Interview 3- Mr. Ramesh Gosai (Textile Project Professional)

We are pleased to interview Mr. Ramesh Gosai in our third interview of our interview series. Mr. Gosai has 45 years of professional experience working in divergent capacities in various fields of textile industries. Sit back and relax while you read this engrossing interview where Mr. Gosai gets candid about his experiences and journey!

Let us take a closer look at his course of work in his own words

I have more than 45 years of Professional Experience working in different capacities in various fields of Textile Industry as follows. This shows my all-round expertise in all spears of textile value chain.

Production / Plant Management: Started carrier as Shop Floor Production Supervisor and rose to position as Director / Chief Executive Officer / Group General Manager of a reputed Groups of Textile Mills. During this span has worked in various textile mills producing silk, wool, cotton, synthetic and blended Textiles using most modern as well conventional technologies / machines of different make & models thus possessing all-round experience.

Corporate Management: Worked as Group Technical Manager with Aditya Birla Group responsible for co-ordination on technical matters between Corporate Management and Plant Management of group’s different textile mills (Total 19 Mills) located in India and abroad. Further worked with Mikado Group and Pasari Group also in handling entire corporate management activities. Recently was working as Director (Operations & Projects) in one of the Indo – American joint venture Company in India.

Technical / Management Consultancy: Worked as Senior Scientific Officer and Head of Department in Government sponsored research organization (BTRA) providing technical consultancy/trouble shooting services to various textile mills of country. Was also responsible for carrying out applied research and process development activities in the field of Weaving Technology and Machines.While Working with GHERZI, apart from Design & Implementation of Textile related projects, was also active on various WORLD BANK sponsored strategy development projects thus has very wide outlook towards project planning, implementation and strategy development ultimately to achieve the targeted growth.

Work Experience in the countries: India, Thailand, Philippines, Indonesia, and Cuba

Also traveled extensively world over to attend various Textile related Conferences, Exhibitions and visited some of the best Textiles plants of the world to study their working style & systems. This has changed my working style and made strong believer in working with specific result oriented objectives & Systems.

Social activities for Textile Industry:Have published many technical articles in reputed textile journals, read papers in National and International Seminars / Conferences and was Author / Co-author of two books published by Bombay Textile Research Association (BTRA) on the subject of Machinery Maintenance.

I am also active with Textile Association (India) as Patron Member and in past occupied honorary positions like all India General Secretary as well Vice Chairman. I was on board of advisor for reputed textile magazines like Asian Textile Journal, member of editorial board of Express Textiles. Also occupied honorary position as advisory committee member of BIS, CII-Western Region, IL&FS-Textile initiative for many years. During drafting of TUF policy, was involved as advisor to the office of Textile Commissioner, Ministry of Textiles – GOI and currently on advisory panel of Ministry of Textiles – GOI.

Currently operating WhatsApp group “Textile Professionals” for knowledge enhancement of Textile Professionals where members share textile industry related news, their expertise knowledge, experience and views on various issues creeping up related to Textiles.

1-How will you frame your journey in textile right from your college days to the present day?

Answer: College days were fantastic with full of all type of naughty acts, but unfortunately our college was ‘BAJARANGI’ college as during those days (early sixties) no girls were opting for engineering studies.

Talking about initial days of professional career, working at first stage as production supervisor in loom shed, were unique, full of tension, but challenging too. Had lots of problems in dealing with some adamant and age old workers like fitters, jobbers, worker union leaders (Textile Industry is more labour oriented). There was also lot pressure from bosses to give the results. कहते है ना सुडी के बिच सुपारी जैसी हालत़. But this situation made me to find out the ways for survival and first thing I thought was how to control those workers and way was, I have to prove that I know more than them about machines and technical aspects. So first thing I learnt was engineering aspects of machines, their functional principles, how to repair them and relationship of each mechanism with principles of textile (weaving) technology. Second I understand labour laws so can take due legal actions on mischievous workers. Third I started learning labour psychology and reason why they tend to misbehave. Thus my task of controlling labour and obtaining desired results from them was made very easy and I could get due success at first stage of professional career. Normally many people fail at this stage and leave career as plant production professional and opt for marketing or other such type of carrier.

