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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.

Evaluation of Manual Skill Degradation Due to Automation in Apparel Manufacturing