pin Board – 1 No & Pins – 135 Nos 11. Sewing Machine and its parts. Threading sequence for different types of Sewing Machines (S/N. d.O/L. .D/N.FOA) STEP 2: Approx Duration: 3 Days Practical 1. Running the machine at low Speed c. General idea of other departments in the factory.

Feed dog etc. Tension adjustment. Folders. Treadle Control PART-II Fabric Exercises (Single ply) with threaded machine. Attachments and their use. Triangle (single ply) . Importance of Daily Machine Cleaning and Preventive Maintenance check-up. 2. Straight line (single ply) 2.Theory 2. Presser Foot. Stitches per Inch (SPI) & Stitches per Cms (SPC) and adjustments. Treadle movement.f. Different kinds of Fabric. 1. Roughing exercises. Selection of Needle. and its general use. STEP 3: Approx Duration: 3 Days Theory 1. Threads and their use. 4. 4. Practical 6. Thread tension. Square (single ply) 3. Thread and SPI for given Fabric. 3. 5.SPI. 3. Different kinds of Needles. Needle change. 5. Different kinds of Stitches. Adjusting Sewing conditions .

6. Long burst practice on waste fabric 2. 3. 4. 5. Cause and Effect diagram. Zigzag Exercises. Structure and Principle of Assembly of Cloths. arranging their work place according to the sequence of motion to reduce handling & increase machine time. Practice of Run stitch. Exercises to improve handling & increase M/c time 1. Sewing Defects. Circle or oval shape (single ply) 6. Curve. Theory 2. Work place Layout & Principles of Motion economy: • In this Session we particular train operators on better handling techniques. Edge stitch. Quality Requirement. Turn & stitch pointed or edge (kinari). Quality Control and Reliability. STEP 4: Approx Duration: 3 Days Practical 1. Precision Start & Stop & various other sewing exercises. Importance of “Alignment” while stitching and its importance to Quality. 3. (Single ply) 5. pointed stitch. Two ply attaching by Run stitch. .4. Trouble shooting.

While releasing the operator to production line. then he /she can been released into the production line using Trainee Operator Release Slip. the recommendation of the instructor & the strength & weakness of the operator is given to IE team for their reference.To consolidate all the above steps. detailing the skill level. . Sleeve operations (placket attach by using folder) c. Once the training instructor has been satisfied about trainee performance during training. Hemming Operations 3. 2. collar top or edge or pointed stitch) b. Here we should make job cards showing correct method (it shows good quality) & wrong method of sewing (it shows defects). 2. Quality Exercises Objective: To make more Quality awareness to all trainees by showing & explaining the different types of defects showing in the readymade board. Practical Exercise . Common Operations in Garmenting of Different Styles a.STEP 5: Approx Duration: 2 Days Practical 1. performance report of the operator during training. STEP 6: Released to Production Line & Follow up 1. Collar operation (collar run stitch.

INDUSTRIAL ENGINEERING. Productive & Profitable Communication in Apparel Business Paradigm Shift towards Quality Assurance Application of Work study in Apparel Manufacturing SOP for Sewing Operator Recruitment and Training Basic SOP for Cutting Section in Apparel Mfg Reducing Product Change Over Time in Apparel Mfg RFID in Production Tracking of Apparels Logical Approach to Wage Fixation/Revision of Sewing Operators of Garments Factory in India Strategy for implementation of IT/ERP solutions in Apparel Manufacturing An Observation of IE/IT Application in Apparels . Newly trained operators have to be constantly monitored by the Training instructor seeking the help of the work analyst & Online training instructor in the line and the industrial engineer of the factory.4 Training Test for Step .My First IE Job Maximum Exploitation of Internet for Effective. Training Tests & Release Slip Formats Trainee Operator Recruitment Slip Trainee Operator Release Slip Trainee Operator Progress Chart Training Test for Step . TRAINING Research Papers • • • • • • • • • • • • • What is Industrial Engineering? Competency Demonstration Report 3 . FILES FOR DOWNLOAD Click on the links below to download the file Trainee Operator Recruitment.3. MANUFACTURING.3 Training Test for Step .2 Training Test for Step .1 Training Test for Step .Plant Layout Competency Demonstration Report 1.5 LABELS: APPAREL. SEWING OPERATOR TRAINING. PRODUCTION MANAGEMENT.

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