Systematic operator training

The following motto, though well

worn is still absolutely true:
IF YOU THINK TRAINING IS
EXPENSIVE THEN TRY
INCOMPETENCE
 Before systemic training: two weeks
practice for new recruits 0n paper
exercises before operation training
began.
After systemic training: attach elastic
to legs with an overlock machine,
FOUR days from recruitment to
release to production lines - Sri
Lankan Swimwear Manufacturer
 Training of new sewing machine operators was
always a problem for us and it would take from
three to four weeks for us t0 have a new recruit
trained and performing at around 40 to 50%
efficiency. But after adopting the methods
introduced to us by Paul Collyer we now have a
new sewing machine operator trained and
performing at 50 to 60% in FIVE working days
Tony Nadaraja,
Hirdaramani Industries, Sri Lanka
Uses of the Trainer
Aid in selection of new recruits
Effectively train new recruits
Improve low performing
operators
Multi-skill existing operators.
The word operator not
machinist
Alien
Contradicts traditional training
practices.
Paper exercises on the fire
1 trainer to 20 trainees - In the
rubbish bin
quality 1st & speed will follow
in the rubbish bin
Alien
If you want quality then you
cannot have quantity & vice versa
- in the rubbish bin
Trainees work without targets - NO
Trainees spend hours learning
threading -boring
Quiet, separate training school -
no, no , no!
Trainer: trainee ratio
1:20
1.5 2 minutes per hour
6-8-10 Weeks in training school
High attrition
Slow paced, low performing
Supervisors complain
Cost of training
Trainees salaries
Lost output
8 weeks in training school=0
1 week in training school =
garments/SAMs/overhead
recovery from week 2.
Trainer: trainee ratio
1:3 = 15 minute per hour
Intensive
Out in a week
Back up in lines
Alien concepts- support
Blocking
Fabric
Cutting
Machines
Support role of trainer
Training: Production
Training is service to production
Not separate entity
Work together
Fashion v standard
Madura Garments
New recruit to 80% performance
inserting sleeves into suit jackets.
12 days
Fashion = different approach
SKILLS
Each company will need own
strategy
Thank you