Apparel Supply Chain Forging New Links

By Jim Borneman, Editor In Chief Apparel Supply Chain: Forging New LinksCotton’s Sourcing Summit 2002 provided forum for retailers, apparel manufacturers and textile producers to explore CBTPA and African trade opportunities. With the Caribbean rhythms of Miami Beach, Fla., in the background, Cotton Incorporated, Cotton Council International (CCI), and the Importer Support Program jointly sponsored Cottons Sourcing Summit 2002: U.S. CBI Africa.Building new relationships to maximize Caribbean Basin and sub-Saharan African trade initiatives, the summit blended an array of presentations from apparel retailers, apparel manufacturers and textile producers. Additional presentations added the perspectives of legal, customs and banking issues. 

Berrye Worsham, president and CEO, Cotton Incorporated, Cary, N.C., stated in his welcome letter, Each of us has experienced the challenges and rapid changes of the textile industry. We have made adjustments in our business operations to accommodate these changes and have looked to opportunities to prosper. Enactments of textile trade legislation continue to impact global trade. Your presence at this sourcing summit indicates a willingness to take advantage of those opportunities presented and to look for new business arrangements. The sponsors of this summit are dedicated to providing you with those opportunities and an excellent venue for building relationships.The event was punctuated with morning presentations, afternoon tabletop trade fairs, and evening receptions and networking opportunities. The first trade fair component featured U.S. cotton yarn and fabric manufacturers exhibiting product samples to U.S. importers and Caribbean Basin Initiative (CBI) and sub-Saharan African apparel manufacturing executives. The second day, Caribbean and African exhibitors, grouped by country, presented products and apparel manufacturing capabilities to U.S. importers and textile manufacturers.Vaughn Jordan, international program director and director of Mexico and CBI, CCI, Washington, coordinated the event. With attendance of 389 people, the summit brought together key players in the apparel supply chain. At the conclusion of the event, the initial surveys of 15-percent attendance revealed 799 new business relationships developed at the summit. Eighty-seven percent of respondents felt very comfortable with U.S.-CBI apparel trade. We believe this was about decision makers breaking down barriers. It was really about business and opportunity. CBTPA BasicsThe Caribbean Basin Trade Partnership Act (CBTPA) and the African Growth and Opportunity Act (AGOA) were passed by the U.S. Congress under the Trade and Development Act of 2000. In October 2000, then-President Bill Clinton signed proclamations designating 34 sub-Saharan African countries to participate in AGOA and extending benefits of 24 Caribbean and Central American countries from the 1984 CBI program.According to U.S. Department of State background information on Caribbean Basin trade enhancement, The main benefit of the CBTPA is duty-free and quota-free entry for U.S. imports of apparel sewn and assembled by CBI countries from U.S. cloth and yarn; this product sector had been excluded from the original CBI law but provided to Mexico by NAFTA. After 1994, CBI countries asserted that Mexicos superior trade terms were harming their trade. The CBTPA program was implemented in October 2000 and will last through September 2008, or before that if the Free Trade Area of the Americas (FTAA) enters into force first.Jonathan Fee, attorney at law with AlstonandBird LLP, provided the summit with an overview of the various classifications available under CBTPA and AGOA agreements. Known as preference groups, these classifications define how and what products qualify as duty-free and how customs relate to the final apparel import. The most widely known preference group, 807A+, provides for garments made of wholly U.S.-formed yarn, wholly U.S.-formed fabric, cut in the United States and assembled in a beneficiary country. CBI BeneficiariesProducts from Honduras, the Dominican Republic, El Salvador, Costa Rica, Guatemala, Jamaica, Haiti and Nicaragua make up the lions share of CBTPA beneficiary exports, according to Julia K. Hughes, vice president, international trade and government relations, United States Association of Importers of Textiles and Apparel. With CBTPA benefits from CBI countries totaling $5.3 billion and representing 2.2 billion square meter equivalents, CBTPA accounted for 22 percent of apparel imports into the United States for 2001. The majority of imports 93 percent qualified under CBTPA by utilizing U.S.-formed yarn and U.S.-formed fabric. Five percent used regionally formed fabric with U.S. yarn. Hughes stated, The yarn forward aspect of CBTPA has helped many North American manufacturers. Events like this, which bring the various parts of the supply chain together, go a long way to bolstering CBTPA and preparing for the changes ahead in 2005 with China and quota elimination. Marketing A New WayRepresentatives of major U.S. fabric and yarn producers were well-positioned at this years summit, with 40 producers showing fabric and yarn to potential clients. Carmer Robinson, international sales representative of Tee Jays Manufacturing Inc., Florence, Ala., said, Ive been to all the recent Cotton seminars by far, this has been the best and most effective of all. With the retailers, manufacturers and piece-goods folks at the same table, at the same time weve developed new contacts and specific inquiries for piece goods. These mini-trade shows are a great opportunity for eyeball-to-eyeball contact it doesnt get any better than that.Another manufacturer commented, People are beginning to understand whats in it for them. They are looking for new things, and as contractors purchase U.S. goods, the relationships are changing. Werner Bieri, president and CEO of Buhler Quality Yarns and member of the Cotton Board, addressed the summit. In a no-holds-barred analysis of U.S. manufacturers, Bieri stated, The industry as a whole is not prepared with adequate sales and marketing strategies. They maintain a sellers-market mentality versus the buyers market that exists in reality. There is a need to build alliances with subsequent manufacturers, sourcing agencies and retailers. We need to respond in time to have goods in the factories and finally on retailers shelves.Looking to the future, Bieri stated, What we need from the government is strict enforcement of existing laws and rules with respect to transshipment and smuggling and to press forward in opening closed markets. In conclusion, Bieri, also an American Textile Manufacturers Institute (ATMI) board member, said, I fully support ATMIs call for unity, but its time to define this unity in a much broader and inclusive context.As CBTPA and AGOA gain ground, establishing new relationships, improving banking and logistics, and forging new links in the apparel supply chain are essential for these programs to work. Communication and inter-industry marketing have never been the textile industrys strong suit maybe its time for a change.What Is “Sourcing”Rodney M. Birkins Jr., JCPenney Private Brands director of sourcing, states the goal of sourcing is to drive value into the products our customers purchase. Birkins defines value as having it right:the right item;the right price;the right quality;the right size;the right color; andthe right time.Birkins sourcing decisions are based on the primary factors of economics and logistics, and secondarily on political stability and the landscape of future events all culminating with the decision drivers of low price and high speed to market.Economic considerations for Birkins include duty avoidance, wage rate, worker productivity, manufacturer overhead, quota availability and cost, textile and trim access, and transportation costs.Logistics, on the other hand, is all about speed. Birkins five logistical considerations are:inbound transit time of textiles and trim;outbound transit time of finished goods;operational efficiency of ports and customs;internal transportation; andcarrier service.For Birkins, sourcing is about achieving the right balance between economics and logistics, which in turn yields the shortest time-to-market at the lowest price.On the issue of human rights, Birkins stated, We will not do business with any entity that is in violation of local laws affecting health, safety or labor these are non-negotiable. In comments echoed by many presenters, Birkins discussed the complexity and constant change sourcing managers confront. Currency, changes in resources, trade legislation and consumer demands all effect the process.Value is not the same as cheap. Birkins emphasized that the second order is the most important order. Achieving a flow of the right goods at the right time, having the flexibility to fulfill demands as they are established at the retail level and reducing closeouts maximize the apparel retailers profitability and are the primary benchmarks of successful sourcing.Material WorldExpanding Opportunities

