Professional Documents
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SAMIT CHAKRABORTY
Doctoral Fellow, Wilson College of Textiles, USA
Samit Chakraborty is a PhD fellow and working as research assistant at Wilson College of Textiles. His research
is based on implementing innovative technologies and ensuring sustainable supply chain management in the textile
manufacturing and fashion retailing industry. He completed his Master’s at the University of Manchester, UK
and Bachelor’s at Bangladesh University of Textiles. He has over five years’ working experience as a production
merchandiser and product developer in the apparel manufacturing industry, where he developed products
for European brands such as C&A and Tom Tailor. With this diverse industrial experience, he joined Daffodil
Samit Chakraborty International University, Bangladesh as a lecturer to continue his research and pursue a career in academia. He
has published articles on consumer behaviour and sustainable supply chain in various international journals.
Textile Technology Management, Department of Textile and Apparel, Technology and Management, Wilson
College of Textiles, North Carolina State University, Raleigh, NC 27606, USA
E-mail: schakr22@ncsu.edu
Manik Chandra Biswas is a doctoral fellow, recipient of North Carolina Textile Foundation (NCTF) Fellowship,
and a polymer and materials engineer with more than ten years’ research and industrial experience seeking to
innovate real-world textile and polymeric products and guide innovations in green chemistry as well as their
adoption by industry. His graduate research (at Master’s and doctoral levels) focuses on innovations in the
conversion of biomass waste into value-added materials and substitution of petroleum-based additives with
biomass derivatives for the strengthening of plastics and regenerated fibres from natural resources. Overall,
Manik Chandra Biswas this research will improve the sustainability of the textile industry by introducing overlap between the circular
economies of both the textile and agricultural industries. At graduate level, since 2015, he has supported work in
five industry-sponsored projects (all related to green chemistry), filed one US patent application, drafted another
patent disclosure and published 12 peer-reviewed journal articles and five book chapters on the use of biomass
derivatives towards manmade fibre production and polymer nanocomposites towards sustainability.
Fiber and Polymer Science, Department of Textile Engineering, Chemistry and Science, Wilson College of
Textiles, North Carolina State University, Raleigh, NC 27606, USA
E-mail: mbiswas2@ncsu.edu
Abstract
Over the past few months, the world has witnessed how COVID-19 pandemic disrupted the supply
chain of the textile, apparel and fashion manufacturing (TAFM) industry in various unprecedented
© HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020 1
ways. As the global textile market is interconnected, this outbreak has a global impact due to travel
restrictions and raw materials shortages. This study highlights the imminent impact of COVID-19 on
the TAFM industry supply chain, focusing on root-cause analysis and statistical data on consumption
of textile goods, both locally and globally. There has not been any academic research on TAFM supply
chain disruption. This paper has fulfilled this research gap. Our research is a two-fold study. The first
part reviews the overall impact of the pandemic on the TAFM industry and conducts a text analysis
on the statements collected from business reports, academic journals, market researchers’ opinions,
manufacturers’ statements and business journals, in order to identify the most frequently used terms
associated with supply chain disruption. The second part is a case study on a ready-made garment
(RMG) industry in Bangladesh, which showed that the supply chain disruption due to COVID-19
would increase the production cost. This is alarming for garment manufacturers and exporters, as
the worldwide apparel consumption is also projected to reduce during and after the pandemic. Lastly,
this study forecasts the takeaways of the TAFM industry from this global pandemic and recommends
a mathematical model to tackle any similar situation in future.
Keywords
COVID-19, supply chain, textiles and apparel industry, fashion manufacturing industry, global impact
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the human body; infected individuals ‘Factory Europe’ and the USA repre-
do not show any symptoms during this sents ‘Factory North America’.37 This
period.29,30 interconnection demonstrates that the
Different research found that absence recent supply chain disruption in the
of preventive measures such as social hearts of the regional factory represent-
distancing could directly generate an ative countries will affect the worldwide
average of 2–4 new infections. Hence, textile market. The size of the boxes
it caused the infection to spread rapidly shown in Figure 1 represents the size
among a mass of people. The rate of the textile and apparel market of the
and number can even increase if no respective country. For instance, the size
preventive measures are taken. This of the box for China is the largest among
illustrates the importance of maintaining all other countries because of its huge
social distancing, self-quarantine and textile and apparel market as well as
isolation to limit the spread of the virus supply chain network compared to other
and diminish the number of infected countries.
