LEARNING TO MANAGE THE FACTORY FLOOR IN ETHIOPIA: SKILLS, WORK CULTURES AND ORGANIZATIONAL CAPABILITIES IN ETHIOPIA'S LIGHT MANUFACTURING

Lead Research Organisation: School of Oriental and African Studies
Department Name: Development Studies

Abstract

In African countries like Ethiopia, the prospects for industrialization through the development of light manufacturing led by foreign direct investment have substantially improved in the past ten years. Many industrial parks and new foreign investors have been established to meet the ambitious industrialization goals of Ethiopia. This development entails a number of critical requirements in terms of infrastructure, policy incentives and workforce skills. Although Ethiopia is supposed to have a comparative advantage in light manufacturing because of low labour costs and the plentiful availability of labour, the reality in the last few years is that attracting, training and retaining a suitable industrial labour force is not as simple as it would seem. Paradoxically, labour constraints may impair the achievement of the ambitious industrialization goals of Ethiopia and other African countries.

Labour outcomes and industrial relations depend much on workplace arrangements and the broader labour market context of each sector and country. Organizational and managerial capabilities are, in this regard, critical to understanding some of the labour challenges that firms face, especially in the case of new foreign firms investing in new sourcing countries as in the textile and garment (T&G) sector in Ethiopia. These are firms that are subject to tight competitive pressures from the global production networks in which they are integrated or willing to join. The factories starting in Ethiopia face the twin challenge of attracting a trainable and motivated workforce in a context of limited industrial development and meeting the productivity and quality imperatives of global production networks. The role of low and middle-level managers seems to be critical in these nodes of the chain as they constitute the interface between the tight demands coming from top management and the responses and demands from production workers. Indeed, some of the key labour problems confronted by new investors, such as high labour turnover, relatively lower than expected staff retention and labour conflict, were linked to the limited progress in incorporating a suitable local managerial force at different levels of factory management and to the difficulties in labour relations when expat managers had to manage/supervise local workers. This was considered by most stakeholders, especially the Ethiopian government (particularly the EIC and the IPDC) as well as private investors' groups, a significant challenge that required some remedy action.

The initial 2015-2019 project focused primarily on the experiences and working conditions of unskilled and semi-skilled workers, i.e. the bulk of workers employed by companies in the construction and manufacturing sectors. However, our qualitative research and interviews with factory managers stressed the equal importance of skilled and management labour force for the success of these industries. These interviews corroborated the importance of and constraints in finding and retaining high-quality local managers for factory floor operations. This is consistent with similar findings from other studies of industrialization in developing countries and diagnostic research by ILO in Ethiopia.
We there propose to extend our current research to deepen the understanding of the current and past experiences of existing and especially new emerging industrial firms in finding, developing and retaining a skilled and managerial workforce, in order to improve the sustainability of the firm in the country and labour relations at the workplace. We will ask questions and do qualitative research about the constraints on hiring and retaining Ethiopian managers and the processes of skill transfer that have worked best to incorporate this labour force at the factory floor level. We will also compile relevant data from existing datasets emerging from other studies that have been conducted in the last 5 years in Ethiopia.

Planned Impact

This proposed project plans to have a broad impact not only on academic audiences but also on policymakers in national governments, regional and international organisations. The focus of the research and related surveys is on the experiences of management employees in new industrial firms and the difficulties of new investors in filling management positions with local workers in Ethiopia. As described in the Case for Support, this is becoming a policy problem of growing significance given the ambitious aspirations to industrialise currently present in Ethiopia. There are also wider implications for other African countries developing effective industrial policies.

Who will benefit from this research?

National and regional governments.
The Ethiopian government has the development of industrial sectors, especially light manufacturing, via industrial parks, as a key policy priority. Different institutions involved in driving the process have admitted the unexpected labour challenges that these sectors are facing in a context of plentiful labour supply. The key institutions that would be interested in the findings of this project are:
a. The Ethiopian Investment Commission, which has a leading role in the attraction of FDI and the management of industrial policy.
b. Ministry of Industry, with direct overseeing role of industrial development and sector-level institutes.
c. Textile Industrial Development Institute, which has a role in training and skill development for skilled and managerial positions.
d. Industrial Park Development Corporation, in charge of coordinating efforts to expand and manage industrial parks where most foreign manufacturing investors are located.
e. Ministry of Science and Higher Education, leading role in national training programmes and universities.
f. Regional governments, where industrial parks are developed and where universities and training centres are located. They may have an interest in playing a role to improve the quantity and quality of local management labour force.