Material World Miami Beach, to be held October 7-9 at the Miami Beach Convention Center, promises to be the international full-package and sourcing event for the sewn products industries in the Americas.Tim von Gal, executive vice president of Atlanta-based Urban Expositions, producers of Material World, explained, The show is open to the entire sewn products supply chain. This is an opportunity to establish the relationships necessary in todays textile industry. Bringing fiber, yarn, fabric, trim, components and equipment suppliers together in one place linking manufacturers and contractors with sourcing managers and retailers. Its really a great opportunity to host the integral parts of the apparel world from design to delivery.Miami Beach, Fla., was selected as the show site because of Miamis strategic location as an international trading hub and U.S. gateway to Latin America. In addition to exhibitors and attendees from the United States, Material World draws traffic from Mexico, the Caribbean, and Central and South America. Miami is also home to many of the largest sourcing operations in the United States, according to Urban Expositions.Recently, the Arlington, Va.-based American ApparelandFootwear Association (AAFA) proposed an alliance with Material World. Our supplier members whether they provide materials, equipment or computer systems need a place to show their wares to their major customers in the Americas. The fact that our new international network of sourcing executives has fully endorsed AAFAs relationship with Material World means that they will be there, looking for new and better ways to do business and for sourcing opportunities, stated Paul R. Charron, AAFA chairman, and chairman and CEO of Liz Claiborne Inc. AAFA President and CEO Kevin Burke said, We are delighted to be partnering with the only supplier trade show in the United States held specifically for the apparel industry.In addition to presenting major fabric and yarn suppliers, Material World will offer networking events and trend pavilions highlighting Autumn/Winter 2003/2004.Atlanta-based American Apparel Producers Network (AAPNetwork) Managing Director Mike Todaro also sees an alliance with Material World as positive for all sides. Our network sees Material World as one-stop shopping in a global business. Its really a win-win for everyone involved. Material World provides a physical face-to-face opportunity for the networking the AAPNetwork does electronically on the Web.AAPNetworks Fall Meeting 02 is scheduled for October 4-6 in Miami Beach for the convenience of its members attending Material World. AAPNetwork also will host a by invitation Sourcing Manager Appreciation Reception sponsored by AAPNetwork members Unifi and Lion Brothers.For details on exhibiting at or attending Material World Miami Beach, contact Urban Expositions (800) 318-2238; or visit www.material-world.com.August 2002