people eventually.31,32 Manufacturers The supply chain shock due to this
and retailers have mandated different pandemic has driven bullwhip effects in
rules for their employees and customers the fashion and RMG industry too, by
as part of these protective measures, forcing companies to stop production
such as wearing masks, washing hands and sales. For instance, according to
with sanitisers, maintaining 2m distance, recent reports, Swedish fashion brand
online deliveries and following check-in H&M announced 45 store closures in
and checkout lanes.33,34 China. Other major brands such as Gap,
Uniqlo, Hugo Boss, Ralph Lauren, Nike,
Levi Strauss and Adidas also publicly
IMPACT OF COVID-19 OUTBREAK announced closure of different stores in
China.39 These incidences will directly
Textile, apparel and fashion affect the economy of the textile and
industry supply chain disruption RMG export-based countries.
The changes in aggregate demand, Wazir (2020) shows that the impact
slowdown in global economy, manufac- on apparel consumption has signifi-
turing stores closure and production cantly affected the export of apparel and
shutdown due to the COVID-19 fashion items worldwide. The EU and
outbreak have created global structural USA are the biggest importers of apparel
supply shocks.35 The textile and fashion products.40 Wazir’s report projects the
supply chain has encountered similar GDP of these two regions will shrink by
impacts from the pandemic. China 3–4 per cent and 5–6 per cent respec-
is a critical supplier of textile inputs. tively over the next quarters of 2020.
Hence, when the disruptions started According to this report, there will be
with China, the impact consequently a closure of bricks-and-mortar fashion
extended throughout the whole global retail stores throughout the USA and
market.36 Figure 1 shows a strong regional Europe for the third quarter of the year.
dimension and interconnection of the Figure 2 shows the change in apparel
global textile supply chain. When it consumption in the USA and EU,
comes to textiles, China is known as the indicating a projection of 40 per cent
heart of ‘Factory Asia’, Italy represents lower apparel consumption in USA and
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al.’s findings showed that millions of journals, fashion blogs, market research
people in the fashion industry would data and online news portals.61–64
lose their jobs due to this impact. The
Clothing Manufacturers Association of
India (CMAI) forecasts a drop of 30 Research method
per cent in apparel sales and profit- After data screening and filtering of
ability, which may cause a 10–15 per statements, data and reports (n=85), the
cent decline in employment in apparel authors have found similar terms related
manufacturing industry and manufac- to economic crisis in a different order of
turing.56 About 1.44m textile and frequency from the literature study of
apparel industry workers in Bangladesh the global financial recession 2008–9.65–71
might be affected by order cancellations Our approach is based on exploring the
from Western countries.57 Thousands most frequently used terms in the state-
of factories in Bangladesh could not ments and information that we collected
provide any income or even severance from these sources, using R software.
pay to their workers while sending The conversion of statements into a
them home temporarily due to order corpus used ‘tm’ package in R. This
cancellations. Temporary or permanent text-mining process used the bag-of-
factory closures in Albania, Cambodia, words approach to convert the text into
Indonesia, Myanmar, Pakistan, Sri a data frame consisting of words used in
Lanka and Central America have also the text frequencies. These are applied
hit hard the low-waged garment workers using document term matrix (DTM)
in these countries.58 The pandemic has and term document matrix (TDM).
