Sewing training & Operation bulletin presentation

Sewing Training & Operation Bulletin

Sewing Training and
Operation Bulletin
Presented by
Muhammad Falak Sher
(Executive Industrial Engineer)
West Point Home, Bahrain W.L.L

Core Responsibilities of
Department
 Training of helpers and stitchers in proper and most efficient way of
doing a work (Sewing Training).
 Operation Bulletin Preparation (Cutting, Sewing, Packing).
 Calculation of Standard Production Rates in Fabrication for costing
purposes.
 Documentation of the operation to convey step by step procedure
including the quality points to check of a process.
 Provide proposals to simplify the operation and drive to lower
stitching cost and other cost as per project.
 Establish the Standard Data for Sewing Activities and its
maintenance.
 Line Balancing and layout of operations.

Key Performance Measures
 Cost Reduction
 Cost Saving Initiatives
 On Time Delivery

1-Sewing Training
 Introduction
i. Apparel and Textile industry is the largest employer after
agriculture in the world. It provides direct employment to people
and another are engaged in related activities. The industry has to
work on many fronts to be successful in a totally competitive
international environment particularly focusing on factors like
development of skilled human resource, quality and productivity,
design development and product diversification and improving lead
time and pricing, effective marketing management.
ii. Against the back ground the WPH has undertaken the task of
competency building through business development services in
Textiles particularly in preparing training for sewing machine
operators / helpers.

Critical Path For Training
 Step 1: (Health & Safety)
1. Testing & Selection Process
2. Introduction to Health and Safety
3. Safety Equipment Types
4. Advantages
5. Roles and Responsibility
6. Feedback Session
 Step 2: (Lean Manufacturing)
1. Introduction to Lean and Its Tools
2. What is 6S
3. Steps of 6S
4. 6S Accountability Sewing Training & Operation Bulletin

1. Feedback Session
 Step 3: (Skill Development & Productivity)
1. Introduction to Sewing Machine, Needle Parts and Seam Types
2. Machine Cleaning
3. Machine Control
4. Sewing Defects and Remedies
5. Paper Sew Exercises
6. Fabric Exercises and Special operation Skills
7. Identification of Skill Level
8. Final Test

Critical Path for Training

Step 1: (Health & Safety)
 Testing & Selection Process
 Following test are performed for testing & selection
process.
i. Hand and Mind Coordination Test
ii. Eye and Mind Coordination Test
iii. Colour Blindness Test

Hand and Mind Coordination
Test
i. This test is
performed by using
both hands at same
time.
 Peg Board
Time Allowed
for Test
1.40 Minutes

Eye and Mind Coordination
Test
i. This test is
performed to check
eye and mind
coordination.
Time Allowed
for Test
1.40 Minutes

Colour Blindness Test
i. This test is
performed to check
the colour blindness
of trainee.

Introduction to Health and
Safety
i. An effective safety and health management system is the key to
reducing number of severity of work place injuries and illness,
resulting in lower accident-related cost.
 Safety: Are the areas safe!
i. We should mark any hazards or hazard areas as required by
OSHA or our local fire code.
ii. Emergency exits should be identified
iii. Appropriate PPEs should be in place
iv. Fire Extinguishers and Fire hydrant shall be proper
v. Masks should be wear
vi. Necessary information should be displayed

Safety Equipment Types
 Following are safety
equipment,
i. Safety shoes
ii. Hand gloves
iii. Mask
iv. Safety helmet
v. Glasses

Advantages of Safety
i. Demonstrate that business is addressing its health and safety
obligations.
ii. Show that business is committed to working within health and
safety principles.
iii. Clarify functions and responsibilities in business.
iv. Insure that safety system of work are recorded, communicated to
workers and implemented in consistent way.
v. Guide the future action of the worker in formal way.
vi. Help your business to manage stuff effectively.
vii. Safe time by allowing health and safety matter to be handled
quickly.

