Regent Garment - IED-SOP 002 New Style Startup Training

Standard Operation Procedure
Title: New style start up training

Reference No.: IED–SOP 002
Effective Date:01/11/07 Revision No: new Page 1 of 7
Revision Record
Revision Date Revision Details Effective Date
DD/MM/YY No. DD/MM/YY
6.2.1
10/01/08 001 6.2.2 11/01/08
6.2.3
8.0
Prepared by Endorsed by Approved by
Signature
Name
Huyen Vu Thi Thanh Dao Tien Zainuddin Yasin
Title
Assistant Officer Assistant Manager Senior Manager
Date
Copyright in receipt of this document is owned by Regent Garment Factory Ltd. No

reproduction of this document or any part by whatever means is permitted without the prior
written consent of Regent Garment Factory Ltd. If the control stamp color is not in red, this is an
uncontrolled copy. Please refer only to the controlled copy.
1. Purpose：
The purposes of this procedure are:
1.1 - To control the production preparation process in IED to ensure fast new loading in the line
1.2 - Ensure correct method for Supervisor/ Line Leader/ Utility Operator before start sewing new
style.
1.3 - Highlight all the technical issue to related department.
2. Scope：
Apply for IED, PPC, MCD, MTN, CUT, CMD –Sample room and production
3. Reference
Manufacture Order
Master plan
4. Abbreviation and Definition：
MO: Manufacture Order
CUT: Cutting
CMD: Computer Maker Department
IED: Industrial Engineering Department
PPC: Production Planning and Control
MCD: Material Control Department
MTN: Maintenance
QA: Quality Assurance
LLD: Line Leader
SAM: Standard Allowed Minutes
WHS: Warehouse
SEW: Sewing
5. Responsibility
Refer to the content of procedure
6. Content:
6.1 - Flow chart:
6.2 - Procedure:
No Procedure and Requirement Responsible
party
6.2.1 PPC issue the information to IED PPC
Receiving information about new style, such as original sample, MO, trim
card, SAM bulletin from PPC. IED will take note and start the duty.
In urgent loading plan, IE will base on the style to reduce the training
quantity of new style to suit with loading schedule. In case PPC has not
received approved sample, MO from customer IED will get agreement from
production to make new style training for Sewing Supervisor/LLD with any
information available in hand to catch up with the schedule.
6.2.2 Prepare standard method
IE Technician base on the paper maker of CMD to cut garment samples, IE
Trainer sews such samples to do study standard operations then do the

analysis of the motions, to make line layout, work instruction, Sam bulletin. IED/MTN
In case the new style is similar or repetition, the garment samples no need to
be sewn. IE technician can use sewn garment of that orders to do the SAM
analysis
When finishing line layout, IE technician will make flexibility study of new
style. Then send to MTN to check and confirm machine, folders & others
equipment needed.
If the loading plan of new style is urgent, IE will study for the style
feasibility study first & pass to MTN for machines & folders checking with
estimated line layout.
All the work instructions, line layouts & standard motion videos (if have)
must be passed to IE Trainer for doing new style training for Supervisor.
6.2.3 Training arrangement
When completing specification check list of new style training, IE cooperates
with SEW to make training schedule.
In case specification items are not completed due to issue occurred, IE will
confirm with SEW about information lacking issue to do the training with any IED/ SEW
information in hand.
IE-Trainer ensures to finish training new style for Supervisor before loading
day to ensure the Supervisors/LLD have full understanding about the sewing
method requirement in new MO/style to start bulk production.
IE inform training schedule to QAD, QAD will has responsible to set QA QAD
staff follow with the training to record(if any) & study for quality issue of
new style training result.
 If the style is repetition of the line, it no need to be trained for Line SEW
Leader & Supervisor
 In urgent loading plan or simple style, the new style training can be
skipped by confirmation of Production heads
6.2.4 Training time IED
All the training time for new style will be done in the working time to ensure
the Supervisor/LLD can attend the training.
Training time & attendance can be variance according to actual production,