Kusters Acquires Calender Division Of Kleinewefers

Kusters Aquires CalenderDivision Of KleinewefersGermany-based Eduard Kusters Maschinenfabrik
GmbHandCo. KG has acquired the textile and nonwoven calender division of KKA Kleinewefers Anlagen
GmbH, also based in Germany. All employees, as well as the technology, will transfer to Kusters.
The Kleinewefers Group has agreed to assist Kusters in any way during the transfer and in the
future structuring of the calender business.
August 2002

Bruckner Sells Range To Ratti Spins Off Division

Bruckner Sells Range ToRatti; Spins Off DivisionItaly-based Ratti, a manufacturer of printed
fabrics for menswear, womenswear and home fashions, recently purchased an Opti-Shrink compressive
shrinking range from Bruckner, Germany. Ratti is processing a wide range of fabric types on the new
range, including cotton, linen, viscose, silk, Lycra®, and fiber blends.In other Bruckner news,
Dipl. Ing. Ulrich von Christen has purchased Apparatebau GmbH, the division of the Bruckner group
responsible for the planning and production of wet textile finishing lines. Christen will change
the name of the company to Erbatech GmbH. The new organization will operate independently, but also
will cooperate with the Bruckner group to develop and sell integrated machinery concepts for dry
and wet textile finishing. Existing projects and orders will be continued by Erbatech. The Scout,
Delphin, Galaxy and Supraflor product lines also will be continued.
August 2002

Donaldson Adds Footprints To Downflo Oval 1 Line

Donaldson Adds FootprintsTo Downflo® Oval 1 LineThree smaller footprints 1-1, 2-2 and 3-3 are now available in the Donaldson® Torit® Downflo® Oval 1 line of dust collectors offered by Minneapolis-based Donaldson Co. Inc., a provider of filtration systems and replacement parts.The new systems use Donaldson Torits patented oval-shaped cartridge filter technology, which increases collection capacity by up to 25 percent over conventional round-cartridge technology. In addition, the new collectors are easy to operate, quiet and easily moved.August 2002

