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Chinese wool textile mills: economic analysis of fibre-input/textile-product selection and new processing technologies
Project ID
ASEM/1998/060
Project Country
Commissioned Organisation
University of Queensland, Australia
Project Leader
Dr Colin Brown
Colin.Brown@uq.edu.au
Phone:
07 3365 2148
Fax:
07 3365 9016
Project Budget
$799,378.00
Start Date
01/01/2001
Finish Date
31/12/2003
Extension Start Date
01/01/2004
Extension Finish Date
31/12/2004
ACIAR Research Program Manager
Dr Ken Menz
Related publications
Overview Objectives
The overriding goal of this project was to improve the long-term viability of Chinese wool textile mills through adaptation to the changing market and policy environment and improvement to the efficiency of operation. The project aimed to improve mill viability through its recommendations on mill fibre-input/textile-product selection and effluent treatment technologies.
Project Background and Objectives
China has the largest wool textile industry in the world, contributing 80 per cent of the growth in world wool consumption in the 1980s. However, recent economic reforms and market developments have posed major challenges to the viability of most Chinese wool textile mills.
The mills are under pressure to become more competitive, to introduce better enterprise management and to improve their environmental standards. Yet in many cases there is a lack of both the decision tools and skills needed to improve management practices.
Understanding the different impacts on mill profitability, for example, has the potential to improve dramatically mill pricing strategies for their outputs and purchase strategies for their fibre inputs. There is also a need to introduce improved scouring efficiency and discharge systems to meet new environmental standards.
China is Australia's largest market for raw and semi-processed wool, accounting for one quarter of Australia's wool exports. In 1997, some 53 per cent of China's wool imports came from Australia. Wool and wool textiles are also the major trading items between China and Australia. These statistics emphasise the economic importance of the continued viability of the Chinese textile industry to both China and Australia.
Progress Reports (Year 1, 2, 3 etc)
Year 1:
2002 was the middle year of the project and so involved building upon what had been achieved during the first year. Fieldwork was conducted in Xinjiang, Shandong, Jiangsu, Gansu and Beijing for a period of around 9 weeks. Raw field work reports are attached. (These raw reports are records of interviews and are intended for research purposes of the Project Team only as they contain unedited sensitive information and also requires significant cross referencing to other reports and checking before they can be used in research analysis. Because of their commercially sensitive nature, field reports of mills visited are not included). Progress was made in all four sub-project areas as outlined below.
Sub-project 1, which involves the development of a mill model and the use of that model to analyse various mill decisions, is at the core of the project. It is also the most difficult of all the sub-project areas as it involves the collection and use of highly sensitive mill information. In 2001, mill visits were used to understand mill systems and to identify how the model could be designed to be of maximum use to mill managers. Two major issues were identified and then confirmed over visits to 13 mills in 2002 fieldwork. First, information, accounting and management systems of the vast majority of mills visited are very rudimentary. Therefore, the mill model can make a very large contribution if it can help mills manage information and make decisions in systematic way (in areas such as pricing, input purchases, inventories, cost controls etc.). Second, with only one exception, mills have no experience or skills in analyzing their own information to derive vital management indicators (and especially cost and yield co-efficients).
In 2002, progress was made in developing the mill model in way that will be user-friendly and useful to mill managers. The aim of analysing mill data first involved gathering highly sensitive data, only possible by building up trust between all parties (mills and researchers) on the basis that the research would be of great use for the mills and that the data would be used only for the purposes intended. Ultimately a relatively large number of mills were interested in participating. However, it was decided to focus on a few select mills that keep detailed and disaggregated information. After developing a solid modeling framework with these mills, it could then be extended to the large number of other interested mills or tailored to suit the needs of specific mills at a later stage in the Project. The focus on a few select mills was also necessary because the disaggregated data often required considerable and time-consuming re-organisation to be in a form suitable for analysis. Data analysis was conducted in the second half of 2002 and is still in progress.
Collection of the data and detailed discussions with mill managers also allowed for the rigorous development of the model in a way that would be most suitable for mills and aligned with existing information systems at the mills. Development of a detailed core model occurred between August and November on return from the fieldwork. The model was developed as a visual basic model embedded in an Excel spreadsheet. The model will undergo much further development as well as validation back at the case study mills in 2003, but is at a stage where it can run basic mill scenarios.
Progress was also made in sub-project 2, especially in relation to understanding domestic wool textile marketing channels and their user preferences. This included visits and analysis of fabric wholesalers and fabric markets. Information on customer types, product attributes and prices was also gathered from mills. Although the research team have a good understanding about the marketing channels and preferences, this sub-project is still in progress.