master plan update & loading days.
In the case they can not attend the training time as schedule, they must inform
to IE Trainer to compensate for them.
In case the Supervisor/ LLD can not attend the training in the working day,
they must inform to IE Trainer and their head department for re-arrange the
training for them.
6.2.5 Prepare machinery, folder IED/MTN
Before schedule date with Supervisor/LLD for training, based on standard
operations of the training style, IE will inform to MTN prepare all the
machines, folders, and equipments in the training center ready for the
training.
Make sure that the machines are suitable to follow the standard method &
quality requirement in MO
6.2.6 Prepare template
IE-Trainer will work with CMD/ Sample room to get the hard paper pattern IED/CMD
to make the template if need.
6.2.7 Training material preparation: Cut panel, thread, trim
Request cut panel in first cut batch for training. If the first cut batch is not CUT/ MCD/
meet the schedule of new style training, IE will arrange to hand cut .The cut IED
panel should ensure ready for training time.
IE makes the requisition to PPC for sub-material used for training. In the
case there’s any kind sub-material shortage, IE-Trainer can use the
substituted material.
Once all the cut panels and trim are available, IE will make date to
Supervisor/LLD/Utility Operator for training schedule.
6.2.8 New style training
Trainer should follow the steps to do the training for Supervisor
1) IE Trainer shows to the trainee about the requirement in MO and sample
garment
2) IE Trainer shows the trainee the video of standard operation IED/ QA/
3) IE Trainer teaches the trainee to do sewing process of the style. CUT
4) IE Trainer check and comment on the completed garment.

These steps can be changed or skipped based on style requirement.
IE Trainer does the training operation by operation for Supervisors so that
they have a clear understanding about new style requirements. Supervisors
proceed to sew new style basing on the guiding of IE Trainer. IE Trainer has
to make sure that all the Supervisors can get the requirement of the MO and
sample garment.
The number of garment training pcs can be difference based on master plan
update days, loading day & the difficulty of the style & the number of
loading lines
Note that each trainee must complete all operation of garments by
themselves.
QA staff follows up with the training process carefully, take note issues
related to quality then inform to PPC, CMD, and Cutting for improvement if
any.
6.2.9 Update the training record and follow up the new style loading in
sewing line
After the training, IE-Trainer will review the garment with trainee about the IED
workmanship quality. Record all the issue and do analysis for improvement. / Supervisor
IE Trainer record the training result and add it into the training profile & ask
for signature from trainee
In case the trainees do not meet the quality requirement, IE Trainer will
inform to IE & production to do the re-training for them.
When the line start loading new style, IE-Trainer will follow the method of
Operator and feedback to Supervisor/LLD/Utility Operator if there’s any
non-standard operation in motion of sewer.
6.2.10 QA audit the training garment
After completing the training, Supervisor will pass the training garments to
QA for auditing. QA will give out their comments and feedback to PPC, QA/IE
IED, CMD, Sample, Cutting and Supervisors in the pre-production meeting. /
In case the pre- production is not handled, QA will inform to all related dept Supervisor/
the result of training garment. WHS
After meeting, Supervisor will have responsible to send these garment to

WHS if it is replaced fabric & material.
If the training garments are done with actual material & fabric, these
garment will be sent the produced line for bulk.
7. Record
Name of record Retention Responsible Party
Checklist for new style training (IED-F001) 6 months IED
New style training record (IED-F002) 6 months IED
8 Appendix:
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Standard Operation Procedure

Title: New style start up training

Prepared by Endorsed by Approved by

Copyright in receipt of this document is owned by Regent Garment Factory Ltd. No

Trainer sews such samples to do study standard operations then do the

Training time & attendance can be variance according to actual production,

4) IE Trainer check and comment on the completed garment.

After meeting, Supervisor will have responsible to send these garment to

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