ONE POINT LESSON

Multi skill training

For sewing operator
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 Introduction

1. Substitute absentee operators

2. To convert fresh trainees into trained operators.

3. I often found the situation that line supervisor ask other line’s operators for help ,

because there are no proper skilled operator for the line in charge.

4. Most operators can handle just specific basic skill. In this case, if they helps another process,

it causes defect issue.

➢ To improve line performance, line balance → Increase productivity, Decrease defect issue

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1. Identify lack of process skill for each line

▪ As I mentioned, I often found the situation that line supervisor ask other line’s operators

for help , because there are no proper skilled operator for the line in charge.

▪ Each line has different skilled operators and is strong for specific product type.

▪ Even thought, your line has many “Grade A” operators, you still ask other line’s operators

for help. Because you do not have any other option, if there are many absentees or fresh

operators.

▪ That’s why you need strong manpower with multi skilled operators.

▪ First step, Identify lack of skill for each line

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1. Identify lack of process skill for each line
1. Prepare line information data

(Product type, low productivity process, high defect process, line efficiency, lack of process skill in line)

2. Make Skill matrix for each operator.

- Grade A,B,C,D → A: can handle critical process & basic process

3. Meeting with line supervisor (Choose training process, operators, skill requirement)

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2. Set training program
1. Set training team (Trainer, mechanic, QC, IE, training coordinator : Lean)

2. Develop training curriculum (Theory, practice)

3. Set Program T&A, organization, training process flow, evaluation

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2. Start training
1. There are 2 types of training curriculums (theory & practice)

2. It would be better to have theory training as well including basic machine function, defect type with wrong handling. Even

though, trainee has many years of experiences, many operators don’t know function of machine and they just focus on

productivity. That is why they need to get training from basic theory for better understanding of machine and defect type.

3. Practice training – paper or stitch with fabric for the first time.

4. Once their skill improve, you can use real fabric in line.

$90b
$72b
$48b

Paper Test 1st Paper Test 2nd Paper Test 3rd Fabric Practice

(Straight &
Curve)
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2. Start training
1. When training starts, it is important that all training team members join. (Supervisor, Mechanic, QC, IE)
2. Supervisor : skill training/ Mechanic : machine preparation & setting/ QC: quality check/ IE: cycle time & motion study
3. Training time depends on top managers decision because there is possibility that training time can be overtime and it
causes over time cost.

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3. Evaluation
1. After training is done, you should validate the result.
2. TEST : 15 ~ 20pcs, → Quality, SMV
3. If there is operator who don’t have good result, you should give training again.
4. After operators starts handle multi process, you need to check KPI.
5. Multi skill training is long term program with rotation.

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CLOSING

▪ I hope this material could help for your factory to develop multi skill training program.

▪ I just gave you an example of multi skill program.

All factory have different system. Develop your own training program.

▪ You don’t need to give training every day but it should be continuous.

▪ Also, you can develop QC skill matrix & QC skill training program or other departments that
need to have strong manpower.

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Thank you !
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• LEAN COORDINATOR (LEE SANGJUN)