International organisations.
There are some organizations that have recently shown a significant interest in industrial development in Ethiopia and the labour challenges mentioned above.
a. International Labour Organization and Better Work programme, both with relevant projects and interventions in this domain.
b. United Nations Economic Commission for Africa, key regional organization with a growing interest in prospects for industrial development and upgrading in Africa.
3. Private sector, business organisations. They are likely to be key stakeholders as directly affected by these challenges. Key examples are:
a. Foreign investors in light manufacturing.
b. Ethiopian Textile and Garment Manufacturers Association
c. Hawassa Park Investors' Association.
d. Eastern Industrial Park management firm.


The findings of this project may provide more precise information on the main sources of the constraints they face, on the examples of best business practices to maximise the incorporation of local management workforce and the most effective mechanisms of skill upgrading, by learning from the comparative analysis of different cases. The project plans to have such a proposed impact through various means and channels, as summarised below:
a. Follow-up informal meetings with top company management (directly through firms or indirectly through relevant business associations) to share initial findings.
b. One dissemination workshop in Addis Ababa where all stakeholders will take part in an open discussion of findings.
c. Additional more focused events to be shared with the ILO and the relevant institutions of the Ethiopian government (especially the EIC and the MoI).
d. Production of focused dissemination briefs tailored to the interests and needs of different stakeholders.
The legacy of the project will be promoted by setting up a special website, where we will be depositing project publications.

Publications

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Description Scope of project

Our aim is to develop a clearer picture of the constraints on, and opportunities for, filling middle-level management positions in Ethiopia's foreign owned apparel firms with Ethiopian staff. We hope our findings will help support interventions to maximise skill development and workforce localisation, particularly in export-oriented production. Our research provides answers to the following questions:

1. The localisation of the management workforce in new foreign-owned apparel factories has been slow but gradually improving since 2018, with some firms, especially larger and more globalised ones advancing more rapidly than others. The timeframe is however too short to reliably assess trends, especially considering the impact of COVID-19 and the current conflict on employment levels in industrial parks. Most sampled firms started operations in 2017 and had to incorporate a workforce with limited experience in global production networks. There was a consensus that most Ethiopian managers did not have the relevant experience when hired and had to be trained from rather low levels, to understand the required skills in this industry as well as to learn corporate culture. Many foreign managers reported that it would take at least five years for a local manager to assume senior management roles.Certain senior management roles (finance, commercial and marketing department) are often reserved to foreign managers partly because they require experience and communication skills in negotiation with international customers but also because of issues of 'trust' and information confidentiality on the part of owners and top company managers. This practice may also be related to imperatives of production and labour control in a tightly competitive global industry, which lead to segmentation of the management workforce.

2. Turnover is relatively high but not a serious problem, according to most senior managers in sampled companies. Retention of high-quality managers is an important priority for most firms, given the costs involved in training them from a low base. The main mechanisms of retention are annual salary increments combined with promotion to roles with greater responsibility and decision-making autonomy. However, only few companies have clearly structured career pathways and actively pushed Ethiopian managers to train and assume more responsibilities. A major factor impeding the effectiveness of retention measures via salary increments and promotion is a substantial divergence in expectations between foreign senior managers and Ethiopian middle managers. Whereas Ethiopian managers expect higher increments and faster promotions, senior company managers report these demands are out of touch with the realities of low-margin globally integrated firms. It was nonetheless acknowledged in many firms that Ethiopian managers play a key role in bridging communication gaps between foreign senior managers and local production workers, which contributes to reducing turnover of production workers, and generally less conflictive industrial relations. Therefore, the pay-off of effective retention packages may in the medium-term outweigh the costs of retention measures.

3. Firms transfer significant knowledge and especially organizational and managerial capabilities to Ethiopian managers through a variety of formal and informal mechanisms, but such transfers are hampered by problems with incentive systems. Some foreign managers have an incentive to stay in their job and limit knowledge transfer to avoid being replaced. Ethiopian managers may move for better opportunities in other firms and therefore discourage firms from investing more in knowledge transfer. All firms engaged in different forms of training, from induction programmes, HQ visits, soft-skill training, to 'shadowing' more experienced managers. Informal on-the-job training was generalised and considered one of the most effective ways of transferring the tacit knowledge necessary to run operations in a high-pressure environment where demands from international customers create the need for constant adaptation. Formal structured training was considered useful only for limited aspects of managers' jobs, e.g. computer skills, company information systems, HR processes. More professionally managed and globalised firms had more structured training frameworks, including inductions focused on key soft skills, periodic managerial/technical training with evaluation, and visits to HQs and other 'model' factories usually in Asia. Therefore, despite the overall preference for ongoing on-the-job informal skill development, training provision significantly depends on the type of company and their international experience.

