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Apparel Manufacturing and
Management Training for
Management Trainees in Gul Ahmed
Leadership Program 2016
Prepared for Gul Ahmed Textile Mills –
Apparel Division
2016
Training Objective and Methodology
Training Objective:
The objective of this course is to train participants on best practices in
Apparel Manufacturing & Management. This course will impart in-depth
and practical understanding of these processes through:
• Knowledge of “best practice” processes
• Tools to implement the processes
• Information on international and regional trends
Training Methodology:
Training will be imparted through:
• Classroom lectures
• Group discussions
• Practical Assignments and case studies
• Presentations Delivery By Trainees on Different Technical Topics
Content
1. Apparel Manufacturing Processes
2. R&D (Research & Development) / Product Development
3. Apparel Sampling Procedures
4. Product Risk Assessment - RFC (Ready for Cut) and Pre-Production
Analysis
5. Industrial Engineering in Apparel Manufacturing
6. Mid Test
7. Apparel Production Planning
8. Apparel Merchandising
9. Lean Manufacturing and Management in Apparel Manufacturing
10. Apparel Quality Management
11. Final Test
Apparel Manufacturing Process• Fabrication
• Woven Fabric Types
• Knit Fabric Types
• Cutting Processes
• Fabric Store
• Process Flow
• Cutting Room Activities
• Cutting Equipment and Method
• Marker Planning
• Spreading
• Material Movements
• GGT, Fabric Utilization
• Sewing Process
• Process Flow
• Sewing Machines
• Seam & Stitch Types
• Process Planning
• Production Follow-up
• Maintenance Guidelines
• Cost Control and Incentive Plan
Apparel Manufacturing Process
• Washing Process
• Garment Dry Process
• Garment Wet Process
• Finishing Process
• Process Flow
• Purpose of Pressing and Finishing
• Pressing Equipment and Method
R&D (Research & Development) –
Product Development
• Introduction
• Product Development Cycle
• Product Development Process Flow
• Market Research
• Calendar and Planning Activities
• Steps of Product Development
• Vender – Buyer Interaction
• Performance Monitoring Tools
Apparel Sampling Procedure
• Sample Room Management & Procedure
• Sampling Stages in Apparel Manufacturing
• Review or Study Reference Garment Sample
• How to Reduce Garment Sampling Time
• Sample Approval Delay Affects in Shipment
Product Risk Assessment – RFC (Ready
for Cut) and Pre Production Analysis
• Product Risk Assessment Overview
• PRA Importance
• Product Analysis
• Introduction of RFC – Pilot Run – Trial Run
• RFC Importance
• Pre Production Overview
• Importance of Efficient Pre Production Management
• Pre Production Meeting Requirement
• Process Cycle
•
Industrial Engineering in
Apparel Manufacturing• SAM (Standard Allowed Minute)
• On Standard and Off Standard Time
• Efficiency Calculation
• Performance Calculation
• Utilization Calculation
• Manpower Calculation
• Quota and Target Calculation
• Skill Matrix
• OB (Operation Bulletin)
• Line Balancing
• Thread Consumption Calculation
Mid Test
Apparel Production Planning
• Introduction
• Importance of Production Planning
• Factory Capacity Calculation
• SAM Based Planning
• Order Quantity Allocation
Apparel Merchandising
• Apparel Merchandising Overview
• Sampling Merchandiser
• Production Merchandiser
• Time & Action Calendar
• Production File Preparation and It’s Importance
• Different Types of Labels
Lean Manufacturing & Management in
Apparel Manufacturing
• Introduction
• Seven Wastes (TEEWOOD) of Lean in Apparel Manufacturing
• Major Block During Implementation of Lean in Apparel Manufacturing
• Benefits of Lean Manufacturing in Apparel Industry
• Preferred Lean Manufacturing Tools for Apparel Industry
Apparel Quality Management
• Introduction
• Quality Control Procedure
• Quality Assurance Procedure
• Quality Inspection / Audit Procedure
• Quality at Fabric Stage
• Quality at Cutting Stage
• Quality at Sewing Stage
• Quality at Finishing & Packing Stage
• DHU and Defective Percentage
• Garment Zones
• AQL (Acceptable Quality Level)
Apparel Quality Management
• Seven Pieces Inspection System – Traffic Light System
• Clock Wise Inspection
• How to measure different garments?
• Four Point System for Fabric Inspection
• Fabric GSM
• Fabric Shrinkage Calculation
• Blanket Process for Shade Variation Control
• Sharp Tools, Broken Needle Policy
• Testing
• FPT (Fabric Package Testing)
• GPT (Garment Package Testing)
Final Test
THANKS