Army Explores Wired Textiles

Army Explores Wired TextilesThe U.S. Army Soldier Systems Center Individual Protection Directorate, Natick, Mass., and the Objective Force Warrior Technology Program Office, Communications and Electronics Command, Fort Monmouth, N.J., are developing techniques to produce textiles containing fiber optics and electric wires for use in lightweight, non-bulky, high-tech battlefield gear. Research partners include military, academic and private organizations. Projects include: integrating invisible antennae into fabric vests; developing a connector system for use in a fabric-based bus or conventional cables; exploring alternative components for flat body conformal connectors and cables; and developing a soft switch fabric for use in a fiber keyboard as part of the Land Warrior soldier control unit. Photonics Laboratories Inc. and Philadelphia Universitys School of Textiles and Materials Technology, both in Philadelphia, are developing techniques to weave or knit wires and optical fibers directly into fabric. Clemson Universitys Clemson Apparel Research, Pendleton, S.C., is using stitchless seam technologies to entrap fiber optics and conductors, and provide electronic networks within and between battlefield apparel components.August 2002

Strength And Uncertainty


G
iven all that has been heaped on the U.S. textile industry in the last year, it’s a
relief to see signs of strength. Spinners, weavers and others note their companies are sold out,
and are participating in the much-reported “work through” during the summer holidays — all
reminiscent of better times.

Industry insiders point out there may be less competition by numbers — acknowledging plant
closings of the last year — but the remaining companies are the really tough competitors. As one
executive remarked, “These are the guys who made it through, and they are not about to take a rest.
If anything, the competition is tougher, and capacity is becoming an issue.”

With signs of relief due to a weaker dollar, strong consumer spending and low inventories,
this may be the beginning of a bit of a run for the industry.

Capital spending is still soft — it’s easy to see this period as an opportunity to enjoy
some positive cash flow and hold off on investment for a while.

But some machinery suppliers see a different picture. Machinery sales are strong for some of
the larger global suppliers, many of which also felt the sting of last year’s plant closings. Much
of their capacity is sold, so delivery times are longer than you might expect. Some suppliers are
adding capacity in Asia to better service and support that market, and note service contracts are
purchased as part of package deals rather than on an “on call” basis common with U.S. mills.

The U.S. market for textile equipment is significant, but it is not the growth or volume
market offered today by Asia. Suppliers are quick to emphasize they fully support U.S. mills, and
the United States continues to have significant sales value. However, machinery suppliers are
facing pressure to compete for their share of growth in China while maintaining sales and service
to U.S. mills.

If you assume better times are ahead, it’s important to realize the U.S. textile industry
will be competing with those machines very soon. Hopefully, U.S. capital spending will pick up to
ensure productivity and product quality to meet the challenge of imports.

But there’s more to it than that — the industry must start to aggressively market and brand
its products; invest in building the network of apparel sourcing managers, and the traditional
textile industry and apparel contractors; demonstrate the viability of U.S. manufacturing to the
financial markets; and push the envelope in nontraditional textile markets.

Sounds like a tall order under normal circumstances, but keep in mind — the remaining
companies are the really tough competitors.



August 2002

Cotton Incorporated Reorganizes Global Marketing Division

New York, August 1, 2002 Positioning itself to better service decision makers in an industry that
has become more global, and to more effectively reach an increasingly discerning consumer, Cotton
Incorporated is reorganizing its Global Product Marketing Division.Effective immediately, the
companys Global Product Marketing Division in the Western Hemisphere will consist of two
departments: Americas Mill Marketing and Brand Marketing.Mike Tyndall, previously senior director
of Global Product Marketing, will now hold the position of senior director of Americas Mill
Marketing. Tyndall will be responsible for strengthening Cotton Incorporateds support of the U.S.
textile industry, as well as the companys activities in Latin America and Canada. He will continue
to report to Dean Turner, senior vice president, Global Product Marketing.Dennis Horstman,
previously manager, Global Product Marketing, has been promoted to director, Brand Marketing.
Horstman will be responsible for strengthening Cotton Incorporateds influence on national and
private label brands in the U.S, which have been identified as the critical link to todays
consumer. The department will focus on reaching branded product management to assist with their
product needs, both from a development and a sourcing viewpoint. Horstman will also report to
Turner.The two departments will continue to coordinate activities with the companys research and
consumer marketing divisions, as well as its global operations covering Europe and Asia.Cotton
Incorporated, funded by U.S. growers of upland cotton and importers of cotton and cotton textile
products, is the research and marketing company representing upland cotton, the number one selling
fiber in the world.

