The Ready-Made Garment (RMG) sector stands as the largest contributor to Bangladesh’s export earnings. This thriving industry is being driven by dynamic leaders who are shaping its future. Among them is Engr. Tarun Kumar Mistry, a highly regarded B.Sc. Engineer in Textile Technology and the Director of Operations at Chaity Group, who has played an instrumental role in the continued success of the company.
Here is a glimpse into his professional journey.
Textile Focus: Could you please share your professional journey and experience in the textile sector?
Indeed, I’d be happy to share my professional journey and experience in the textile sector. I began my career after graduating from the University of Dhaka with a degree in Textile Technology in 2006. Overcoming significant financial hardships during my education taught me resilience and determination, which have been instrumental throughout my professional life.
My first role was with Mondol Group, one of Bangladesh’s leading export-oriented companies. I started as a Production Engineer, gaining hands-on experience in the production processes. Over time, I took on increasing responsibilities, leading departments such as Production planning, Quality Control, Fabric Development, Knitting, Dyeing, Marketing and Merchandising, Ready-Made Garments (RMG), and Operations.
One of the most notable projects I led was the transformation of Cotton Field (BD) Ltd. Initially, the factory operated in a rented building and faced challenges due to compliance constraints. We were compelled to relocate to a newly purchased 5-acre piece of land, which had only one building under construction and lacked a proper production layout.
Faced with financial constraints and structural challenges, I spearheaded a complete redesign of the factory layout, focusing on sustainability and LEED certification. This involved demolishing and reconstructing layouts, I oversaw the demolition of inefficient structures and planned new layouts that optimized production flow.
Implementing Sustainable Practices: We integrated green initiatives to create an environmentally friendly workplace, transforming the factory into a green oasis.
Managing Financial Constraints: We overcame financial hurdles by optimizing resources and prioritizing critical investments without compromising on quality or efficiency.
Under my leadership, Cotton Field (BD) Ltd. evolved from a struggling operation into one of Mondol Group’s flagship factories, employing over 3,000 workers. This transformation boosted productivity and improved employee morale by providing a refreshing and sustainable work environment.
Throughout my 17-year tenure at Mondol Group, I have consistently sought challenges and opportunities to innovate.
I am passionate about:
Lean and Kaizen Management: Implementing continuous improvement methodologies to enhance efficiency.
People Management: Delegating effectively and fostering a collaborative team environment.
Learning and Development: I pursued additional qualifications, such as the Certified Supply Chain Manager (CSCM) from ISCEA, Ohio, USA, and conducted training programs for employees to share knowledge and best practices.
As of August 2024, I embraced a new challenge as the Director of Operations at Chaity Group. In this role, I am eager to leverage my extensive experience to drive success and innovation within the organization.
My journey in the textile sector has been one of growth, resilience, and a constant quest for excellence. Starting from humble beginnings, I’ve navigated numerous challenges, which have shaped me into a leader who is focused on operational success and empowering others to achieve their potential.
I’m excited about the future and the opportunity to contribute further to the textile industry through my professional endeavors and by mentoring mid-career professionals to become the next generation of legendary leaders.
Textile Focus: Knitwear is a self-sufficient sector in all respects; currently the sector is supplying 90% of the knit fabric requirements, How do you evaluate this?
Engr. Tarun Kumar Mistry: Bangladesh’s achievement in making the knitwear sector self-sufficient, supplying 90% of its knit fabric requirements, is a significant milestone with profound implications for the country’s economy and the global textile industry. Here’s how I evaluate this accomplishment:
1. Strengthening the Economy
Boosting Export Earnings: The knitwear sector is one of the most significant contributors to Bangladesh’s export earnings. Self-sufficiency reduces dependency on imported raw materials, improving trade balances and increasing net export revenues.
Job Creation: The industry’s growth generates employment opportunities for millions, particularly empowering women and alleviating poverty.
Value Addition: Producing fabrics domestically adds more value within the country, enhancing GDP and fostering economic development.
2. Enhancing Competitive Advantage
Reduced Lead Times: Local sourcing of fabrics accelerates the production process, enabling quicker turnaround times and responsiveness to global market demands.
Cost Efficiency: Eliminating the need to import fabrics reduces costs associated with tariffs, shipping, and currency exchange fluctuations, making Bangladesh’s knitwear more price-competitive.
Quality Control: Domestic production allows for better oversight of quality standards, ensuring that products meet international requirements.
3. Supply Chain Resilience
Mitigating Global Risks: By being self-sufficient, the industry is less vulnerable to international supply chain disruptions, such as those caused by geopolitical tensions or global pandemics.
Sustainable Practices: Local control over production processes offers opportunities to implement environmentally friendly practices and sustainability initiatives.
