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ABSTRACT
This paper will provide the overview of the factors likely to affect the competition in the global
yarn market related to yarn production and consumption. This report examines research, trade
literature and government statistical reports regarding the yarn production, exports and imports,
movement of machinery, preferential trade agreements and yarn consumption. To conclude, the
trends in yarn production and consumption in different regions will be identified. Ad ditionally,
this study will provide the factors that should be considered for the yarn industry to stay
competitive in this globally dynamic yarn market.
Keywords: Yarn Production, Yarn Consumption, Global Dynamics, Competitiveness, Imports and
Exports
According to Bair and Gereffi Since the late 1990’s, East Asia has
(2002), the first migration of apparel become an apparel production complex, and
production was from North America and other major regions were consolidated to
Western Europe to Japan in the 1950’s and become regional apparel complexes, such as
1960’s. Since Japan turned its interest to the Americas and Europe. The reason lies in
more profitable products such as cars, the trade-off between labor costs on the one
stereos and computers, and the Japanese hand and the need for market proximity on
textile and clothing sector lost 400,000 the other. Because time-to-market and the
workers (Catholic Agency For Overseas need to response of short-cycle production
Development (CAFOD), 1998). As a result, are beginning to impact competition in
the second supply shift of apparel retail, apparel and textile channels, three
production took place in the 1970’s from global regions are emerging: 1) the United
Japan to the Asian Tigers – South Korea, States plus Mexico and the Caribbean Basin;
Taiwan, Hong Kong and Singapore. The 2) Japan plus East and South East Asia; and
trend of relocation of production did not 3) Western Europe plus Eastern Europe and
stop there, and in the 1990’s the textile and North Africa. Each of these regions includes
apparel industry had been dominated by the both advanced economics and developing
final wave of exporters, which include areas that are close to consumer markets
Bangladesh, Sri Lanka, Pakistan and (Abernathy et al., 1999) that might give the
Vietnam (Dicken, 2003). While China was benefit when the manufacturing system give
the principal beneficiary of the shift (in less the quick response.
than ten years from the late 1980’s), China
became the world’s major producer and The creation of the EU and the
exporter of clothing (CAFOD, 1998). North American Free Trade Agreement
During the 1990’s, the relocation in (NAFTA) has led to the imposition of
production moved towards the Americas, preferential tariffs within regional markets,
which was focused on the United States, which has generated a major shift in global
Mexico and the Caribbean. sourcing dynamics (United Nations
Industrial Development Organization
Article Designation: Scholarly 3 JTATM
Volume 5, Issue 4, Fall 2007
(UNIDO), 2003). Furthermore, US apparel world of textiles. The six main drivers in
and home textile operations will continue to textile industry today are as follows:
move offshore, to lower cost locations, due
to further downward pressures on prices Labor costs
through trade liberalization and the need to The driving force of transition in the
be closer to major apparel manufacturing textile business is competitive advantage.
centers (Kilduff, 2005). However, domestic One component of competitive advantage is
operations will continue in innovation to labor; labor cost has driven the textile
produce leading edge products, while the industry to sourcing products from
brain function of design, marketing, developing countries. Similar to other
operations management and related industries, the hourly labor cost is one of the
functions will remain centered in the USA major factors that impact competitiveness.
for the future (Kilduff, 2005). According to a Werner International (2005)
newsletter, Switzerland has the highest
Global Dynamics hourly labor cost. Japan has dropped from
the first place in 2000 to the third place in
Globalization is creating a growing 2004 (see Figure 2). Several countries
level of interconnectedness and competition positions have changed, due to the changes
in the world economy, and geographical in the exchange rate of the United Stated
clustering of activity is an important way in Dollar. When compared to those in 2003,
which firms and localities deal with these there is not much change in the low labor
pressures (Dicken, 2003). As a result, wage countries of ranking: the lowest labor
extraordinary changes are taking place in the costs are noted in Asia, with Sri Lanka,
Vietnam, and Pakistan.