Gaumer Offers New Vaporizer IDH Duct Heater

Gaumer Offers NewVaporizer, IDH Duct HeaterA new vaporizer from Houston-based Gaumer Process Heaters is designed for use in process industries that use large amounts of heat at high temperatures and low operating pressures. The vaporizer maintains recirculating fluids as high as 750°F, achieving high heat-transfer rates and close temperature control when using the vapor from these fluids.The company also has introduced a line of IDH high-temperature duct heaters for use in dryer, rotary-gravure press and heat-treating applications. The heaters use heavy-duty incoloy heating elements to achieve air temperatures up to 800°F. Other features include a stainless-steel frame, potted terminals and a moisture-resistant terminal housing.August 2002

Demand Remains Reasonably Strong


M
odest mill improvement continues. Indeed, industry output is now running ahead of a year
ago for the first time in 2 1/2 years.

Zero in on broadwoven fabrics, and the figures are even more encouraging, with first-quarter
2002 activity running better than 7 percent above the previous quarter. And all fabric subgroups
except wool are sharing in the gain. A still-firming economy — bolstered by falling fuel prices,
low interest rates and high home tags — also should help in the months ahead.

These plus factors will more than offset the downward pressure of current Wall Street
turmoil. Not surprisingly, most economists remain optimistic.

A new Wall Street Journal survey of 55 top analysts puts 2002 gross domestic product (GDP)
growth at 3.5 percent. And profits, despite all the recent Wall Street financial deceits, should
continue to improve.

All this, in turn, would seem to assure more mill pickup — enough to push textile output up
another 1 percent by year’s end.

bfgraph_2187


New Positive: 2000-2010 Projections


A just-released Bureau of Labor Statistics (BLS) long-term forecast also is encouraging. The
agency sees average annual textile output gains of 1 percent over the current decade.

That’s a welcome change from the declines of recent quarters. And better-than-average
performances are seen for both the knitting mill and carpet subgroups (up 1.7 percent and 1.2
percent annually). Equally upbeat are the 1.3-percent annual gains expected for apparel.

In short, BLS analysts aren’t buying all the recent gloom-and-doom textile forecasts. The
same study also suggests good news on the productivity front.

Compare projected declines in employment with the expected production advances, and overall
textile productivity could fare even better — with the estimated annual gain put at near 4 percent.


Prices Remain Sluggish


On a somewhat less rosy note, prices continue to present some problems as competition puts a
lid

on meaningful increases. To be sure, declines of the past year or two are over. But that’s
about it.

Overall mill averages, for example, are still running about 1 percent under year-ago levels.
Equally significantly, these quotes are no higher than they were three years ago — in sharp
contrast to continuing increases in the general inflation level over the same period.

Nor is all this likely to change very soon — and for several reasons. For one, lower-priced
imports are still coming in at an impressive clip. Other price-rise inhibitors would have to
include competitive pressure from downstream manufacturers and retailers who are unable to boost
their own tags and from continuing excess capacity.

On this latter score, overall mill operating rates remain in the low 77-percent range — a
far cry from the more than 91-percent peak hit back in 1994.


Profit Data Are Revised


Worth noting for those tracking industry trends: Profit figures have been reclassified to
reflect the ongoing shift from the old Standard Industrial Classification (SIC) system to the new
North American Industry Classification System (NAICS). This had previously been done for shipments
and inventories.

One problem: Comparisons with earlier times won’t be all that easy.

Nevertheless, there’s some good news here. Fourth-quarter 2001 figures show the industry
eked out a small 0.7-percent return on sales. For 2001 as a whole, this margin figure was put at
0.4 percent — reversing the negative 0.6-percent reading of 2000. Yearly comparisons for profits as
a percent of stockholders’ equity are even more favorable — 3.3 percent for 2001 versus a negative
2.8 percent in 2000.


Fiber Costs Edge Higher


But further earnings gains could be hard to come by because of competitive pressures and
somewhat higher fiber costs.

On the latter score, raw cotton is now near 40 cents per pound — up from the 30 cents per
pound lows of late last year. Blame it on forecasts for only a 17.8-million-bale domestic 2002/2003
crop year — down 2.5 million bales from 2002/2001. Foreign crops are also expected to be lower.