To get further elevation on higher position, I need to understand working of allied sections like weaving preparation, spinning, fabric processing, production planning/quality management, utility management, material management etc…to reach to the position of production head.

Then to become factory/profit centre head, learning of commercial aspects like costing, marketing/purchases negotiations, inventory and cash flow management, MIS, company laws, factory act etc. were must.I learnt all those aspects by keenly observing working styles and carrying out some task by self of bosses.

In nut shall practical knowledge, ability to learn new things, analyzing and understanding/learning from bosses working style is must for success in professional career.

2-What turns out textile as an unique branch in contrast to other branches.

Answer: Textile is unique as well very complex industry in many ways. It has very long process chain/batch process with lot different type of raw material / finished products each demanding entirely different process and technological parameters. It is highly labour oriented with lots of human interfaces affecting ultimate end results. It requires involvement of all (Mechanical, electrical/electronic/instrumentation, air, atmosphere, human) branches of engineering as well physics (fiber and motion) and chemistry (Sizing, fiber/yarn/fabric processing) too. It is technology (spinning), science (processing) and art (weaving/knitting & garmenting/making up) also. To say on a lighter side, I am dreaming some innovator will come up with machine where on one side you feed fibers and on other side ready to wear shirt/pant will come out, which will automatically take care of all required process parameters as fed in to the computers attached to the machine.

It is evergreen/much more fashion oriented industry slowly moving towards intelligent wears. Further and particularly with more and more advancement in all 12 branches of technical textiles and non woven’s, it will become must industry for all other industries.

3-What changes or elevations you have witnessed in your course of journey from conventional era to unconventional era vis-a-vis with textile industry.

Answer: When you talk about conventional era, it is:

A)Conventional manufacturing technology/machinery:Here there was no automation, all manual handling, use of very conventional technology. This was requiring huge man power / human interfaces. End results, very poor productivity, low product quality, high material wastage thus supervisor’s ability to control human was of more importance against his technical knowledge. At that time, we used to say, who can sought at workers using top of his voice with all type of nasty words, is more successful supervisor. Principles of pendulum was more used.

B)Conventional way of running industry/doing business:Here more importance was how close and trusted you are to your bosses then your knowledge. Judgments and decisions were made using experience rather than data analysis and testing’s. Hire & fire was more prevalent. Bosses words were final. Appointments were more on reference over merits. Business owners were considering themselves knowing everything. Businesses were more done on trust and relationship. MIS were mainly based on collection of confidential information through trusted peoples. Business owners were happy in producing easily marketable items.

Unfortunately in India, +90% of textile production is still produced by decentralized manufacturing sector and they continue to follow this conventional type of business style.

Unconventional era is now in practice at many places where they believe more on modern automatic manufacturing technology, trying unconventional but high profit yielding products, using modern & scientific techniques of running business. Adopting more professionalism and confidently facing challenges.

Normally you have two types of business models:

One is “Low per unit price but high volume”. Majority of our textile companies prefer this business model as it is easy and less risky.
Other one is “High per unit price but low volume”. This model requires constant R & D and innovations in product portfolio, bit risky (due to many copy masters in industry) but give better profitability. Now a day’s many people started adopting this business model.

4-How do you think digitization has played its part to cause a transformation as far as textile industry concerned?

Answer: Yes and major reasons are:

Modern machines are more equipped with microprocessor based controls and operating systems
Easy availability of modern digitalized MIS systems (easily linkable with microprocessor systems of modern machines) capable of giving quick analysis on behavior of man, machine, material thus trouble shooting and adoption of remedial measures became quick and easy.
Record keeping is easy with quick analysis.
More adoption of internet based B2B & B2C business models.
Savings on manpower and quick results.

All those together are changing style of doing business in to unconventional way and are going to help industry on large way. But again unfortunately, our decentralized manufacturing sector is very slow in adopting it. Main reason is they still believe in secrecy of business and transactions.

5-In your opinion what culture should industries adopt for improving employees life?Answer: Get away from hire & fire policy. Develop transparent relationship. Invest on skill development. Motivate performers and treat them as important part of company. Provide equal opportunity of growth and help them to excel in their performance. Follow modern HR systems. .