40
35.33
35
30 27.77 27.69
25
$US
18.61
20 15.78
15
10 7.1 6.21
3.8
5 2.88 2.86 2.83 2.19 1.97 1.29 1.18
0.67 0.55 0.48 0.46 0.37 0.28
0
Chian Mainland
Hongkong
Switzland
Colombia
Thailand
Indonesia
Argentina
Germany
Brazil
Sri Lanka
Mexico
Vietnam
Turkey
Malaysia
India
Pakistan
Canada
Japan
S. Arfica
S. Korea
USA
Figure 2. Average cost per operator hour comparison in the primary textile industry ($US) in 2004,
selected countries
Source: Werner International. (2004). Primary Textiles Labor Cost Comparisons Winter 2004/2005.
Reston, VA: Werner International, Infotext Division.
Note: Employee benefits are not included [U.S. Department of Labor. (2005)].
% Share of
Selected countries Asia & Oceania (b)
China ( Mainland) 5,422.5 6,575.7 10,976.6 21.3 66.9 64.0
India 1,834.0 2,290.0 2,147.2 24.9 (6.2) 12.5
Pakistan 1,210.5 1,706.7 2,106.2 41.0 23.4 12.3
% Share of
Americas
United States 2,012.4 1,906.2 1,052.2 (5.3) (44.8) 44.1
(a) Asia & Oceania represents 19 countries; China, Hong Kong, Taiwan, Australia, Indonesia, Japan, Korea, Malaysia,
Philippines, Thailand, Vietnam, Afghanistan, Bangladesh, India, Myanmar, Pakistan, Sri Lanka, Iran, Israel.
(b) Three Asia countries represents 88.8% of the total share of Asia & Oceania.
Source: International Cotton Advisory Committee (ICAC). (2004). World Textile Demand. Washington, DC:
Author.
21,000
19,000
17,000
15,000
1995 1997 1999 2001 2003 2005
America, North
6%
Asia/Oceania
75%
Other countries
2%
Europe, other
(Turkey)
5%
10,000.0
8,000.0
6,000.0
4,000.0
2,000.0
0.0
1997 1998 1999 2000 2001 2002 2003 2004 2005
40 26
20
20 9 8
US= 100
0 2
0
-3 0
-9 -6 -6
-20 -14
-40
Brazil China India Italy Korea Turkey
Figure 13. Cost inde x for ring and rotor spun yarn compared to the U.S. yarn cost in 2003
Source: ITMF. (2003), International Production Cost Comparison. Zurich, Switzerland: International
Textile Manufacturers Federation.
600
Million of Dollars
400
200
-200
-400
World Canada Mexico China _CBI _ASEAN _EU15
United States’ imports of cotton yarns yarn (see Table 2). Mexico and Canada
continued to rise during 2000-2004. continued to occupy second and third place
Together, the leading ten suppliers to the in 2004, followed by Brazil at number four,
United States accounted for 90.3% of U.S. and Indonesia at number five. Thailand,
imports of cotton yarn in 2004 (see Table 2). South Korea and China moved up the
Pakistan, Indonesia, and Brazil are gaining position to be the eighth, ninth, and tenth
new market share in the United Stated place respectively in 2004 (these countries
market. Pakistan currently is the U.S.’s ranked the twelfth, twenty-seventh, and
largest supplier of cotton yarn with a 32.8 fourteenth place in 2000).
percent share of total U.S. imports of cotton
Table 3
Machinery Shipments
The textile machinery shipment report represents one of the most essential sources of information
that can be used to judge the likely future migration of the textile industry globally. This information
helps companies to better focus on investment decisions and to formulate company strategies (Burgi,
2005). There was a small amount of growth in overall shipments of short staple spindles in 2004 (see
Figure 7). The decline in overall shipments reflected uncertainty among buyers because of the elimination
of quota in the beginning of 2005.
Spindles (Thousands)
8,000
7,000
6,000
5,000
4,000
3,000
2,000
1,000
0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
year
AMERICA, NORTH ASIA&OCEANIA EUROPE,WEST TURKEY
Table 4
Source: ITMF, International Textile Machinery Shipment: 2003-2004[Data file]. Zurich, Switzerland: International
Textile Manufacturers Federation.