4. The quality of training in Ethiopian institutions is variable and not yet adequate to the needs of firms integrated into highly competitive global production networks. Most firms value the theoretical knowledge acquired by Ethiopian graduates, which makes them immediately trainable, but decry the gaps in practical skills, computing skills, and knowledge of new production processes, technology and equipment. There is also some concern over the lack of soft skills and adaptation to high-pressure work environments where quick troubleshooting skills and work flexibility are deemed essential attributes, although it is not clear how training institutes can provide these skills without a suitable formula for on-factory learning experiences. While some senior foreign managers also highlight the lack of effective communication in English as a further gap, Ethiopian middle managers regard English language as one of the benefits of their graduate training. A lack of coordination between different Ethiopian training institutions was found to be a binding constraint on more effective university - private sector linkages, which would be important especially for two purposes: (a) curriculum reform and development towards modernised methods and systems; (b) availability of apprenticeship/real factory training experiences for students.
Exploitation Route We expect significant engagement with key stakeholders in Ethiopia's apparel sector, notably the Ethiopian Investment Commission, the Ministry of Science and Higher Education, the ILO and some companies participating in the project. If these stakeholders receive and act on the findings of this project, we will be able to achieve our engagement and impact objectives, which we can report next year.

The findings from these qualitative research could also be used to scale up a research programme focused on the localisation and upgrading of industrial management workforces in low-income countries, especially in Sub-Saharan Africa, through comparative country case studies and large-scale quantitative surveys.
Sectors Government, Democracy and Justice,Manufacturing, including Industrial Biotechology

 
Description Research collaboration with EconInsight Center for Development Research, to contribute to data collection and key informant interviews on management employment in apparel factories in Ethiopia 
Organisation EconInsight Center for Development Research
Country Ethiopia 
Sector Academic/University 
PI Contribution We will provide technical and conceptual support, interview guides and generally oversight of the data collection process, in addition to funding to conduct the fieldwork activities
Collaborator Contribution EconInsight will contribute to qualitative research and document collection relevant to the project.
Impact none yet. Data collection is just starting
Start Year 2021
 
Description ODI-DEGRP Workshop 'Africa's economic transformation: the role of Chinese investment - DEGRP synthesis report launch'. This report drew on the findings of our research projects. Held on 30 June 2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact This was a webinar that included some of the top experts in the field of Africa-China relations and those with an interest in issues of industrialization and economic transformation in Africa. There was significant interest in the findings among African policy makers and representatives of international agencies such as FCDO and UNDP.
Year(s) Of Engagement Activity 2020
URL https://www.gov.uk/research-for-development-outputs/africas-economic-transformation-the-role-of-chin...
 
Description Participation at the Development Studies Association Conference in 2020 with a presentation on "Learning by making: skill development, training and industrial policy in the Ethiopian apparel export sector" at the panel "Industrial policy for economic development in the 21st Century - beyond EOI vs. ISI" 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Postgraduate students
Results and Impact Around 60 people attended this panel, where we presented preliminary ideas based on secondary research and evidence from Ethiopia, which sparked questions of high policy relevance in relation to how to maximise the impact of FDI in manufacturing by upgrading the quality of the workforce, especially managerial and supervisory workers. There was a lot of interest in the potential findings of this project.
Year(s) Of Engagement Activity 2020
URL https://nomadit.co.uk/conference/73#8917
 
Description Presentation of findings on Management Workforce Localization Issues in Ethiopia's textile and apparel sector at the "National labour workshop on issues of management skills localization, labour productivity, turnover, decent work conditions and labour sourcing to fulfilling manufacturing jobs creation", organised by the Ethiopia Investment Commission of the Government of Ethiopia. This was a formal forum that included representatives of the Ethiopian government, International Organisations and 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Policymakers/politicians
Results and Impact This was a forum titled "National labour workshop on issues of management skills localization, labour productivity, turnover, decent work conditions and labour sourcing to fulfilling manufacturing jobs creation", organised by the Ethiopia Investment Commission (EIC) of the Government of Ethiopia. This was a formal forum that included representatives of the Ethiopian government, International Organisations and private business in the sector. The EIC which had been engaged in different phases of the project and received the draft report in 2022, invited us to present the finding to this formal forum, which included all the key stakeholders in the textile and apparel sector in Ethiopia. The findings sparked a lively debate and were generally well received. Several participants, especially from the government and the International Labour Organisation, commented on the pertinence of some of our policy recommendations.
Year(s) Of Engagement Activity 2023