Operations / Textiles [ India ]

1 day

Senior Textile Advisors with experience in Manufacturing/Operations across spinning, weaving, cutting and sewing process for a site visit | Global Management Consulting Firm

CLIENT:
A Global Management Consulting Firm for an Indian Multinational Group End-Client
CONSULTANT:
He is a distinguished textile industry veteran with over four decades of experience across the entire textile value chain—spinning, weaving, processing, garments, and home furnishing as well as general textiles. He has held top leadership roles including CEO, Business Head, COO, and Vice President at leading Indian and international companies such as Opex Group (Bangladesh), NSL Group, Birla Century, GHCL, Welspun, and Mafatlal Industries. Known for his ability to turn around underperforming textile units, he has led several successful greenfield and brownfield projects, implemented robust quality systems (ISO, OEKO-TEX), and driven SAP-based digital transformations.

His expertise spans operations management, cost optimization, process engineering, strategic planning, and training & development. He has an exceptional track record in scaling production, reducing lead times, and aligning manufacturing with business goals—delivering measurable improvements in productivity, quality, and profitability. With deep familiarity with global textile machinery and best practices, combined with academic credentials from Harvard Business School and technical training in Japan, he brings a rare blend of technical depth, leadership acumen, and global exposure.
ASSIGNMENT:
The client was undertaking a pitch to drive an end-to-end cost reset for a client in the home textiles manufacturing space, specifically focused on bedsheets and towels. The objective was to identify and implement cost optimization levers across the value chain, with a focus on manufacturing operations, procurement, and planning within a largely Make-to-Order (MTO) business model. They were looking to engage senior advisors with deep expertise in textile manufacturing—particularly across spinning, weaving, cutting, and sewing processes. Expertise in automation within weaving, cutting, and sewing is highly desirable, with the goal of reducing manual intervention, improving throughput, and enhancing quality. Additionally, they seeked advisors with experience in the procurement of cotton (both domestic and imported), who could bring insights into managing raw material cost volatility and improving sourcing strategies. The assignment also required knowledge of planning and production management in a B2B context, especially for MTO setups, to improve forecasting, lead time adherence, and working capital efficiency. The engagement involved a diagnostic of current operations, identification of cost-saving opportunities, and development of a clear implementation roadmap.
OUTCOME:
The assignment delivered a comprehensive cost optimization roadmap for the client’s home textile operations, specifically in the bedsheets and towels segment. It resulted in significant improvements in manufacturing efficiency by identifying and implementing automation opportunities in weaving, cutting, and sewing, and optimizing productivity in spinning processes. The engagement also delivered a more resilient and cost-effective cotton procurement strategy that helped the client manage raw material price volatility and improve supplier leverage. On the planning front, the project streamlined the Make-to-Order (MTO) process, enhancing demand visibility, reducing lead times, and lowering inventory holding costs. Overall, the assignment delivered clearly quantified cost-saving opportunities across manufacturing, sourcing, and planning, along with a phased implementation roadmap that enabled the client to realize immediate gains while setting the foundation for sustained long-term efficiency.