Here is a practical advise by global industry advisor Dr. Rajesh Bheda
As global uncertainties persist, the apparel industry continues to face challenges in consumption patterns and supply chain stability. The added burden of current and anticipated US tariffs is further straining competitiveness for manufacturers across Asia. International buyers are pushing for price reductions, asking suppliers to absorb tariff costs partially , or delaying shipments—while rising wage costs compound the pressure on profitability. Bangladesh is no exception to this phenomenon.
In this context, Textile Focus engaged with Dr. Rajesh Bheda, a globally trusted advisor to apparel manufacturers, to uncover practical strategies that protect and grow profit margins—even in turbulent times.
“Self-help is the best help.”
“At Rajesh Bheda Consulting (RBC), we believe that manufacturers can increase profitability by 15% or more within 6–9 months—without depending on external factors.
In uncertain times, the winning strategy is to strengthen internal systems and capabilities. “Money saved is money earned.”
7 Profitability Levers Identified by Dr. Bheda which also support sustainability
1. Fabric Saving Initiatives and material flow management
Smarter pattern engineering, marker planning, and width/end allowance optimisation can unlock 1.5% or more in fabric savings—translating directly into cost reduction. RBC-led interventions have often exceeded this benchmark. In addition, ensuring material flow through. Etter planning will reduce disruptions to production line.
2. Cut-to-Ship Ratio Enhancement
Raising the cut-to-ship ratio by just 1% can drive 5–7% gains in profitability of FOB orders. Despite ongoing quality efforts, most factories still have substantial room for improvement for improving Right First Time Quality across the processes.
3. Line Balancing for Productivity
Optimising machine and workforce utilisation through better line balancing can yield up to 10% efficiency improvement—a high-impact operational lever.
4. Method Improvement, Low-Cost Automation and digitalisation
Standardising efficient work methods and integrating simple tools like laser guides, templates, and pneumatic devices can enhance throughput and consistency without heavy capital investment. Powerful dashboards can provide great real-time insights for performance review and quick decision making to support for performance improvement.
5. Upskilling for Productivity Gains
Using RBC’s proven Low Performer Improvement methodology, worker productivity on sewing and finishing lines has risen by 15% or more, with skill upgrades of 25–30% observed across 150+ factories in Bangladesh through initiatives like Sudokkho, Progress, and Sarathi.
6. Supervisor & Manager Capability Building
Sustainable performance requires informed leadership. Training floor managers and supervisors in key production concepts ensures that operational improvements are maintained and scaled.
7. Strengthening HR Systems
Robust HR practices reduce absenteeism, control attrition, and enhance worker motivation—critical for consistent, high-level factory performance.
Practical. Proven. Profitable.
These strategies are neither capital-intensive nor disruptive. With expert guidance, apparel factories can offset rising wage costs, reclaim eroded margins, and boost profitability by 15% or more. Moreover, all of these levers help reduce waste and improve resource efficiency contributing to ESG targets.
Ready to take the next steps? Reach out at RBC@rajeshbheda.com or drbheda@rajeshbheda.com to explore how rbc can help you transform performance and drive sustainable and profitable growth.
