Mapping the Digital Journey of Texport Industries: Raghavendra Shah, SVP, Texport Industries

As the global apparel manufacturing landscape undergoes digital transformation, the factories in Asia are also emphasising on integrating tech-driven approach. While traditional business methods still hold some relevance, adapting to digitalisation is looked at as an imperative to control costs, reduce human intervention, cut redundant processes and increase process visibility.

In a recent interview with Apparel Resources, Raghavendra Shah, Senior Vice President, Texport Industries Pvt. Ltd. (TIPL), shed light on the impact of digitalisation on the apparel manufacturing industry and shared insights into the company’s tech-driven initiatives. The interview also delves into how digitalisation has contributed to improving Key Performance Indicators (KPIs) at TIPL, while addressing the broader question of technology adoption and human-centric approaches.

AR: Traditional vs. Digitalisation! What holds more relevance in garment manufacturing today?

Raghavendra: While traditional business methods may still have some relevance, adapting to digitalisation is increasingly becoming a necessity in today’s business landscape. Digitalisation will help to align the processes, reducing wastage, improving supply chain management and most importantly enabling data-driven decision making. All these factors lead to better efficiency and quality which needs real-time intervention. Companies that resist digital transformation risk falling behind competitors in terms of efficiency, innovation and meeting evolving customer expectations. A balanced approach that incorporates digital technologies while respecting proven business principles can be a winning strategy for apparel manufacturers.

AR: TIPL boasts an impressive tech-driven manufacturing infrastructure and a mindset to welcome the new tech trends. Can you please throw some light on your digitalisation endeavours?

Raghavendra: TIPL always welcomes and experiments with newer technologies and fully understands that technology plays an important role in determining and building an efficient and productive manufacturing set-up. We have implemented advanced ERP for day-to-day business transactions that will cover all the departments like merchandising, procurement, inventory management, finance, banking and logistics, while our Manufacturing Execution System (MES) gives clear visibility of shopfloors and 3D tools like CLO, Browzwear and Optitex help provide quick design solutions.

At Texport, all our factories are paperless, which is a rare feat to achieve in the Indian apparel manufacturing landscape. The data compliance is 100 per cent as there is no manual intervention. Recently, we have introduced our custom-made Digi Shopfloor Platform which captures all the production and quality movements through the system automatically and gives us real-time insights.

Not just the garmenting unit, Texport fabric mill is also completely tech-driven as all the machines are controlled by systems with zero manual intervention. The entire production is robotic and digital that helps us achieve quality, productivity, efficiency and speed.

AR: How does digitalisation improve KPIs such as productivity and quality?

Raghavendra: With the right direction of collaboration in system, digi shopfloor platform and human resources, we are already getting to see the results in last few months to the tune of almost 10 per cent increase in the efficiencies. Our thrust has been on training on MES and, as a result, our ‘Defects Per Hundred Unit’ (DHU) rate has reduced by almost 45 per cent which directly adds to our productivity, quality and bottom line.

To improve workers’ efficiency and get desired outputs, it’s important to impart training, skill development, offer a favourable work environment and inculcate a culture of collaboration. MMS (Man Machine Systems) collaboration is the trick which we take care of across top to bottom management.

AR: What does it take for a factory to successfully transform processes digitally?

Raghavendra: A successful transformation needs a strategic and well-executed approach which includes key factors like leadership commitment, clear vision and strategy, collaboration with all the departments, suppliers and customers, employee management and training, data management and analysis, automation, proper technological infrastructure and continuous improvement. This is the approach that TIPL follows in its efforts towards digitising our processes.  By carefully addressing these factors, a factory can not only successfully transform its processes digitally but also gain a competitive edge in the market by becoming more agile, efficient and responsive to customer needs. More importantly, the vision in the direction and patience to walk the path can make this happen.

When we talk about technical approach and technologies like automation, robotics, Internet of Things, data analytics and AI, we aim at finding bottlenecks, improving quality, optimising workflow, streamlining operations, doing predictive analysis, making correct decisions and managing inventory. Choosing the right equipment, knowing and using all the features of the machines are critical aspects and doing these will directly or indirectly help improve overall productivity, reduce wastage and identify areas for improvement. Having said that, I believe in people as they are key to productive and efficient factories. We, as a company, work around human approach areas like employee engagement, training and skill development, continuous improvement culture, collaboration and communication that are necessary factors to add value for factory’s improvement.

Simply put, a successful strategy for enhancing efficiencies on the shopfloor involves integrating technology with a human-centric approach in TIPL that leads to sustainable improvements in manufacturing efficiency.

AR: What are your upcoming technology projects?

Raghavendra: In today’s world, there are so many solutions present to facilitate the production tracking on the floor. We are opting for various technologies for our upcoming facilities like automatic hanger system (UPS) for line production, an advanced MES system for shopfloor, cutting automation, BMS for building management, finishing automations, IOT integration for controlling/measuring devices like energy consumption, humidity air quality, etc., and next-gen sewing machines. Traditionally, we did not use high-end sewing machines as manual cost was cheaper than machine automation but we have now realised that automated machinery will pave way for long-term business profitability.

Our new projects also include platinum green buildings where we would be eyeing at bio fuels, solar panels, zero liquid discharge and low liquor ratio laundry operations. This investment will in turn reduce the MMR (Man Machine Ratio), which in turn will result in sustainability.