4. Encouraging Innovation and Skill Development
Technological Advancement: The sector’s growth incentivizes investment in advanced machinery and technology, fostering innovation.
Skill Enhancement: A thriving industry encourages the development of a skilled workforce, providing training and educational opportunities that uplift the community.
Challenges and Considerations
While the self-sufficiency of the knitwear sector brings numerous benefits, it’s essential to be mindful of potential challenges:
Sustainability Concerns: The environmental impact of large-scale textile production must be managed through sustainable practices, waste reduction, and responsible resource management.
Global Competition: Other emerging economies are also advancing in textile production. Continuous improvement and innovation are necessary to maintain a competitive edge.
Market Diversification: Relying heavily on a single sector or limited markets can be risky. Diversifying products and exploring new markets can mitigate this risk.
Infrastructure Development: Ongoing investment in infrastructure, such as energy supply and transportation networks, is crucial to support the industry’s growth.
Compliance and Ethical Standards: Adhering to international labor laws and ethical standards is imperative to maintain relationships with global buyers and protect the industry’s reputation.
Conclusion:
Overall, the self-sufficiency of the knitwear sector is a significant asset for Bangladesh. It boosts the economy and enhances the country’s reputation as a reliable and competitive source of high-quality knitwear products. By proactively addressing challenges and investing strategically, Bangladesh can continue strengthening its position in the global textile industry.
Textile Focus: What are the Challenges you are facing in the Knitwear Production?
Engr. Tarun Kumar Mistry: As someone deeply involved in the knitwear industry, I’ve encountered several challenges that require constant attention and innovative solutions. Here are some of the key challenges I face:
1. Fluctuating Raw Material Prices
The prices of raw materials like cotton and synthetic fibers are highly volatile due to global market fluctuations, weather conditions affecting crop yields, and geopolitical tensions. This volatility affects production costs and makes maintaining stable pricing for clients challenging.
2. Maintaining Quality Standards
Ensuring consistent quality across large-scale production is a significant challenge. Variations in yarn quality, dyeing inconsistencies, and machinery calibration can lead to defects. Meeting international quality standards requires rigorous quality control processes and continual technological investment.
3. Skilled Labor Shortage
While the knitwear sector employs a large workforce, there’s a shortage of skilled technicians and machine operators proficient in modern knitting technologies. Training and retaining qualified workers is an ongoing challenge, especially with the rapid advancements in machinery.
4. Technological Advancements
Keeping up with the latest knitting machinery and software demands substantial capital investment. Integrating automation and digital technologies is essential for efficiency but can be challenging due to costs and the need for specialized knowledge.
5. Compliance and Sustainability Requirements
International buyers increasingly demand compliance with strict labor laws, environmental regulations, and sustainability standards. Adhering to certifications like LEED, OEKO-TEX, and others requires significant resources and organizational changes to processes and culture.
6. Supply Chain Disruptions
Global events such as pandemics, political unrest, or natural disasters can disrupt the supply chain. Delays in receiving raw materials or exporting finished goods affect production schedules and client relationships.
7. Energy Costs and Power Reliability
High energy costs and inconsistent power supply are substantial obstacles. Investing in alternative energy sources or backup systems like generators increases operational costs but is often necessary to maintain uninterrupted production.
8. Customization and Short Lead Times
The rise of fast fashion has increased demand for customized products with shorter lead times. Adjusting production processes to accommodate smaller, varied orders without sacrificing efficiency is challenging.
9. Environmental Concerns
Managing environmental impacts such as wastewater treatment, chemical use, and carbon emissions is critical. Implementing eco-friendly practices requires investment in new technologies and processes and ongoing monitoring and compliance efforts.
10. Global Competition
Competing with other countries offering lower production costs means continually improving efficiency, innovating product offerings, and providing superior service to retain and attract clients.
11. Financial Constraints
Accessing financing for capital expenditures like machinery upgrades or facility expansions can be difficult. Interest rates, credit availability, and economic conditions influence our ability to invest in growth.
12. Infrastructure Limitations
In some areas, inadequate transportation infrastructure leads to delays and increased logistics costs. This affects the timely delivery of raw materials and shipment of finished products.
13. Adapting to Technological Disruption
The industry is experiencing rapid technological changes, such as 3D knitting and automated design systems. Adapting to these technologies requires investment and a shift in traditional manufacturing mindsets.
14. Regulatory Changes
Changes in trade policies, tariffs, and international agreements can affect export markets and cost structures. Staying abreast of these changes and adapting accordingly is essential but challenging.
15. Cultural and Language Barriers
Working with international clients involves navigating cultural differences and language barriers. Misunderstandings can lead to errors in production specifications or contractual agreements.
