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