Documente Academic
Documente Profesional
Documente Cultură
I.OBJECTIVE
II.SCOPE
III.INTRODUCTION OF QUALITY TRAINING MANUAL FOR SUPERVISORS
i. Overview
ii. Timeline
iii. Training concept
IV.IMPORTANCE OF QUALITY TRAINING MANUAL
V.TRAINING METHODOLOGY
VI.MODE OF TRAINING
VII.TRAINING COURSE CONTENT
i.Roles & responsibilities of Supervisors in Quality
ii.Roles & responsibilities of Quality related Personnel
iii.Equipment requirements for Quality
iv.Operation based training
Module 1: Pre- Production (Supervise in cutting)
Module 2: Production (Supervise in manufacturing)
Module 3: Post- Production (Supervise finishing and pressing)
Module 4: Supervise and monitor quality
IX.TRAINING OUTCOME
i. KPI Mapping
I. OBJECTIVE
The objectives of the quality training module for supervisors are:
Acquire the operating skill and knowledge of Stitching Machine for industrial stitching
along with minor maintenance of machine.
Qualitative production of the garments and ensure quality training in each and every
aspects
Produce skilled supervisor for garment Industry in the field of garment manufacturing.
Improve the level of skill of supervisory staff in industry and increase the economic
potential of the country.
Provide industry with workers whose scope with job knowledge and skills are identified.
Assist in human resources development by providing precise and assessed country’s
skilled manpower quantitatively as well as qualitatively.
Provide technical and vocational training which reflects the requirements of industry.
Defect training in terms of identification, isolation and rectification thus imparting quality.
Assessment of different kind of production processes and various quality issues prevalent
in them.
II. SCOPE
The quality training manual consists of modules which are a combination of training
activities focusing on the aspect of quality through visual mode of training through mediums
such as power point presentations, images and cue cards, having duration of 15- days.
i. Overview
The training module has been designed on the basis of the basic requirements which benefits
quality as well as overall skills of a supervisor. The following are the major activities on
which the training module is based upon:
(a) Identification of Needs
(b) Design Training
(c) Implementation of the training
(d) Evaluation of the training
(e) Feedback
The Training Model
ii. Timeline
The design of training programs covers the planning and creation of training and development
programs. Instructional systems design includes the systematic design and development of
instructional methods and materials to facilitate the process of training and development and
ensure that training programs are necessary, valid, and effective. Although the instructional
design process can take on variety of sequences, the process must include the collection of data on
the tasks or skills to be learned or improved, the analysis of these skills and tasks, the development
of methods and materials, delivery of the program, and finally the evaluation of the training's
effectiveness.
Responsible for ensuring that during inline inspection standard quality specifications for each
operation are being met at all the operation points.
Responsible for communicating any quality discrepancy during inline inspection to the Quality
Assurance Head and bringing the same to the immediate notice of the Line In charge.
While Checking the Cut Parts of the garment should be properly maintain with the bundle number.
If any basket is available the cut parts should be put in the basket and put forward. Make sure if any
parts doesn’t fall apart or get soiled. Keep your hand clean or Wear the gloves.
The duties of quality assurance personnel in the garment industry will typically include:
Sewing thread
Button
Stitch
Zipper
Cut panels
Assembly
iv. Factors
1. Needle Selection
Selection of needles
When we select the needle for a specific fabric, we have to decide on two things,
Needle thickness
Point shape
We sew some rough cloth using different needles and check the seams. If the
needle is not right, we can see the damage to the cloth by pulling it slightly.
2. Thread
Suitable filament
Needle Suitable spun thread Cloth material
thread
Glossy silk, synthetic
No.5 No.120 No.100 ultra-light weight
cloth (satin etc.)
Glossy silk, synthetic
light weight cloth
No.7 to No.8 No.100 No.80 to No.100
(satin, crepe de chine
etc.)
Light weight silk,
satin, crepe de chine,
No.9 to No.10 No.80 No.60 to No.80 georgette, voile, knit
20G to 26G
(single/double)
Light- weight calico,
broadcloth, light-
No.11 to No.12 No.60 No.50 to No.60 weight wool,
knit/double 16G to
20G
Normal broadcloth,
No.13 to No.14 No.40 to No.50 No.50 wool cloth, general
fabric
General heavy-
weight fabric(
No.16 No.30 to No.40 No.40
overcoat etc.) water-
proof cloth
Bed- clothes, bags,
No.18 No.20 to No.30 No.20 to No.30
vinyl shoes
No.19 No.10 to No.20 No.10 to No.20 Leather shoes, sheets
No.20 to No.21 No.10 No.8 to No.10 Leather shoes, tents
Extra heavy weight
No.23 to No.24 No.8 No.8
materials, tent, sheets
Aim: This module develops competency to get acquaintance with the production process of
garment and understanding of technical garment knowledge.
