Abstract
Manual skill degradation is a common problem that production managers face in assembly lines due to frequent changes in batch styles. Since the advancement in automated machinery, reliance on manual machines has been reduced. However, due to the high cost of fully automated machinery, it is still not available on a large scale in apparel manufacturing setups as most of the setups are in developing countries. Few related studies regarding the effects of automation on manual skills have been conducted in aviation and other emerging technological advanced fields; little focus was given on the effects of automation in apparel manufacturing. This exploratory study examines automation-induced performance degradation in the apparel production line. Sixty-seven sewing machine operators were initially trained on manual sewing machines to learn a complex production operation. Then, participants were divided randomly into three groups to experience varied amount of automation exposure. The manual machine group (MMG)kept working on the manual machines after the initial training and skill development. In contrast, the automation group (AG) shifted to automated pocket setting machines after skill development. Finally, the refresher training group (RTG) rotated between manual and automated machines after the skill development. The skill retrieval assessment was carried out after six weeks in the production line. The result of an independent t-test showed no significant differences among performances of the three groups after the initial training stage. A significant increase in the average single cycle time (ASCT) and decrease in the right-first-time percent (RFT %) was found in the AG while the ASCT decreased and the RFT% increased among the MMG after the retention interval. The RTG almost maintained its production output and the ASCT due to refresher training drills. Relevance to industry: Production managers usually maintain a skill set among the operators to run the production line smoothly. Therefore, capacity development drills of sewing operators are essential to maintain an efficient required skill set.
Highlights
Automation of things in manufacturing setups has made worker’s manual tasks much easier and faster
Out of sixty-seven operators, sixty sewing machine operators were included in the study due to the resigning of seven operators from the job
A post-initial training independent t-test among the groups revealed no significant difference in the average single cycle time (ASCT), production/day, and average dexterity time among the manual machine group (MMG), refresher training group (RTG), and automation group (AG)
Summary
Automation of things in manufacturing setups has made worker’s manual tasks much easier and faster. Along with numerous benefits in manufacturing setups, excessive automation is indirectly causing risks for individuals. Either people have to adapt to changing working environments by learning new skills or look for other career opportunities [2]. The labor-intensive apparel manufacturing industrial shift from developed to developing countries has created a competitive race among developing countries [3]. In order to remain competitive, these apparel manufacturing set-ups need to adapt to new technologies, which they are doing, but not at the same pace as being done by other industries. Due to different complex operations in apparel manufacturing, the complete shift of automation of tasks is costly and difficult. There are some other strategies that these industries can adopt to increase their productivity
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