Conclusion
The knitwear production industry is dynamic and filled with challenges, but it’s also ripe with opportunities for those willing to adapt and innovate. By addressing these challenges head-on with strategic planning, investment in people and technology, and a commitment to sustainability, I aim to overcome obstacles and contribute positively to the industry’s growth. The journey isn’t easy, but my experiences have taught me that resilience, continuous learning, and a proactive mindset are crucial to navigating the complexities of knitwear production. I’m dedicated to transforming these challenges into stepping stones toward tremendous success and making a meaningful impact in the textile sector.
Textile Focus: Most textile students focus on merchandise, Could you plz share us the career opportunities in the Knitwear Sector?
“The future belongs to those who believe in the beauty of their dreams.” — Eleanor Roosevelt
Introduction
Engr. Tarun Kumar Mistry: As a textile student, I noticed a common trend: most of my peers gravitated toward merchandising. It seemed like the default path, the well-trodden road everyone assumed led to success. However, the textile industry, especially the knitwear sector, has a vast ocean of opportunities to explore. Let me share with you the myriad career paths in the knitwear sector that go beyond merchandising, both challenging and rewarding.
Textile Focus: Why Look Beyond Merchandising?
Engr. Tarun Kumar Mistry: Merchandising is essential to the textile industry, but focusing solely on it can limit your potential. The knitwear sector offers diverse roles that allow you to innovate, lead, and make a significant impact.
Exploring Career Opportunities in the Knitwear Sector
The knitwear industry is rich with diverse career opportunities that go beyond the commonly known roles. If you’re considering a career in this sector, here are some paths you might explore:
1. Product Development and Design:
Becoming a product developer or designer could be an exciting option if you have a flair for creativity and an eye for fashion. In this role, you blend artistic talent with technical knowledge to create new knitwear products. You’ll design knit patterns and garments, select suitable yarns and materials, and collaborate with fashion designers and trend analysts to stay ahead of market trends. Imagine crafting a sustainable knitwear line that becomes a fashion sensation and promotes eco-friendly practices.
2. Technical Knitting Specialist
For technically inclined people, the role of a technical knitting specialist might be appealing. This position focuses on the machinery and processes involved in knitwear production. You’ll be operating and maintaining knitting machines, troubleshooting technical issues, and implementing new technologies to improve efficiency. With
mechanical aptitude, attention to detail, and strong problem-solving abilities, you’ll ensure that the production process runs smoothly and efficiently.
3. Quality Control and Assurance
Ensuring that knitwear products meet high-quality standards before they reach consumers is crucial. In a quality control and assurance role, you’ll inspect products for defects, implement quality control procedures, and work closely with production teams to enhance quality. A keen eye for detail, knowledge of quality standards, and analytical skills are essential. For instance, by catching minor defects early, you can save the company from potential setbacks and maintain its reputation for excellence.
4. Production Management
If leadership and organization are your strengths, a role in production management might suit you. You’ll oversee the entire production process, ensuring efficiency and timely delivery of products. This involves planning and scheduling production, managing teams and resources, and coordinating with other departments. Your ability to lead, communicate effectively, and understand production processes will keep operations running smoothly.
5. Sustainability and Compliance Officer
With the increasing global emphasis on environmental responsibility, the role of a sustainability and compliance officer is more important than ever. You’ll focus on implementing eco-friendly processes, ensuring compliance with environmental and ethical regulations, and educating teams about sustainability practices. A passion for the environment, knowledge of relevant rules, and the ability to influence and inform others are vital. Leading green initiatives, you help reduce waste and promote ethical practices within the company.
6. Research and Development (R&D)
If innovation excites you, a career in research and development might be the perfect fit. You’ll work on creating new materials, techniques, and technologies in knitwear. This could involve experimenting with new fibers, developing advanced knitting technologies, and collaborating with academic institutions. Scientific and technical knowledge, creativity, and analytical thinking are crucial. For example, developing a new moisture-wicking fabric could revolutionize athletic wear and set new industry standards.
6. Supply Chain and Logistics Management
Managing the flow of goods from raw materials to finished products is essential in the knitwear industry. In supply chain and logistics management, you’ll coordinate with suppliers and distributors, optimize logistics and inventory management, and ensure timely delivery of products. Strategic planning, problem-solving skills, and knowledge of logistics software are essential to excel in this role.
6. Marketing and Brand Management
Marketing and brand management offer exciting opportunities for those with a creative and strategic mindset. You’ll promote knitwear products and build the brand’s identity. This includes developing marketing strategies, engaging with customers through various channels, and analyzing market trends to stay competitive. Strong communication skills, creativity, and an understanding of consumer behavior are essential.
. Entrepreneurship
If you’re ambitious and willing to take risks, starting your knitwear line or business could be fulfilling. As an entrepreneur, you’ll identify market gaps, develop business plans, and manage all aspects of the business. This role requires passion, resilience, business acumen, and a willingness to embrace challenges. Your innovative ideas could lead to the next big brand in knitwear.
