ACCESSORIES & GEAR SOURCING

MANUFACTURING EXCELLENCE

M.E. Module 10.1 – Operator Training

Tauqir
Sep 2015
OBJECTIVE aDIDAS TRAINING SCHOOL

1. To understand the need of an organized training program for

factory operators
2. To provide a general outline of the principles of aTS
3. To help understand the aTS methodology and its benefits

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INTRODUCTION

1. A&G industry is labor intensive by nature.

2. One of the biggest challenges faced by A&G industry is shortage
of trained work force.
3. In the present scenario, where there are many options for the
workforce to choose their industry, shortage of labor and a trained
pool of employees or low performing employees turns out to be a
‘real limiting factor for organization’s survival and growth.
4. To deal with it, Industry world over agrees to a single solution –
“Training”.

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WHAT IS aTS (adidas Training School)?
• derived from AAMT (Advanced Analytical Method of Training
• specifically designed for the training of operators without any prior experience
Development on the sewing machines
• proven scientific method of training

To foster:
• Systematic Skill, Stamina and Knowledge Development
Goal • Established Goals or Targets at each phase
• Defined Quality Specifications

• To provide an easy, efficient and rapid learning

Purpose • retraining, cross training (multi skill)
• method improvements

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PHASES OF OPERATOR TRAINING
Stamina
build up

Single
Cycle

Parts of the
Job

Job
Exercises

Basic
Exercises

Operator
Selection Tests

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 PHASES OF OPERATOR TRAINING
PERFORMANCE

QUALITY
THO
THE THREE

E
PAC
LEGGED STOOL

ME
ANALOGY

METHOD QUALITY PACE

ACCURATE MOVEMENTS
RAPID MOVEMENTS
KNOWLEDGE OF CORRECT MOVEMENTS
CONFIDENCE
STANDARDS EFFECTIVENESS
(KNOWLEDGE)
PERCEPTION STREAMLINED
COORDINATION
ALERTNESS PATTERNED
RHYTHM (SMOOTHNESS)
CONTROL

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PHASES OF OPERATOR TRAINING
Stamina
build up

Single
Cycle

Parts of the
Job

Job
Basic skills required for a successful sewing
Exercises
operator:
•Manual dexterity (Speed of hand movements)
Basic
•Finger Dexterity (Speed of finger movement)
Exercises •Hand-Eye Co-ordination
•Color blind test
Operator
Selection Tests

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 PHASES OF OPERATOR TRAINING
Stamina
First Stage of Training
build up
Designed to train and develop the general
skills required job
Single
Cycle

Parts of the
Job

Job
Exercises
Basic Exercises
Basic
Exercises - Board Exercises
•Pin Boards
Operator •Ball & Tube Exercise
Selection Tests •Needle Boards
- Ergonomics
 PHASES OF OPERATOR TRAINING
Stamina
Job Exercises
build up
Designed to develop the specific skills
required for each particular operation
Single Paper Sewing Exercise
Cycle - Set of 11exercises
•Single Needle Lockstitch Machine
Parts of the •High bed
Job •Over Lock stitch machine

Job
Exercises Exercise # 1 to 8 & 11: Single Needle Lockstitch Machine

Basic Exercise # 9 to 10 : Overlock Machines

Exercises

Operator
Microsoft Excel
Selection Tests
Worksheet

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 PHASES OF OPERATOR TRAINING
Stamina
Parts of the job
build up
• Machine Exercises
• Exercises on parts assembly / Single
operation
Cycle

Parts of the Parts of Jobs

Job
•Introduction to Machine and Operating
SOP
Job •Types of Stitches, seams & Needle
Exercises •Different types of sewing attachment
•Training on actual parts of product
Basic •Sewing defects and Remedies
Exercises

Operator
Selection Tests

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 PHASES OF OPERATOR TRAINING
Single Cycle Stamina
- Crucial stage in training build up
- Combines all parts of the job and
the skills required of a good
operator Single
- Capacity studies on the trainees Cycle
by the trainer
Calculated in Capacity Study:
Parts of the
Job •Average cycle time
•Capacity percentage or single cycle
Job percentage
Exercises •Actual minutes
•Hourly capacity of the operators
Basic
Exercises

Operator
Selection Tests

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 PHASES OF OPERATOR TRAINING
Stamina build up Stamina
Accomplished by gradually increasing
the build up
length of time spends on the combination
of
exercises that comprises the job
Single
Cycle

Parts of the
Job

Job
Exercises

Basic
Exercises

Operator
Selection Tests

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 TRANSFER AND FOLLOW UP

- Applied when trainee’s production and quality met the

standards for graduation
- Normally performed for several weeks

 Purpose
• To allow the supervisor to evaluate the trainee
• To determine if the trainee is acceptable as a trained employee
 Process
• After the trainee has been transferred to the production department until the trainee
has maintained a satisfactory performance level
• Monitor trainee’s performance for a year if possible

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GRADUATION

Requirements to be a candidate
Established by local management representatives prior to the start up of
the program
Minimum of 90% performance for 5 consecutive working days.
RFT higher than 92%

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BENEFITS OF adidas TRAINING SCHOOL

Benefits:
 More successful learners
o 50% to 75% reductions in the cost per successful trainee
o 300% increases in the number of successful trainees
 Reduced Labor Turn Over
 Reduced Training Costs
o 50% to 60% reductions in the time required to train an
employee to the productive level
 Improved Quality
o 25% to 30% increases in trainee productivity during the
training process

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thank you