China and India were the major movements showed a time lag in shipments
countries investing in short staple spinning. (see Figure 8 and Figure 9). According to
For the ten-year period (1995-2004), China analysis by region, the shipments of
was the biggest investor, taking almost 29% spinning and weaving machinery to Asia &
of world purchases. India accounted for 25% Oceania were increasing, while those to
of the total (Anson & Brocklehurt, 2005). North America were decreasing. This has
implications for sourcing of material since
Comparison shipments of short staple one key to diversity of manufacture is the
spinning and weaving machinery to different availability of variety of raw material close
regions, 1995-2004 to the spindle point and then yarn production
close to fabric forming units. It is
The shipment of short staple advantageous for the weaving manufacturers
spinning machinery moved following the not to have the cost burden of transporting
shipment of weaving machinery during the yarn long distances (Dinsdale, 2004).
last ten–year period (1995-2005), but these
(Thousands)
70
Weaving
Spinning
60 6,000
50
40 4,000
30
20 2,000
10
0 0
1995 1997 1999 2001 2003
YEAR
Weaving Spinning
Figure 8. Shipment of short staple spinning and weaving machinery to Asia & Oceania
Source: ITMF. (2004), International Textile Machinery Shipment: 1995-2004[Data file]. Zurich,
Switzerland: International Textile Manufacturers Federation.
The shipments of short staples that covers most of the world's deliveries of
spinning to North America in 2000 showed textile machinery, based on data supplied by
exception data (see Figure 9). In 1999, the some 120 manufacturers of spinning, draw
overall of shipments of short staple spindles texturing, weaving, and knitting machinery.
to North America dramatically increased, These manufacturers represent almost all of
while the weaving shipments have decreased the world’s output. Coverage was expanded
since 1997. These causes can be the lag time significantly in 2000 by incorporating data
of data reported to ITMF, or this may be the from more than 25 Manufacturers in China
increased number of countries that applying China market and the international
participated in this report. According to the market. Delivery data for 2000-2004 is
World Textile and Apparel Trade and therefore not strictly comparable for the
Production Trends (2005) report, these previous year (Anson & Brocklehurt, 2005).
changes might be due to ITMF’s survey data
(Thousands)
(Thousands)
Weaving
Spinning
7 350
6 300
5 250
4 200
3 150
2 100
1 50
0 0
1995 1997 1999 2001 2003
Year
Weaving Spinning
Figure 9. Shipment of short staple spinning and weaving machinery to North America
Source: ITMF. (2004), International Textile Machinery Shipment: 1995-2004[Data file]. Zurich,
Switzerland: International Textile Manufacturers Federation.
50
40
30
20
10
0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
60%
50%
40%
30%
20%
10%
0%
1999 2000 2001 2002 2003 2004
Figure 11. World consumption of raw materials in the short staple system by main fiber types,
1999-2004
Source: ITMF. (2004), International Textile Machinery Shipment: 1995-2004[Data file]. Zurich,
Switzerland: International Textile Manufacturers Federation.
Europe, Others
6% Africa, 3%
America, North
Europe, West
9%
3%
Europe , East
2% America, South
6%
Figure 12. Regional distribution of world cotton consumption in the short staple system, in 2004.
Source: ITMF. (2004), International Textile Machinery Shipment: 1995-2004[Data file]. Zurich,
Switzerland: International Textile Manufacturers Federation.
Global trade has seen a sharp increase Technology and innovation factors
in Regional Trade Agreements (RTA’s) over The trend in labor cost is considered a
the past decades. The increasing trend of less important factor when compared with
RTA’s will continue, with 51.2 % of world productivity. For example, comparing
merchandise trade occurred under the productivity in each spinning type, a rotor
umbrella of RTA’s (Singhal, 2004). These frame can produce the same yarn 7.5 times
trade agreements are increasing due to many faster than the ring frame. An air jet frame
driving forces, such as gains from trade over can produce 13.75 times faster, and a Vortex
the competition, movement to eliminate frame can produce this yarn 18.75 times
terrorism, which bring attraction for foreign faster than ring frame (Dodd, 2000). Over
direct investment, and more bargaining the past 15 years, yarn and fabric
power at multilateral negotiations. manufacturing mills have average annual
efficiency gains of 5.2 percent and 4.4
The United States (U.S.) is seeking percent, respectively. As spinning producers
to increase Bilateral Agreements (see continue to invest in new, increasingly more
Appendix B), and is aggressively efficient and sophisticated equipment and
negotiating agreements (see Appendix C). processing techniques including automation,
The U.S. has been busy over the past five this can hold down the relative costs per
years attempting to increase the number of textile worker. Costs per unit of output have
Free Trade Agreements (FTA’s) with been falling about 1 percent each year since
trading partners and the Bush administration 2002 (Reichard, 2006). The productivity in
is particularly interested in establishing a different processes of spinning will have an
Middle East FTA by 2013. So far, FTA's important role in determining the future
have been concluded with Jordan, Morocco strategies in the spinning industry, with
and Bahrain, with Oman not far behind. consolidation of capacity in one region, and
Negotiations are currently underway with into particular countries.