But, cotton quotes are still under a year ago, with few signs of any big spike, as the
projected domestic carryover remains at nearly double that of the 1999/2000 low. There’s also been
some firming in man-mades. But here, too, hikes have been modest — with polyester staple remaining
well under year-ago levels.



August 2002

Pollution Standard Causes Problems For Textiles



NEWEPA_2242T

he Environmental Protection Agency’s (EPA) proposed standard covering toxic air pollutant
emissions is not likely to sit very well with U.S. textile manufacturers. The long-awaited
standard, as currently proposed, could have a major impact on virtually all dyeing and finishing
operations as the government moves toward its goal of achieving Maximum Achievable Control
Technology. The proposed standard would make significant revisions in the way dyeing and finishing
operations calculate the amount of hazardous air pollutants they release into the air.

At present, textile plants are permitted to calculate the fraction of organic hazardous air
pollutants they believe are actually emitted from water solutions. Under the proposed rule,
companies would have to assume that 100 percent of the organic hazardous materials entering a plant
are in fact emitted into the air.

Once the permissible levels of hazardous emissions are exceeded, companies must either
change the finishing materials they are using or modify their emissions controls, something that
could prove quite costly.

Textile manufacturers attending a recent EPA briefing on the proposed standard raised a
number of concerns about the effect of the standard. They were particularly concerned about the
permissible emission levels and the fact that the measuring period does not take into consideration
seasonal changes or product mix changes.

As is always the case with such regulations, the comment period will drag on for some time,
but textile companies need to let the EPA know of their concerns.


Flammability Regulations Overhaul Proposed


The staff of the Consumer Product Safety Commission (CPSC) is proposing a major overhaul of
its standards under the Flammable Fabrics Act, saying that the 50-year-old regulations are out of
step with today’s products and current cleaning and care practices.

In calling for an Advance Notice of Proposed Rulemaking, the CPSC said numerous new
technologies, products and modern equipment have been developed since the original standard was
issued in 1953. The staff is particularly interested in how its test methods might be updated to
reflect modern technologies, new products and consumer practices.

A Federal Register notice will seek information from the fiber, textile and apparel
industries, safety and health organizations, and other interested parties to help determine the
best ways to bring the standards up to date.


Textile Rules Of Origin Under Attack


India, which has long been a thorn in the side of the U.S. textile industry, has launched an
attack on the U.S. textile country of origin rules, and the World Trade Organization (WTO) has
agreed to consider India’s complaint. India has never liked the country of origin rules, which are
basically designed to police textile and apparel quota agreements and prevent illegal
transshipments of products made in Third World countries.

In its complaint to the WTO, the government of India contends the rules of origin
incorporated in the U.S. Trade Development Act of 2000 are “extraordinarily complex” and are
applied in an inconsistent fashion, and, therefore, are illegal under the WTO’s trade regulations.

The basis for India’s complaint is that the criteria for determining the country of origin
of silk products such as neckties and scarves are different from those for cotton and wool
products, and other types of wearing apparel and made-up goods. U.S. trade officials say the U.S.
rules are practical and make common sense, and are consistent with WTO regulations.

They believe the Indian complaint eventually will be turned down. However, if India should
prevail, the complaint could have a major impact on the worldwide U.S. textile and apparel import
quota system, which remains in effect until 2005.


Industry Fears Erosion Of Customs Inspections


U.S. textile industry officials are afraid the Customs Service’s efforts to combat textile
and apparel import fraud could become a casualty in the war on terrorism.

In testimony before the House Ways & Means Committee, the American Textile Manufacturers
Institute (ATMI) warned that the “essential mission” of the Customs Service could be weakened if
that agency is transferred to the new Department of Homeland Security.

Pointing out that illegal imports of textiles and apparel amount to “billions of dollars
each year,” ATMI said: “Any redeployment of Customs’ assets from the Department of the Treasury to
a newly-created cabinet-level Department of Homeland Security must not in any way diminish or
impair Customs’ ability to investigate, detect and interdict illicit textile and apparel trade.”

In recent years, Customs enforcement of textile and apparel imports has suffered as that
agency devoted more of its resources to the war on drugs. The Bush administration has made a firm
commitment to step up textile apparel fraud enforcement, but that effort could get lost in the
shuffle at the new homeland security agency.



August 2002

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