6-What suggestions would you like to give to the budding entrepreneurs who are striving to do well in textile field?

Answer: Change style of doing business which your ancestors were following. Adopt more of professionalism than family run type business.

Don’t think you know everything and don’t hesitate to take help from expert consultants like me.
Get away with word ‘Secrecy’. Don’t work as competitor but be a complimentary.
Follow modern management practices and make use of all such available tools.
Higher capable professionals and keep trust on their knowledge.
Be a thinker, planner & policy maker. Leave execution jobs on professional managers / technocrats.
Do ethical business, think on long term goals, work with strategic planning.
Concentrate on product R & D, think of value added/alternate product.
Regularly invest major portion of profit for business development as well creating reserves for future calamities.

7-How should a young textile engineer refine his or her technicalities for better career in textile?

Answer:

Do your own SWOT analysis and choose your field accordingly.
Make your own carrier planning and develop strategies to achieve that growth in carrier.
Be a master in your chosen field so no one can question your ability. (Please go through my answer on question no. 1). Keep faith in your capabilities and always think that I can do it & will do it.
Keep on reading various textile magazines to keep your knowledge updated on various research / developments taking place as well various happenings going on in industry.
Choosing right company and having right boss can help you lot to grow.

8-Can you share your views on textile curriculum in textile institutes

Answer: Yes. According to me lot has to be done on this issue.

Omit teaching age on old technology and ancient machines. Concentrate more on modern technology and machine. Teach machine repairing also as practical’s.
Teach basics of Mechanical, Electrical / Electronics / Instrumentation, Air, Humidification / refrigeration engineering.
Teach basics of labour laws, company laws, industrial economics, product costing etc…
Induct some lectures on modern problem solving techniques like Just in Time, Zero Defects, Quality Circle, Industrial engineering, statically data analysis & trouble shooting.
Regularly (at least one lecture per month) invite professional technologist / industry experts every time from different field, as guest lecturer to share their experience, problem solving techniques (Not to talk on technological/machinery developments as knowledge about this is available in books/machines broachers). Such lectures should be followed by question answer session.
Organize regular industry visits of students. For every visit choose different industry sector. During such visit allow students to interact with management and technical persons of visiting factory. Dedicate one question paper based on such industry visits during exams.
Devote one/two semester for internship (paid or unpaid) in industry for practical training and also student to get feel of industry culture. On this too there should be one question paper in exam.
Academic institutes must regularly interact with expert professionals and industry owners, take their feedback and suggestions for fixing textile curriculum and make corrections accordingly. This should be done at least every 3 years.
Most importantly, teaching faculty must have minimum three years practical industrial experience working on shop floor.

9-As per you, where do students lack post joining the industry.

Answer: There are many areas.

Knowledge about modern technology and machines.
Knowledge about new products, new raw material and their physical relationship.
Knowledge about machine designing and their relationship with material being processed on them.
Knowledge about industrial environment.
Worker’s behavior, ways to tackle them and their psychology.
Basics about industrial economics and relationship with performance.
Basics of labour laws, company laws and their impact on their industrial functions.
They must understand working at shop floor is not white color job but it is more a blue color job. They must learn machine repairing also.

Majority of these issues I have discussed in my answers to question no.1 & 8.

10-Students often opt for marketing rather than production as regard to jobs. What can be done to change this scenario so that the young textile engineers favour production too.

Answer: Marketing, R & D, academic carriers are white color jobs so they are more preferred.

Production/shop floor jobs are blue colored but more dynamic, challenging but offering very high rewards too. My answers to question no. 8 & 9 as well write up about my career graph, if properly understood they will willingly opt for it.

11-How can learning textile made more compelling so that young minds gravitate towards textile and consider it as a career option?

Answer: For this industry and textile academicians should work together. Academician should give what industry needs and industry should start respecting textile professionals and work for making their industrial career more rewarding.

Hopefully more and more industry owners switching to modern management styles, scenario will change.

12-According to you how will the post COVID-19 situation give rise to different opportunities?

