Annex II Standard Operating Procedures for STU training programme Worker Training Advanced Analytical Method of Training (AAMT)

) Stages of Training STAGE ACTIVITIES Develop hands and fingers abilities Paper Exercises Machine Exercises Fabric Exercises APROX. DURATION

Basic Exercises

AAMT Tools and Controls: Operators Progress Record (Master trainer) Progress Control Sheet (Prog. Cord.) NOTE: It is completed once all the Basic Exercises are cleared under the allowed time. Fabric Exercises to be done as per Training Course Design Aimed to develop skills in key operations of the product/style to be sewn in the plant as per specific skill group Gradual increase in difficulty level Exercises in SNLS Exercises in OL Any other product specific machine AAMT Tools and Controls: Operators Progress Record (Master trainer) Progress Control Sheet (Prog. Cord.) Training Course Design Instructors Loading Exercise Documentation NOTE: Exercises to be cleared under the allowed time. Ideally to be performed in the AAMT Center. In case of use of any specific method or work aids, train on that specific part individually Operator is moved to the assigned machine in the line. Review threading and cleaning of

Max. 7 days

Skill Exercises

Max. 5 days

Max. 10 days

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KSA-

Operational Exercises (Trial Production)

machine. Demonstration of the technique using the methods documented by Engineering. Provide copy to keep in the machine. Explain and provide written copy of the quality specifications Practice of the operation with training garments. Affirm correct methods with the operator Train operator to unstitch neatly and redo the operation, if quality is inappropriate. Begin quality drills (3 daily) 100% quality checks Certification in the operation.

AAMT Tools and Controls: AAMT daily sheet (Master Trainer) AAMT Audit (Prog. Cord.) NOTE: It is completed once the operator is certified. Begins commercial production. Methods assurance; comply with methods check list 3 capacity studies 8 quality checks. One every hour. 3 quality drills Start measuring performance Start the daily progress summary Performance Development AAMT Tools and Controls: AAMT daily sheet (Master Trainer) Daily Progress Summary (master Trainer) AAMT Audit (Prog. Cord.) NOTE: Start graphing when the operator reaches a capacity of 30% or two weeks after certifications, whatever occurs first. Methods assurance; comply with method document 3 capacity studies 8 quality checks 3 quality drills Depends upon Training curve

Graphing Training Curve

It depends on the curve. Its when the operators capacity is

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KSA-

Performance follow-up Daily progress summary Daily graphing of performance and quality between 30% and 50%.

AAMT Tools and Controls: AAMT daily sheet (Master Trainer) Daily Progress Summary (Master Trainer) AAMT Audit (Prog. Cord.) Ops above/below the curve report (Prog. Cord./weekly) ( % red/green) Methods assurance 3 Capacity studies 8 quality checks 1 quality drill 8 stamina runs using the 50% rule. Performance follow-up Graphing Stamina Development AAMT Tools and Controls: AAMT daily sheet (Master Trainer) Daily Progress Summary (Master Trainer) AAMT Audit (Prog. Cord.) Ops above/below the curve report (Prog. Cord.) NOTE: The operator can begin graduation when she/he has a capacity higher than 100% and performance higher than 90%. Methods assurance 2 Capacity studies 8 quality checks 4 stamina runs of at least 2 hours, or Bundle by bundle follow-up. Performance follow-up Graphing Make sure the operator has plenty of work to achieve target. AAMT Tools and Controls: Daily Progress Summary AAMT daily sheet (Master Trainer)

It depends on the curve. From 50% capacity to 100% performance (graduation).

Graduation *

5 days.

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KSA-

*Requirements for graduation:

The operator should obtain an average performance of higher than 90% or more during five consecutive days. A minimum of 75% of total clock time per day should be on-standard time. The operator needs to have a capacity of higher than 100% in all the operations that she/he performs. In-line quality level (DHU) less than 12. No bundles rejected during the 5 days.

Graduation on two or more operations: All of the above, but with an average performance of 90% or more. At least 180 produced (worked) minutes in each operation.
To be decided with individual factory

List of Formats to be used S.No. Formats 1 Individual Operator Work sheet 2 Group Work sheet 3 4 5 6 7 8 9 10 11 Bundle Diagnosis AAMT Daily work sheet Bundle by Bundle Follow up Exercise documentation Training Curves Daily Attendance Report Training course design and Skill group allocation Instructors Loading Weekly Report

Detail Daily by The MTs Daily By MTs and PC On the basis of the requirement in the training curves Daily after Single cycle starting On the basis of the requirement in the training curves on Machine on Machine Copy with all For all the operations For all the MTs Saturday

The Master Trainers trained by GEN-PROM/KSA Technopak will be retained for at least 5 training cycles as per the guidelines mentioned above. These Master trainers have to be dedicated to the working on the training methodology which can be either physically located at the STU or at sewing lines (during the follow up of the training curves).

UNDP technopak

KSA-