The global apparel industry is currently working to become a significant player in the international market. To reach this objective, industry leaders are shifting from basic production models to diverse product portfolios, adapting to the changing needs of global buyers. This transformation highlights the urgent necessity for modern, forward-thinking skills development programs that address the current market realities. However, in many export-driven countries, traditional training models still dominate and are offered to the industry as a way to enhance productivity. Unfortunately, these conventional skills programs have limited value as they mainly focus on enhancing skills at a basic level of individual performance. Yet, productivity in just-in-time (JIT) manufacturing relies on optimizing manufacturing resources and the collaborative efforts of the entire production team.
To effectively support skills development, both national and international government agencies are making significant investments in training initiatives. However, these efforts often depend on outdated programs that fall short of delivering the impactful results anticipated by the apparel industry. For genuine growth in the sector, skills development programs must evolve to meet the demands of modern manufacturing and the competitive global market. Upgrading training systems, structures, methodologies, and approaches through capacity building at vocational centers, training service providers, and industry training centers is essential. This cannot be overlooked if the goal is to cultivate talent, maintain high productivity levels, and drive growth in the apparel sector.
Dagher & Partners recently conducted a global research study to examine the perspectives of apparel industry leaders on skill development programs, as well as their current and future expectations. The study revealed that many leaders view these programs as essential for training new recruits in specific tasks, seeking more timely methods compared to their existing training approaches. Others see them as vital tools for boosting productivity by upskilling or reskilling their existing workforce, leading to improved work methods for specific products. Both perspectives highlight the urgent need to align all training efforts with the advanced modern manufacturing environment. It is evident that skill development programs are fundamental for any manufacturing company. However, their effectiveness relies on accurately identifying and addressing the right skills, driven by new, optimized, and market-driven production processes. This also involves identifying other skills necessary for training that aims to effectively support the workforce in meeting the evolving demands of manufacturing.
Throughout the study, Dagher & Partners posed several critical questions that directly impact productivity—questions that industry leaders struggled to answer. These questions include:
- Beyond practical training in specific tasks, what genuine value do skill development programs bring to your organization, especially when the training often relies solely on the trainer’s personal experience and fails to consider potential changes in manufacturing processes?
- How effective can these programs be in managing small or frequently changing orders if they primarily focus on individual skills related to a specific product?
- What are the implications for productivity when demands require frequent product changeovers, such as throughput time, performance curves, worker skills, and quality?
- How can enhancements in individual skills boost overall productivity when production lines encounter challenges like workflow imbalances, poor resource utilization, varying worker pace, unexpected delays, quality defects, and bottlenecks—all contributing to excessive inventory and high levels of work-in-progress (WIP)?
Today's challenges and feedback highlight the necessity for leaders to adopt a more holistic and strategic approach to skills development. This approach should not only focus on individual performance but also align with the comprehensive demands of the modern JIT manufacturing platform. To succeed in this new era, the apparel industry must rethink its approach to workforce development. The traditional method of concentrating solely on individual skills related to specific tasks and products is outdated. Organizations now need to implement programs that promote agility, teamwork, and adaptability to continuous change. Only through these initiatives can skills development truly empower a workforce that is prepared, agile, and flexible enough to excel in a Just-In-Time manufacturing environment and consistently overcome industry challenges.
Projects aimed at improving productivity through skill enhancement need to shift to a focus on Adaptive Skill Development. This new approach should integrate process changes and cost-effective practices while ensuring that adequate training is provided to essential productivity support roles, such as supervisors, maintenance, and supply staff, to effectively lead production processes. An integrated program that combines these elements into a complete skills enhancement package is essential.
To empower a future-ready, agile, and flexible workforce in apparel manufacturing, Dagher & Partners has transformed its approach and methodologies. They have designed advanced and modern skills development programs aimed at boosting productivity through flexibility, fixed worker positions, quick changeovers, zero production delays, and consistent quality.