Answer: Post COVID-19, peoples buying and spending pattern will change but of course they will not stop buying cloths. More preferences will be given to cloths/textile items which give better protection against virus and bacteria. Cloths with antibacterial / antifungal / stain repellant finishes will get preference. Demand for medical textiles will grow. May be demand for one time use type clothing’s too come up. You must be seeing many textile companies like Arvind, Vardhman, Trident etc… have already entered in manufacturing of such items.

So far online buying of clothing is concern, I do not see much big change as clothing is item where buyer want to see look/design/colour by own eyes, feel comfort / smoothness by touching it / try fittings before buying so normal buying pattern will more over continue.

As far China factor is concerned, some export demand will increase as replacement to China from Europe/USA/Japan but who will get major portion of cake is to be seen because Vietnam/Indonesia/Bangladesh type countries will offer stiff competition to Indian textile industry.

13-To sum up this interview, what advice would you like to give to our readers?

Answer: Textile is and going to remain evergreen industry, may have some peaks and valleys but it is common for all. Yes some week company may die but new entrants will fill the gap. Indian textile industry is facing this pattern successfully from 1958 so no need to worry. Fittest will survive and get advantage of opportunities.

Technical textile and non woven sector will have more opportunity compared to apparel clothing manufacturers.

For aspirant ready to start professional carrier, my special advice is:

Get internship / initial training in best company so you will learn best practices and systems. Try to get maximum practical knowledge.
Here I would like to share experience of my six month unpaid internship. During the period, I was instructed on very first day to be ready to soil my cloths. During this period many times I was asked to clean, lubricate, repair the machines and operate them for full shift as machine operator. This type of training was given almost on every type of machines and in every department of spinning and weaving. My every act was strictly monitored & was taught corrections where I did mistakes. At that time was feeling humiliated but later during actual professional carrier, realized how important role that training played in my carrier.
Start your carrier with worst company so from initial stage itself you will face/experience all type of problems and will learn ways to find solutions.
Settle in company who can offer better carrier planning and growth opportunities, have policies of employee’s skill enhancement and bosses who are ready to teach you.
Don’t hesitate to change company if you find no growth and learning opportunities. But also be sure not to change company without sufficient & convincible reason otherwise you will be labeled as rolling stone. No company will prefer rolling stone.
For any task given to you, don’t say no but yes demand what extra training, support and time limit you will need to satisfactorily complete the task.
So far possible, on job keep your mouth shut but eyes and ear open (See & think, listen and learn but speak out anything only if you have understood the matter and have something concrete to offer).
If are faced with any problem don’t run away from it but try to find out solution by asking yourself these question: a) when problem was arised? b) how it was arised? c) why it was arised? d) what happened when problem was arised? e) what I did so problem arised? If you can find out honest answers of all these questions, you will automatically find the solutions too.
Your grade in final exam and your qualification can help you for initial entry in profession but for rest, it will be your capability, your confidence, your way of working, your learning skills, your problem solving skills, your reputation as achiever and finally how strategically you plan your carrier growth will only help you to reach at top.
Be a showman and learn how to show cast your on job achievements & convey them to the topmost authority of company

GRATITUDE:

I am thank full some of Textile and industry Experts under whom I had privileged to work and really they well guided me, taught me, helped me to grow in my professional carrier of coarse they all are tough task master.

Late Mr. H D Patel my supervisor during internship.
Late Dr. S M Betrabet / Late Mr. C V Modi, both of BTRA giving due shape to my carrier by giving all tough assignments and introducing me to industry.
Dr. S B Agrawal-Textile SBU head at Aditya Birla group, for teaching me management & commercial principles thus converting me from Textile Technologist to Techno-Commercial Manager. Specially I respect him because even after retiring from professional life, he continue to learn and obtained his doctorate degree at the age of 79.
Dr. Marco Gherzi / Mr. Gussepe Gherzi (father & son) Owner of Gherzi Textil Organisation-Switzerland for Trusting on me in deputing me to World Bank as well allowing me to work freely on some most prestigious consultancy assignments.
Lastly but most importantly Late Mr. Aditya Birla for all time forcefully throwing me in tough sea of challenges allowing self sweeming to reach shore, way of generating my own confidence on my own capabilities.