Of all the sub-projects, most progress to date has been achieved on sub-project 3. From the fieldwork in Xinjiang, the research team gathered complete and detailed information on domestic wool marketing and supply chains. They were also able to conduct a comparative analysis based on fieldwork they conducted on wool marketing in Xinjiang ten years previously. The fieldwork debunked some popular myths that were appearing in the Australian press at the time of the fieldwork (including China's capacity to expand high-quality fine wool production). A very important side benefit of the fieldwork in Xinjiang was that it was able to bridge the information gap between mill buyers and wool producers in some tangible ways. Although much has been achieved on sub-project 3, it is still intended to conduct fieldwork in Inner Mongolia to compare and contrast developments there with other pastoral regions.
Considerable time and resources in 2002 were also devoted to sub-project 4, namely an analysis of the imported wool supply chain. Interviews with a wide variety of participants including wool traders, wool buyers, inspection agencies, port and customs authorities and other agencies was carried out. Although many of the problems and issues have been identified, this sub-project is still in progress.
In summary, progress has been made in all sub-projects but especially in the all-important sub-project 1. It is hoped that this progress will allow for detailed specific analysis in the final year of the project in 2003.
Year 2:
2002 was the middle year of the project and so involved building upon what had been achieved during the first year. Fieldwork was conducted in Xinjiang, Shandong, Jiangsu, Gansu and Beijing for a period of around 9 weeks. Raw field work reports are attached. (These raw reports are records of interviews and are intended for research purposes of the Project Team only as they contain unedited sensitive information and also requires significant cross referencing to other reports and checking before they can be used in research analysis. Because of their commercially sensitive nature, field reports of mills visited are not included). Progress was made in all four sub-project areas as outlined below.
Sub-project 1, which involves the development of a mill model and the use of that model to analyse various mill decisions, is at the core of the project. It is also the most difficult of all the sub-project areas as it involves the collection and use of highly sensitive mill information. In 2001, mill visits were used to understand mill systems and to identify how the model could be designed to be of maximum use to mill managers. Two major issues were identified and then confirmed over visits to 13 mills in 2002 fieldwork. First, information, accounting and management systems of the vast majority of mills visited are very rudimentary. Therefore, the mill model can make a very large contribution if it can help mills manage information and make decisions in systematic way (in areas such as pricing, input purchases, inventories, cost controls etc.). Second, with only one exception, mills have no experience or skills in analyzing their own information to derive vital management indicators (and especially cost and yield co-efficients).
In 2002, progress was made in developing the mill model in way that will be user-friendly and useful to mill managers. The aim of analysing mill data first involved gathering highly sensitive data, only possible by building up trust between all parties (mills and researchers) on the basis that the research would be of great use for the mills and that the data would be used only for the purposes intended. Ultimately a relatively large number of mills were interested in participating. However, it was decided to focus on a few select mills that keep detailed and disaggregated information. After developing a solid modeling framework with these mills, it could then be extended to the large number of other interested mills or tailored to suit the needs of specific mills at a later stage in the Project. The focus on a few select mills was also necessary because the disaggregated data often required considerable and time-consuming re-organisation to be in a form suitable for analysis. Data analysis was conducted in the second half of 2002 and is still in progress.
Collection of the data and detailed discussions with mill managers also allowed for the rigorous development of the model in a way that would be most suitable for mills and aligned with existing information systems at the mills. Development of a detailed core model occurred between August and November on return from the fieldwork. The model was developed as a visual basic model embedded in an Excel spreadsheet. The model will undergo much further development as well as validation back at the case study mills in 2003, but is at a stage where it can run basic mill scenarios.
Progress was also made in sub-project 2, especially in relation to understanding domestic wool textile marketing channels and their user preferences. This included visits and analysis of fabric wholesalers and fabric markets. Information on customer types, product attributes and prices was also gathered from mills. Although the research team have a good understanding about the marketing channels and preferences, this sub-project is still in progress.
Of all the sub-projects, most progress to date has been achieved on sub-project 3. From the fieldwork in Xinjiang, the research team gathered complete and detailed information on domestic wool marketing and supply chains. They were also able to conduct a comparative analysis based on fieldwork they conducted on wool marketing in Xinjiang ten years previously. The fieldwork debunked some popular myths that were appearing in the Australian press at the time of the fieldwork (including China's capacity to expand high-quality fine wool production). A very important side benefit of the fieldwork in Xinjiang was that it was able to bridge the information gap between mill buyers and wool producers in some tangible ways. Although much has been achieved on sub-project 3, it is still intended to conduct fieldwork in Inner Mongolia to compare and contrast developments there with other pastoral regions.
Considerable time and resources in 2002 were also devoted to sub-project 4, namely an analysis of the imported wool supply chain. Interviews with a wide variety of participants including wool traders, wool buyers, inspection agencies, port and customs authorities and other agencies was carried out. Although many of the problems and issues have been identified, this sub-project is still in progress.
In summary, progress has been made in all sub-projects but especially in the all-important sub-project 1. It is hoped that this progress will allow for detailed specific analysis in the final year of the project in 2003.