Step 2: (Lean Manufacturing)
 Introduction to Lean and Its Tools
i. A systematic approach to identify and eliminate non value added
activities through continuous improvement by following the product
at the pull of customer in pursuit of perfection is called lean.
 Lean Tools
i. 6S
ii. Kaizen
iii. GEMBA
iv. SMED Sewing Training & Operation Bulletin

Step 2: (Lean Manufacturing)
 What is 6S
A visual tool of lean manufacturing to eliminate the search time and
make our work station neat & clean.
 Steps of 6S
i. Sort
ii. Set in order
iii. Shine
iv. Standardize
v. Sustain
vi. safety

Step 3: (Skill Development &
Productivity)
 Introduction to Sewing Machine, Needle
Parts and Seam Types
i. In 1859, Isaac Singer, whose name has become a household word
because of his mass production of the sewing machine. He
developed the foot treadle, an improvement that left the hands free
to guide the fabric, and mass-produced these machines.
 Types of Sewing Machines
i. Single Needle Lock Stitch
ii. Double Needle Lock Stitch
iii. Over Lock
iv. Flat Lock
v. Zig Zag

Productivity)
i. Sewing Machines
Single Needle Lock Stitch Over Lock

Productivity)
i. Parts of Machine

Productivity)
 Needle Parts and Types

Productivity)
i. Machine Cleaning
ii. Machine Oiling
iii. Machine Threading And
rethreading
iv. Needle Changing
v. Safety Precaution

Productivity)
 Paper Sew Exercises
i. Paper sew exercises are performed on paper shapes
as requirement of the operation.
ii. These exercises are performed without thread, and
main emphasis is put on Machine control.
iii. When an operator is attain 60 % efficiency in a paper
Sew exercise, he shifted to next exercise.
iv. After all paper sew exercise operator is transferred to
next step

Productivity)
 Paper Sew Exercises

Productivity)
 Fabric Shapes Exercises
i. These exercises are performed on fabric pieces
according to requirement of operation.
ii. In these exercises the method and quality is developed.
iii. when operator is attained 60 % efficiency on fabric
shapes, he is transferred to next step.

Productivity)
 Fabric Shapes Exercises

Productivity)
 Training on actual Production Pieces
i. After getting training on fabric shapes, operator is
transferred on actual production pieces under
supervision of training instructor.
ii. In This stage main emphasis is put on method and
quality.
iii. When an operator completely understand and follow
method and quality points then he shifted to next stage

Productivity)
 Speed Build Up
i. In this stage, speed of an operator is build with standard method
and exact quality. When an operator is 60 % efficiency w.r.t Single
Cycle Time, he is shifted to next stage
 Stamina Building
i. In this Stage stamina of the operator is build up gradually and step
by step. When operator attains 60 % efficiency, he is transferred to
next stage
ii. Stamina build Up For One Bundle
iii. Stamina build Up For Half Hour

Productivity)
 Stamina Building
 Stamina Build Up For One Hour
 Stamina Build Up For Two Hour
 Stamina Build Up Four Hour
 Stamina Build Up For Eight Hour
 When stamina for eight hour if attained at 80% efficiency
and 100% Single cycle, the operator is transferred to
next stage

Productivity)
 Final Test
i. In this stage examiner held test of trainee operator.

Productivity)
 Classification of Operators Skills
On the basis of result of tests the selected
operator is allocated a Skill Level
Skill Level - I 85% and above
Skill Level - II 70 % - 84 % Marks
Skill Level - III 60 % - 69 % Marks
Skill Level – IV 50 % - 59 % Marks

2-Operation Bulletin

Operation Bulletin
i. The method of preparing operations' list in a sequence is called as
operation breakdown.
ii. The sheet of listed operations of a style is also known as operation
breakdown.
 An operation breakdown includes information like
Sewing and non-sewing operations
i. Name of the machines to use for doing the specific
operations
ii. Estimated time to do each operation for one unit

Operation Bulletin Sheet

Layout Setting Sewing

Formulas Used In Operation
Bulletin Sheet
 St (sec) = CT / (1-Allowances)
 St (minutes) = St (sec) / 60
 Operator required = Target*St (Minutes)/S.T/Efficiency
 Allocated Operator = =IF((O.R-INT(O.R))>0.2,INT(N19)+1,INT(O.R))
 Capacity Per Shift = (Shift Time / St (min))*Efficiency
 Capacity Per Hour = 60 / St (Min)

Formulas Used In Operation
Bulletin Sheet
 Hours required For Order = St (min)*MO Size / 60
 Days Required For Order = Hours Required / (A.O*20)
 Machine Required = SUMIF(range, criteria,{sum_range}
 LS (Costing) Pcs/hr = LS(prod.)pcs/hr / (1+15%)
 Layout Sewing = VLOOKUP(lookup_value, table_array,
col_index_num,{range_lookup})

Line Balancing
 Line Balancing is leveling
of the workload across all
operations in a line to
remove bottlenecks and
excess capacity, defined
by Six Sigma Material.

Sewing training & Operation bulletin presentation

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