caused the closure of several garment This text-mining approach is widely
manufacturing industries in Myanmar, used to explore reviews, opinions and
which may lead to tens of thousands facts that generally describe a common
unemployed.59 Although the ILO phenomenon.72–76
predicts approximately 305m jobs might
be lost due to COVID-19,60 it should
provide a breakdown of this number Result and discussion
based on the type of industry. This The bar chart shown in Figure 4
will help the textile, apparel and fashion presents the most frequent words and
manufacturers, retailers and researchers the dendrogram shown in Figure 5
to gain a deeper understanding of the presents the taxonomic relationships
industry-based crisis and take steps based among the terms which support the
on the essential measures. authors’ discussion on economic impact
of COVID-19 on the TAFM industry
and supply chain disruption. These text
Economic impact analysis using analyses depict the severity prevailing
natural language processing on the economy based on the state-
technique ments and information collected from
This paper conducted a text analysis different sources.77–81 These findings
using natural language processing bolster the previous findings related
technique (NLP) to explore the insights to loss, decline in consumption, store
of economic impact due to COVID-19, closure and unemployment. The overall
based on the data collected from business analysis depicts an inevitable depression
8 © HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020
FIGURE 4: Bar chart showing the terms most frequently deployed in various business magazines, market research
reports and newspapers. These terms also relate to the factors that have been discussed in this paper to describe
supply chain disruption of the TAFM industry
Source: Authors
FIGURE 5: Dendrogram showing the taxonomic relationship among the terms mentioned in Figure 4 and explored
from the text analysis of statements sourced from business magazines, fashion blogs, market research reports and
newspapers
Source: Authors
© HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020 9
and recession that the TAFM industry is after COVID-19. The calculations were
about to face due to the pandemic, and completed in an ERP software platform
shows the high stress level that exists in of the respective industry. The net fabric
the socio-economic environment of the consumption (Net Cons/Dz) required to
industry. make a dozen garment pieces in a repeat
style was found using computer aided
design (CAD) consumption. The free-
CASE STUDY ON A BANGLADESH on-board (FOB) price (transport finished
RMG INDUSTRY garments up to seaport) was analysed
The supply chain of the RMG industry is to explore the change in garment price
connected to backward linkage industries before and after COVID-19.
such as spinning mills for yarn manufac-
turing, knitting or weaving mills for
fabric manufacturing, coloration industry Results and discussion
for fabric dyeing, printing and finishing.
This chain is joined to forward linkage FOB pricing before COVID-19
activities such as packaging, logistics, Table 1 shows the fabric price for a
banking, port services and government single piece (pcs) garment considering
support.82,83 In the current research, the the direct cost associated with fabric
disruption in the textile apparel and manufacturing. The yarn price, knit
fashion supply chain management can charge and dyeing and finishing cost are
be attributed to changes in garment based on the average price found from
production and distribution costs due to the company’s 2019 financial report.
the effects of the pandemic. The total price per kilogram (kg) of
fabric has been derived by multiplying
raw material price and processing cost
Methodology with net consumption per dozen, then
The authors conducted a case study on a dividing the total price per kg fabric by
knitwear-based RMG c in Bangladesh. 12 to obtain the fabric price per piece.
The company provided useful insights Cost is one of the key elements in the
and information on its production and garment sector. The company’s annual
marketing details. The collected data is turnover and future survival depends
based on the costing of a 100 per cent on accurately determining the projected
cotton basic t-shirt. The company is cost of making (CM). Table 2 shows the
expecting to ship the produced styles to calculations for cost per minute (CPM),
its European brands after withdrawing which is the cost of an entire factory
lockdown, despite making no profit associated with one minute of production
because of unwanted newly added and is greatly affected by elements such as
inventory and logistics costs. For the quality, absenteeism, production delay
purposes of this research paper, however, and management support. Standard
it has provided the current change in minute value (SMV) is the time required
price of raw materials and projected for making a garment, which indicates a
associated production costs to make company’s efficiency.
similar styles in the post-pandemic Table 3 shows the rest of the important
period. The study compared two different metrics that determine the FOB price of
costing and pricing scenarios, before and a garment piece (pcs) and a company’s
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TABLE 3: FOB price including fabric price, CM and Taiwan. The unusual price hike
and other associated costs
in cotton and different types of yarn is
Item Price/pcs common in RMG export business. The
Raw material cost US$1.08 authors have projected an increase in
Accessories US$0.14 yarn price of approximately US$0.20
CM US$0.53 per kg taking into account the added
Commercial cost US$0.029
cost of logistics and safety measures as
Courier charge US$0.01
well as the unstable situation due to
Lab test US$0.01
COVID-19. This projection is based on
Sample charge US$0.05
Total cost US$1.85
historical information of the company’s
Profit (5%) US$0.09 report and previous history of yarn price
Net cost US$1.94 fluctuation in both local and interna-
Sales commission (3%) US$0.06 tional markets.84–86 Table 4 shows that
FOB price of a garment US$2.00 the knit and dyeing charge has been kept
constant as per the company’s speculation
and projection.