Learning units:
Aim: This module develops competency to get acquaintance with finishing and pressing
processes.
Learning units:
Aim: This module develops competency to get acquaintance with the quality of product.
Learning units:
Process - Fabric rolls are opened and passed through a fabric checking machine having the light
under the fabric and the fabric checker does the visual inspection of the fabric. While checking
fabric checker marks the defects with a chalk or put a sticker on the defects.
At the end of the checking, a fabric roll inspection report is made for that fabric roll.
Objective- To deliver quality fabric to the garment makers and to make quality garments. To
avoid processing defective fabric in production, as a preventive action, fabric rolls are inspected.
This way defective and damaged fabric can be separated and sent back to the fabric suppliers.
5.2 Spreading
Process - It is pre preparatory process of cutting fabric. Fabric spreading is done after marker
making. Fabric spreading is an important part of a garments construction to cut the fabric and
sewing properly and proper shape. Maintaining quality in fabric spreading is an important factor.
Objective – To carry out the spreading process in ways which should not affect the quality while
spreading the fabric?
Defect Description Cause Remedy
Crack A crack seen along the Differences in warp Avoid uneven
between length of the fabric between release due to uneven build of beam
stripes the stripes woven with beam surface. surface by proper
different weaves. system of denting
Differences in crimp
relationship of ends at the sizing
grouped in separate machine.
dents in the reed and Ensure that
in weaves. denting at weaving
is such that ends of
the two weaves are
not separated by a
reed dent.
Float Knots with long tail ends Attend to broken Ensure cleanliness
leading to entanglement ends without delay of loom.
of ends. on looms equipped Take maximum
Fluff with long tail ends with warp stop possible care while
leading to entanglement motion; ensure blowing the looms.
of ends. proper functioning of
Use screens to
the same.
Fluff or foreign matter avoid fluff flying
trapped in the shed. Avoid long tail ends to adjacent looms.
in knots in weaving
Broken heald unable to Inspect the healds
preparatory and
lift or lower the thread. for wear before
weaving.
putting on a new
beam.
Ensure proper
selection of drop
pins.
Misdraws Incorrect positions of ends Faulty drawing-in of Bring the defect to
in the fabric causing beam. the notice of the
considerable damage in drawing-in
Faulty drawing-in of
fabrics with woven design operator.
broken ends by the
or stripes.
weaver. Ensure periodic
inspection of the
fabric on loom by
the supervisory
stuff.
Thick end A warp end having diameter Excessive count Avoid it.
larger than normal. variation. Conduct frequent
Accidental mixed-up checks to avoid
of counts in winding mix-up of counts.
and warping. Inspect the thrums
Piecing up of broken provided on the
end with a wrong loom.
thread during
weaving.
Broken Weft is inserted only for Weft break or weft Check the shuttle
pick a portion of a pick. exhaustion on for loose fitting of
ordinary looms. pirn or roughness
Weft break or of surfaces as
improper size of these cause more
bunch on auto-pirns. weft breaks.
Improper functioning Check also the
of weft fork. shuttle boxes for
Weft change effected settings and
through weft fork surface condition
mechanism on to prevent cutting
automatic looms. of weft.
Check the shuttle
and shuttle boxes.
Ensure proper size
of bunch on auto-
pirns.
Cut Weft A defect generally randomly Improper condition Check the emery
distributed over the fabric, or quality of emery roller covering.
not clearly visible in the roller covering. Ensure proper
grey stage, but becomes
Viscose yarn from check on the
pronounced in the finished
old lot or of lower quality of blended
fabric.
strength is used. yarn.
Double Two or more picks inserted Failure of the weaver Resort to pick
Pick in the same shed where only to find out the correct finding while
one is desired. shed when restarting restarting.
an ordinary loom. Effect the pirn
Pirn change when change with weft
affected by weft fork feeler mechanism.
on automatic loom.
5.3Cutting
Process - cut out the pattern pieces from specified fabric for making garments. Using the markers
made from graded patterns and in accordance with the issue plan, fabrics are cut to
prepare garment assembly.
Objective – To carry out the cutting process in ways which should not affect the quality of cut
pieces?
Module 6: Production
Aim: This module develops competency to get acquaintance with the quality of product.
Learning units:
OPEN SEAM
Provided solutions:
Causes Solutions
Open seam of piping As the operator was not skilled for that
kept.