Conclusion
The knitwear sector is more than just an industry; it’s a canvas for innovation, creativity, and impact. Don’t limit yourself to the paths most traveled. Explore the vast opportunities that await you in knitwear. Remember, your career is your journey. Make it one that excites and fulfills you. Your potential is limitless. The knitwear sector has opportunities for those willing to step outside their comfort zone. Embrace the challenges, seize the opportunities, and you might find a career that’s not only successful but also profoundly satisfying.
“The only way to do great work is to love what you do.” — Steve Jobs
Leap and weave your own success story in the knitwear industry!
Textile Focus: As an industry, expert, how will you contribute more to the Textile Sector?
“The best way to predict the future is to create it.” — Peter Drucker.
Engr. Tarun Kumar Mistry: Rising from humble beginnings to the CEO position in the textile industry has been a journey filled with challenges and lessons. This path has ignited a deep commitment to give back to the sector that has shaped my life. My experiences have fueled a passion for innovation, sustainability, and empowerment, and I am determined to impact several vital areas significantly.
1. Mentoring the Next Generation
I have observed a noticeable gap between academic learning and the practical requirements of the industry. Many young professionals lack the guidance needed to navigate their careers effectively. Remembering my struggles, I understand the profound impact a mentor can have. To bridge this gap, I plan to conduct workshops and seminars connecting theoretical knowledge with real-world applications. Additionally, offering one-on-one mentoring will help aspiring professionals unlock their potential and confidently grow.
2. Promoting Sustainable Practices
The textile industry often faces scrutiny over its environmental footprint and the excessive consumption of resources like water and energy. At Cotton Field (BD) Ltd., we transformed barren land into a LEED-certified green factory, setting new standards for sustainability. By integrating eco- friendly processes and energy-efficient machinery, we demonstrated that environmental responsibility and industrial growth can go hand in hand. I am committed to educating industry peers and employees about sustainable practices to foster a culture of environmental stewardship.
3. Driving Technological Innovation
Keeping pace with rapid technological advancements can be daunting, and there is sometimes hesitancy in adopting modern methods. However, embracing innovation is not just a choice; it’s a necessity for growth. I plan to invest in research and development to create innovative materials and techniques. By adopting automation and digital tools, we can enhance efficiency and set new benchmarks in productivity. When a colleague once asked, “Is adopting new technology worth the risk?” I responded, “Embracing innovation is essential for our progress.”
4. Enhancing Global Competitiveness
The industry faces intense global competition and an over-reliance on traditional markets. To stand out internationally, focusing on producing superior quality products is vital. Exploring new markets and expanding our international footprint will diversify our reach and reduce dependency on a limited customer base. My mantra is simple: innovate to compete, lead, and succeed.
5. Strengthening Industry Collaboration
Fragmented efforts and limited sharing of best practices hinder the industry’s collective growth. We can foster collaboration and knowledge exchange by organizing industry forums and encouraging partnerships. Joint ventures can help tackle common challenges more effectively. As Helen Keller wisely said, “Alone we can do so little; together we can do so much.”
6. Fostering Ethical Practices
Concerns over worker rights, safety, and the pressures of meeting stringent international standards are prevalent. Promoting fair labor practices and ensuring compliance with global standards are ethical obligations and pathways to enhanced productivity and morale. Implementing employee welfare programs demonstrates a commitment to our workforce. By prioritizing worker safety and satisfaction, we comply with regulations and create a more dedicated and efficient team.
7. Supporting Education and Community Development
Many talented individuals lack access to quality education, and rural areas often face infrastructural deficits. Having faced educational hardships, I am passionate about making education accessible to all. Providing scholarships and grants to students pursuing textile education can open doors for the next generation of innovators. Investing in infrastructure and educational facilities in underdeveloped areas will uplift communities and nurture future talent.
8. Encouraging Diversity and Inclusion
Limited opportunities for women and minorities, along with cultural biases, hinder diversity within the industry. We can build a more dynamic and innovative workforce by ensuring equal opportunities for all candidates through inclusive hiring practices. Promoting the importance of diversity within the industry is essential. When someone asked me, “Do you think diversity makes a difference?” I affirmed, “Diversity isn’t just fair; it’s a strength that drives innovation and growth.”
9. Sharing Knowledge through “The CEO Leap”
Professionals often lack accessible resources and guidance on career advancement. Overcoming self-doubt and fear of failure can be significant hurdles. To address this, I am writing a book named “The CEO Leap,” a blueprint for aspiring leaders to achieve executive excellence. Hosting workshops and seminars will delve deeper into the book’s concepts, helping others learn to lead, inspire, and transform.
Engr. Tarun Kumar Mistry
B. Sc Engineer in Textile Technology
Director of Operation, Chaity Group