profit margin. Any change in the The COVID-19 pandemic will
direct and indirect cost metrics forces force companies to invest in protective
companies to reduce their profit margin measures for their employees. This cost
during negotiations with buyer. will be added the CPM. Availability of
skilled labour force can increase the SMV
for a garment piece. It has been projected
FOB pricing before COVID-19 that average fluctuations of these metrics
The recent lockdown will have a direct based on a company’s market history can
impact on the increase of yarn price. increase the CPM from 1.5 to 2 times.
Almost all the spinning industries The average change in CPM and SMV
in Bangladesh that produce yarn for will lead to an increased CM, as shown
export-based RMG industries import in Table 5.
cotton fibre from India. Many of the The associated costs such as estimated
RMG industries directly import yarn changes in accessories and trimmings
from India, Pakistan, China, Indonesia import and commercial cost test will
© HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020 11
TABLE 6: FOB price including fabric price, CM and 37 per cent increase in FOB price.
and other associated costs
Retailers will attempt to maintain the
Item Price/pcs pre-COVID product price to meet
Raw material cost US$1.28 consumers’ expectations, which will
Accessories US$0.18 further reduce the company’s profit. As a
CM US$0.98 result, there will be an unstable condition
Commercial cost US$0.035
in the RMG industry supply chain.
Courier charge US$0.03
Lab test US$0.01
Sample charge US$0.05
TEXTILE AND FASHION
Total cost US$2.57
INDUSTRY TAKEAWAYS FROM
Profit (3%) US$0.08
Net cost US%2.65
COVID-19
Sales commission (3%) US$0.08 There have been different opinions and
FOB price of a garment US$2.73 analysis on reconstructing the supply
chain after COVID-19 or how the
textile and fashion chain will look after
also increase the final FOB price of the pandemic. These sources suggest
the product. These changes will be due that industries and societies can take
to import restrictions, supplier–buyer lessons from the surrounding failing
negotiation, transport cost and delay supply chain systems and modify them
in port facilities. On the other hand, after the pandemic for the betterment
the reduced consumption in Western of consumers and society in general.87,88
countries can force manufacturers to First, ensuring safety and security of
reduce profit margin to 3 per cent from 5 the workforce is the priority now for
per cent. The company has to reduce its manufacturers and retailers. Different
profit margin several times while there manufacturing industries have promised
is a delay in shipment, increase in bank and planned accordingly to ensure
interest and recession. It has to compete safety measures after reopening their
with other garment suppliers to survive businesses.89 Governments, representa-
in the global market. tives of manufacturing organisations
The final result shows a projected and retailers should strictly monitor
decrease in the company’s profit margin that every industry complies with the
12 © HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020
preventive and safety measures taken for industries for making PPE and masks94
its employees. may reinforce reshoring initiatives and
Secondly, there should be careful reduce sole dependence on importing
studies and analyses of consumer medical textiles from remote supplier
behaviour during this pandemic, because countries such as China. Therefore,
it will provide a smart means for retailers every country should develop a just-in-
to futureproof their businesses. Experts time and lean-based textile and apparel
predict that this unprecedented time of manufacturing and distribution system
stillness will give consumers not only that can immediately support its local
valuable perspective regarding the prior- healthcare officials and patients with PPE,
ities of various commodities in their gowns, masks and other medical textile
lives, but will also bring changes in their products during any future emergency.
