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A Lean revenge against mass production from ”The Economist” point of view. Part III

“… Only in the 1970s, after the first oil shock, did faults start to become visible. The finned and chromed V8-powered monsters beloved of Americans were replaced by dumpy, front-wheel-drive boxes designed to meet new rules (known as CAFE standards) limiting the average fuel economy of carmakers fleets and to compete with Japanese imports. As well as being dull to look at, the new cars were less reliable than equivalent Japanese models.

By the early 1980s it had begun to dawn on GM that the Japanese could not only make better cars but also do so far more efficiently. A joint venture with Toyota to manufacture cars in California was an eye-opener. It convinced GM’s management that “lean” manufacturing was of the highest importance. Unfortunately, that meant still less attention being paid to the quality of the cars GM was turning out. Most were indistinguishable, badge-engineered non-entities. As the appeal of its products sank, so did the prices GM could ask. New ways had to be found to cut costs further, making the cars still less attractive to buyers….”

Briefing. The bankruptcy of General Motors. A giant falls. The Economist. June 6th-12th 2009. Pp 58-60. Ed. The Economist Newspaper Ltd.

 
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A Lean revenge against mass production from ”The Economist” point of view. Part II

”…The foundation of blue-collar America have all crumbled. Global competition, first from Japan and now from almost everywhere, has transformed manufacturing. Even shop-floor workers are expected to work with their brains as well as their hands, as flexible production replaces mass production. …In fact, the golden age of blue-collar man was the product of a peculiar set of circumstances, when Europe and Japan were on their backs, mass-production ruled in the factories and a small number of companies could dominate the American economy.

… those blue-collar workers bear much of the responsibility for their own fate. This is particularly true in the car industry, which tended to set the pattern for much of the rest of the American economy. Trade unions frequently hampered their industries with rules that blocked more flexible and productivity-boosting manufacturing techniques…

… But there is still hope for blue-collar workers as long as they are willing to learn from the calamity that is General Motors. Plenty of manufacturing companies, even carmakers, have flourished at a time when General Motors has floundered…”

Lexington. Blue-collar America. The Economist. June 6th-12th 2009. Pp 46. Ed. The Economist Newspaper Ltd.

 
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A Lean revenge against mass production from ”The Economist” point of view. Part I

“…GM, Ford and Chrysler tried to improve: by 2006 they had almost caught up with Japanese standards of efficiency and even quality. But by then, GM’s share of American market had fallen go below a quarter. Rounds of closures and job cuts were difficult to negotiate with unions, and were always too little too late. Gradually the cars got better, but Americans had moved on. The younger generation of carbuyers stayed faithful to their Toyotas, Hondas or Mercedes assembled in the new cheaper factories below the Mason-Dixon line. GM and the other American firms were left with the older buyers who were, literally, dying out.

GM’s demise should not be read as a harbinger of doom for the car industry. All around the world people want wheels: a car tends to be the first big purchase a family makes once its income rises much above $5000 a year, in purchasing-power terms. At the same time as people in developing countries are getting richer, more efficient factories and better designs are making cars more affordable. That is why the IMF forecasts that the world will have nearly 3 billion cars in 2050…

… Yet although the long-term prospects for ales growth look excellent overall, the car industry has a problem: it needs to shrink dramatically. At present, there’s enough capacity globally to make 90m vehicles a year, but demand is little more than 60m in good economic times. Even as the big global manufacturers have been building new factories in emerging markets, governments in slow-growing rich-world markets have been bribing them to keep capacity open there.

Because the industry employs so many people and is a repository of high technology, governments are easily lured into the belief that car firms must be supported when times are tough. Hence Mr Obama’s $50 billion rescue of GM; and hence, too, the German government’s financial backing for the sale of Opel, GM’s European arm, to Magna, a Canadian parts maker backed by a Russian state-owned bank. German politicians have made it clear that they plan to keep German factories open even if others elsewhere in Europe have to close. At least the American rescue recognizes the need to remove capacity from the market: GM will, as a result of the deal, lose 14 factories, 29.000 workers and 2.400 dealers

It could still be a great business

For all its peculiarities, the car industry is no dinosaur-Toyota, for instance is a byword for manufacturing excellence. But the unevolved GM deserves extinction. Detroit employed so many people and figured so large in American culture that governments felt they had to protect it; but in doing so, they made it vulnerable to less-coddled competitors from abroad. By trying to keep their car industry big, America’s leaders ended up preventing it from becoming good. There is a lesson in that which all governments would do well to learn”

The decline and fall of General Motors. Detroitosaurus wrecks. The Economist. June 6th-12th 2009. Pp 10. Ed. The Economist Newspaper Ltd.

 
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Posted by on June 8, 2009 in Lean Manufacturing

 

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