Year 3:
Year 3 (01/01/2003-31/12/2003)
Fieldwork was conducted in Inner Mongolia, Zhejiang, Jiangsu, Shandong and Beijing for a period of around 7 weeks. Raw field work including records of interviews requires cross referencing to other reports and checking before they can be used in research analysis. Because of their commercially sensitive nature, field reports of mills visited are not included.
The development of a mill model and the use of that model to analyse various mill decisions, is at the core of the project. A full pilot version of the model was developed during 2003 and it was intended to trial the model on various mills in China in the middle of the year. The outbreak of SARS delayed that testing, however the model was well received by the trial mills and various refinements were suggested. The pilot version of the model was also fully translated into Chinese and tested on the Chinese version of Excel and Visual Basic.
Detailed plans were also made for the project workshop, planned for Wuxi in mid-2004, that will explain the model and associated analysis to a large number of mill managers.
One of the major objectives of the fieldwork in November was to fill gaps in the domestic marketing of wool textiles. Intensive fieldwork in Zhejiang (Wenzhou and Jiaxiang) added much to the understanding of China's garment making and fabric trading sectors.
Further fieldwork on the domestic wool supply chain was conducted in Inner Mongolia and Shandong to compare with the developments observed in Gansu and Xinjiang in the previous years fieldwork. This has provided comprehensive and detailed information on domestic wool marketing and supply chains, allowing the project team to interact with local officials on ways to improve these domestic supply channels.
Various interviews were also conducted in relation to the imported wool supply chain. The scope of this sub-project has been extended through the close involvement of a PhD student, in the project examining in-depth the impediments to smooth Sino-Australian wool trade and ways that the trade may be facilitated.
Project Outcomes
The "core" component of the project - the development of a wool textile mill management model - demanded access to large amounts of internal mill data that was both very commercially sensitive and time-consuming to collate and prepare. Development of the model was made possible because of the goodwill built up with collaborating mills and industry organisations. On this basis, the research team built the CAEGWOOL mill management model. Capturing the complexities of mill processes within a model usable across China proved to be highly demanding from both analytical and programming perspectives. The model was calibrated in mills in China which, by the end of the project, reported that from its application they were producing robust results that closely reflected actual mill operations.
The model was extended to managers from a broader group of around 15 worsted mills and other industry officials at a training workshop in Wuxi City in June 2004. They learned to use the model in an interactive way, and in connection with a series of papers and talks about management systems and analytical approaches. Questionnaires conducted at the workshop indicated that the mills will use the management tool and/or the management approaches to complement existing decision-making practices. The model was subsequently presented at the International Wool Textiles Conference, attended by all major industry officials and senior staff from hundreds of Chinese wool textile mills. The interest in the model, and encouragement for its further dissemination across the industry generated at this Conference, has seen the Chinese research team seek funding from Australian Wool Innovation Ltd. to further develop and disseminate the model.
Measures are now being undertaken to move from a "research" to a "commercial" model and to transfer all knowledge to a Chinese organisation that will pro-actively target a large proportion of the hundreds of wool textile mills in China, teaching them to use the model. This more "scientific" management tool promises to make a significant contribution to the management and, ultimately, the viability of Chinese wool textile mills that are the dominant customers for Australian wool.
Amongst many publications arising from the project are the following major flagship publications, each of which targets a specific audience:
an ACIAR technical monograph that includes the "research model" itself, the manual for its use, and a range of supporting technical documents (published bilingually in Chinese and English and made widely available in China);
a book entitled Modernizing China's Industries: Lessons from Wool and Wool Textiles, written by the Australian members of the research team;
a book entitled The Chinese sheep industry - markets, trade and industry organisation, written by the Chinese members of the research team.
Through these and previous project activities and publications, the research team has become highly visible in industry activities in both China and Australia. Chinese members of the research team are now regularly invited to deliver presentations on wool textiles and the Chinese sheep and wool production and marketing systems. At the same time, Australian team members have provided advice on developments in the Chinese wool and wool textile industries to industry groups in both Australia and China.
The consistent message conveyed through these forums is that the Australian and Chinese wool industries are complementary rather than competitive, and that there are various measures that can improve the flow of Australian wool to China and the way that Chinese mills use that wool. The Chinese wool textile industry needs to become more pro-active and turn attention to improving management practices, and to improve co-ordination between industry sectors.
In December 2004 and January 2005, the Australian research team prepared two detailed briefs for Australian Wool Innovation Ltd. about Chinese wool production, marketing, and supply chains. These two reports, together with a much shorter set of Notes prepared for a National Farmers Federation delegation visiting China, were used to inform Australian industry leaders about the domestic wool industry in China, and to brief Australian government officials preparing for the negotiations surrounding the China-Australia Free Trade Agreement.
Location
There are no project locations defined for this project.