attitude towards shopping and product
types in the post-pandemic world.90
Implementation of transparency at all Proposed model development to
phases of supply chain management, predict economic impact on the
diversification of essential resources, TAFM industry due to COVID-19
lean supply, total cost ownership and As other industries, the TAFM industry
genuineness in maintaining customer should also prioritise analysing the
retention will help in recovering from impact of the pandemic on supply chain
financial crisis as well as reconstructing disruption in the future. The mathe-
supply chain management.91 According matical model and statistical analysis
to some market researchers, however, the allow us to gain a better understanding
economic impact can pause the growing of sourcing, manufacturing and major
trend of sustainable business models. barriers to sustainable growth during
The supply chain will take a different the pre- and post-pandemic period. It
direction because investors will concen- will benefit fashion manufacturers and
trate more on economic recovery rather retailers to measure the unexpected supply
than spending further on sustainability.92 chain risks and disruptions in the future.
Therefore, researchers and industries The multivariate linear fit regression
should work in tandem to maintain model presented here can be applied to
balance between reconstructing the predict the probable impact on GDP
existing supply chain and coping with the based on the fluctuation in production,
rapid changes in business. They should consumption, unemployment, import,
also focus on developing data-driven and export and investment due to COVID-19.
technology-based digital supply chain These factors have largely affected the
to overcome unwarranted supply chain GDP and contributed to the on-going
disruption. economic crisis due to COVID-19 as
Finally, there should be new sourcing, well as during the recession of 2008–9.95–
production and distributing strategies 98
These studies concentrated on GDP
to restructure the supply chain system. projection, economic impact forecasting,
Market researchers assumed that retailers employment determinants, econometric
would be more interested in reshoring perspective and recession have empha-
and near-shoring in the post-COVID-19 sised the importance of using these
period.93 The recent initiatives taken by factors in their statistical probabilistic
US textile and apparel manufacturing and auto-regressive models.
© HENRY STEWART PUBLICATIONS 2516-1814 JOURNAL OF SUPPLY CHAIN MANAGEMENT, LOGISTICS AND PROCUREMENT VOL. 3, NO. 2, 1–19 Winter 2020 13
The above-mentioned factors have and discussed the key points related to
been combined here and applied using this disruption and also reported how
second order interactions to develop it had affected the global production,
a complex linear fit regression model, import, export, GDP, employment and
where β0 represents the intercept of the consumption. The case study showed
relationship in the model, β1, β2, …, β21 that COVID-19 significantly affected the
are coefficients for independent variables supply chain management of one RMG
and their interactions and ε is the error manufacturing industry, which resulted
term. Here each of the factors may in significant disruption to the supply
have multiple levels (high, medium, low) chain of the entire TAFM industry.
measuring their respective increase or The graphs and visuals, based on recent
decrease in multiple financial quarters. business reports, market overviews,
As a result, the effect will be different journals etc., reflect the economic and
for different countries based on their social impacts currently prevailing in the
export/import ratio. TAFM industry due to COVID-19. The
We have defined our factors as restructure of the TAFM supply chain
consumption = X1, unemployment = systems has been urged for the betterment
X 2, production = X 3, import = X4, of manufacturing and retail industry
export = X5 and investment = X6 for our in the near future. The authors also
model development. suggested that companies should develop
GDP fluctuation in TAFM industry a lean supply chain model convenient
= β0 + β1X1 + β2X 2 + β3X 3 + β4X4 for producing both ready-made garments
+ β5X5 + β6X6 + β7X1X 2 + β8 X1X 3 and PPE, as many countries may need
+β9X1X4 +β10X1X5 +β11X1X6 +β12X 2X 3 to import large volumes of PPE very
+ β13X 2X4 +β14X 2X5 + β15X 2X6 + soon. This holistic approach will help the
β16X 3X4 +β17X 3X5 + β18X 3X6 + β19X4X5 textile, apparel and fashion industry to
+ β20X4X6 + β21X5X6 + ε rebound after the COVID-19 pandemic.
Since the variables are collected in
different forms or scales of measurements,
they should be standardised or trans- AUTHOR’S NOTE
formed by using the log of their values This research did not receive any
so that the coefficients can be measured specific grant from funding agencies
in a same scale. This model can be tested in the public, commercial, or not-for-
further in a research paper using the data profit sectors. The authors declare no
collected from the economic reports of competing financial interest.
the respective country.
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