Training Outline for Management Trainee

Outlines Area

• Store• Cutting• Sewing • Finishing• Industrial Engineering• GSD• Planning• Maintenance• QC & QA System• ERP

Preparation for Bulk Cutting

Cutting Flow ChartFabric

Relaxation for 12 Hrs(Report)

Table Set up as per grain line

Spreading (Rep)& Marker and

Spreading Inspection(Rep)

Marker setting Cutting

Audit(Report)Numbering

as per bundle summary

100% Cut Panel

Inspection (Report)

Audit(Report)Bundling as

per bundling summary (report)

Print/ Embroidery if

require

Input Supply with Bundle

Summary

Feeding System in Sewing line

Sewing

Finishing(Bottom)Loop &

Thread TrimPrimary

InspectionRepair if require

Button/Rivet attach

Patch Attach

Iron Inspection Accessories Attach

SKU CheckFolding

Poly Assortment Packing

Final I

Job Profile IE• Knowledge about various sewing production systems• Knowledge of all types of Sewing machine necessary for the company• Time study (Cycle timing)• Motion analysis of the operations• Operation break down• Preparation of OB (Operation bulletin)• SAM Calculation• M/C Layout and Work station layout• Line Set up• Production estimation of a line• Work Sampling• Method Study (Seeing Movements of an operation)• WIP Control• Line Balancing • Capacity study• Cost estimation of a garment• Developing and Maintaining Skill Matrix• Incentives schemes • Calculating Thread Consumption• Work aids, Guide and Attachment• Performance Rating

Role of Industrial Engineer in Garment Production Management

• Recruitment of sewing operators through standard test.• Evaluation of existing production target and fix a new production target. • Extend work measurement in other processes like cutting section and finishing section.• Constant control of direct labor cost.• Data analysis and look into monthly trends of each KPIs • Preparing daily production reports, Monthly improvements reports with graphical

presentation.• Time study and updating time study database including videos on constant basis.• Research on motion study and implementation of the better system to eliminate excess

motions.• Research on new machinery and latest systems that meets companies long term goal

and preparing cost benefits analysis and ROI for the same.• Initiative on lean manufacturing, learning of lean tools and looking for scope of

implementation.• Research and development for samples prior to production start.

IE

• How to calculate SAM for a garment?• Garment CM cost estimation using SAM or SMV• The Concept of Operator's Performance Rating• How to calculate efficiency of a batch or line?• How to calculate operator efficiency at work?• How to set production target of a line? • How to Calculate Production Capacity of a Factory?• Functions of Production Planning and Control (PPC)

Department in Apparel Manufacturing• Garment production systems

IE

• Work aids and equipment for garment export industry • Machinery used for garment sewing in mass production• How to calculate Machine requirement for garment to be

made in an assembly line? • How to reduce line setting time? • What is on-standard efficiency and off-standard efficiency?• Operation Break-down and SAM of the Full Sleeve Men's

Formal Shirt?• Engineers, Be careful with data what you presenting to your

boss• Can anybody hit 100% Efficiency of GSD SAM?

IE

• How to grade sewing operators?• What is Pitch Time, Pitch Diagram and how to make a Pitch

Diagram?• What is Productivity?• How to calculate thread consumption?• How to do Method Study?• How to calculate machine SPI?• Use of Takt time in apparel industry? • 7 Ways to Reduce to WIP from Bottleneck Operations • Operation Breakdown and SMV of Trouser

IE

• Operation Breakdown and SMV of Trouser• What is Skill Matrix for Sewing operators?• How to do Line Balancing using Operator Skill History?• KPIs for Garment Manufacturers• What is Man to Machine ratio in garment industry?• Characteristics of a good workstation layout• How to determine number of sewing line needed for an

order?• Role of Industrial Engineers in Garment Production

Management• How to Make an Operation Bulletin for a Garment?

IE

• Difference Between SAM and SMV• How Line Supervisors do Hourly Target Follow up?• How to Allocate Sewing Operators for Different Styles?• How to Do Skill Upgrading for Machine Operators?• How to Calculate no. of Machines, Working Days and Output

Based on Order Quantity?• How to Calculate Manpower Requirement of Finishing

Section?• How to Calculate WIP level in Cutting, Sewing and Finishing

Section?

Planning

• What is Line Planning? • How to Calculate Production Capacity of a Factory? • Functions of Production Planning and Control (PPC)

Department in Apparel Manufacturing• How many days factory needs to make 5,000 Polo Shirts?• 5 Reasons that fail production plan and cause shipment delay• Formula for calculating Sewing Room Capacity• How to make line loading plan for garment production