Placement of the panel A well skilled operator of that operation
Faulty fee dog Feed dog and hook set timing should be
checked periodically
TWISTED ALLOWANCE
Provided solution:
Causes Solutions
In order to produce more, garment tampered Incentives were suggested for morale
Provided solution:
Causes Solutions
Fabric holding too tight Before the style starts concerned person will
Operator
by line supervisor
much
well judged
LOOSE/SKIP STITCH
Provided solution:
Causes Solutions
is been handles
Needle worn out New needle has to be replaced and forte keep
PIPING WAVY
Provided solution:
Causes Solutions
Folder used not proper As the folder was slightly tilted new folder
was need to be attached
PUCKERING
Provided solution:
Causes Solutions
checked
UBT/trimmer should be used instead of
Rusty eyelids and thread Feed dog, eyelets and thread guides
guides
should be checked periodically for
damages
Needle-thread-fabric combination should
be well judged
Operator training
Finishing
Process - Finishing defects is very important issue for the buyers. Generally defects signify
lack of quality. During apparel manufacturing process various types of defects occur in
garments like faulty zippers, irregular hemming, loose buttons, raw edges, improper button
holes, uneven parts, inappropriate trimming, and difference in fabric colours.
Objective – To carry out the finishing process properly such that the quality will be followed
in the last step of the production process
i. Training exercises
Step 1:
Approx. Duration:
Theory:
1. General idea of other departments in the factory.
2. Different types of Sewing Machines
3. Sewing Machine and its parts.
4. Threading sequence for different types of Sewing Machines (S/N,O/L,D/N,F/L,FOA)
Step 2:
Approx. Duration:
Practical
5. Stitches per Inch (SPI) & Stitches per Cms (SPC) and adjustments.
Step 3:
Approx. Duration: 3 Days
Theory
Adjusting Sewing conditions - SPI, Thread tension, Presser Foot, Feed dog etc.
Needle change, Tension adjustment.
Selection of Needle, Thread and SPI for given Fabric.
Folders, Attachments and their use.
Importance of Daily Machine Cleaning and Preventive Maintenance check-up.
Practical
Treadle movement, Treadle Control PART-II
Fabric Exercises (Single ply) with threaded machine.
1. Straight line (single ply)
2. Square (single ply)
3. Triangle (single ply)
4. Curve. (Single ply)
5. Circle or oval shape (single ply)
6. Zigzag Exercises.
Step 4:
Approx. Duration:
Practical
Step 5:
Approx Duration:
Practical
1. Practical Exercise - To consolidate all the above steps.
3. Quality Exercises
Objective: To make more Quality awareness to all trainees by showing & explaining the
different types of defects showing in the readymade board. Here we should make job
cards showing correct method (it shows good quality) & wrong method of sewing (it
shows defects).
Step 6:
Released to Production Line & Follow up
Once the training instructor has been satisfied about trainee performance during training,
then he /she can been released into the production line using Trainee Operator Release
Slip.
While releasing the operator to production line, performance report of the operator
during training, detailing the skill level, the recommendation of the instructor & the
strength & weakness of the operator is given to IE team for their reference.
Newly trained operators have to be constantly monitored by the Training instructor
seeking the help of the work analyst & Online training instructor in the line and the
industrial engineer of the factory.
These tests are very important for assessment of basic Skills such as Manual dexterity
(Speed of Hand Movements), Finger Dexterity (Speed of hand movements), and Hand
Eye Co-ordination & Sewing tests (Only for experienced operator, these basic skills are
very Important for making successful Sewing Operators).
Apparatus Required: Peg Board, Metal pegs (120) one end painted red, & Stopwatch
Grade: 1to5 (Grade 5(82 sec); Grade 4(83-90 Sec); Grade3 (91-100Sec); Grade2 (101-
105 sec); Grade1 (Above 105 sec)
Target: 82 seconds
Note: 1 Being Least & 5 Being Highest
Apparatus Required: Ball tube Stand & Boxes with one lid, 25 balls & Stopwatch
Target: 25 Seconds
Test: Right Hand & Left Hand
This test is conducted to analyse the colour sensitivity of the operator. In this test
operators are asked to differentiate and rank different shades of the same colour in
Ascending Order. We also can give them some cones of thread of different colours and
blocks of same or nearly same colours and asked to match the thread to the block of
colours.
After passing of above tests by trainees, then only they are eligible for to entering the
training department
Resources Required:
Sewing Machines
Single Needle Lock Stitch – 10 No’s
Double Needle Lock Stitch – 1 No
Over Lock Machine – 3Thd – 1 No
Over Lock Machine – 5Thd – 1 No
Flat Lock Machine – 3Thd - 1 No
Manpower – Sewing Instructor – 1 Person
Continuous Availability of Fabric, Thread & Needle for Sewing Training
Cupboard of Documentation – 1 No
Soft Board – 4X4 – 1 No
While Board – 4X4 – 1 No
Duster - 1, White Board Marker – 4, Permanent Marker – 1, Measuring Tape – 5
Stop Clock – 2 No’s
Peg Boards – 1 No & Metal Pegs – 120 No’s
Pin Board – 1 No & Pins – 135 No’s
Ball & Tube Stand – 1 No & Marble Balls – 25 No’s