the United Arab Emirates while Egypt has
entered into preliminary discussions laying Important technological developments
the groundwork for full-blown FTA are aimed mainly at raising productivity,
negotiations (EmergingTextiles, 2006). improving quality and control, and making
manufacturing more environmentally
Rule of Origin is the example of friendly. Innovation in new products is
FTA’s for the textile sector. Textiles and expected to increase, due to the fact that
apparel will be duty-free and quota-free customers today are becoming more
immediately if the products meet the individualistic as there is an increased
agreement’s rule of origin, promoting new demand for customized clothing, either
opportunities for U.S. fiber, yarn, fabric and through niche differentiated brands or
apparel manufacturing (The Office of the made–to–measure garments (KSA, 2004).
United States Trade Representative, 2006). There are growing numbers of eco-friendly
The FTA with Peru is a good example of concerns in many countries, for example,
this. Rule of origin is generally based on the cotton yarn produced without the aid of
yarn forward standard, thus encouraging pesticides and chemical washes (Reichard,
production and economic integration 2006). Therefore, it is significant for
between the United States and Peru. This manufacturers to consider environment-
agreement is specially designed to eliminate protecting issues and to develop innovative
the use of the material from strong new products that will gain more demand in
exporters, such as China (EmergingTextiles, the future.
2006). Therefore, it cannot use cheaper
imports from other countries (such as
Article Designation: Scholarly 21 JTATM
Volume 5, Issue 4, Fall 2007
According to World Markets for Spun MA: Harvard Center for Textile
Yarn: Forecasts to 2010 (CIRFS, 2001), and Apparel Research.
world yarn production will continue to rise, Anson, R. & Brocklehurt, G. (2005, July).
but production will shift to developing World Capacities and Shipments of
countries, mainly in Asia. U.S. exports of Textile Machinery. Textile Outlook
cotton yarns to the CBI region will increase, International, pp.135-170.
due to the advantage of their preferential Bair, J. & Dussel, E. (2004). Global
trade agreements. Spinning manufacturers, commodity chains and endogenous
as suppliers, who are geographical close to growth: Export dynamism and
the end market (e.g. Caribbean Basin for the development in Mexico and
U.S.; Eastern and Southern Europe and Honduras. New Haven: Yale
North Africa for the EU) will maintain a University.
significant advantage over China in terms of Barrie, L. (2005). Prospects for the textiles
“speed to the market” providing that the and clothing Industry in Guatemala.
suppliers can meet all the customers other Textile Outlook International, pp.
needs. Developed countries should move 13-44.
their yarn production to the high value- Burgi, T. (2005). Dawn of a New Era.
added products, so they can stay competitive International Textile Manufacturers
with differentiated products. Federation (ITMF) Annual
Conference Report 2005, pp. 7-9.
Footnotes Catholic Agency For Overseas Development
(CAFOD). (1998). The Asian
1
Yarn-forward Rule of Origin: Parties garment industry
agreed to a “yarn forward” rule , meaning and globalization. Retrieved
that only apparel using yarn and fabric from September 1, 2005, from
the U.S., Central America nations and the http://www.cafod.org.uk/policy/gar
Dominican Republic qualifies for duty-free ment_industry.shtml.
benefits. Other parts, trims and findings can Chesnutt, J. (2006, January). Working
be from any CAFTA country. together for textiles, Textile World,
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2
Short Supply: Certain specified typed of Chiron, C. (2004). An overview of apparel
yarns and fabrics, which cannot be supplied and textile quota, tariff and trade
by the US industry in commercial quantities agreements. Retrieved January 15,
in a timely manner, can be sourced from 2006, from http://www.hctar.org.
third countries. (Office of the United States Cole, M. (2004, September 30). Apparel
Trade Representative, 2005) industry cautiously equips for global
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Appendix B: Bilateral Free Trade Agreements between United States and other countries
(negotiations completed or already in force)