For decades, every trend in manufacturing favored the developing world and worked against the United States. But new tools that greatly speed up development from idea to finished product encourage start-up companies to locate here, not in Asia. Could global trade winds finally be blowing toward America again?
Near the end of this year’s second presidential debate, Candy Crowley of CNN pointed out that iPads, iPhones, and other globally sought-after Apple products are all made in China. What would it take, she asked both Mitt Romney and Barack Obama, to “convince a great American company to bring that manufacturing back here?”
I listened to this question with special interest, since I was following the debate, via hotel-room TV, from the Shenzhen manufacturing zone of southern China, where many of those same iPads and iPhones are made. For the few days before the debate, I’d been revisiting PCH International, an outsourcing company I’d first written about for this magazine in 2007, in “China Makes, the World Takes.” The company’s revenues have increased more than sevenfold since then and its workforce has grown almost as fast, despite the years of global recession. This is testament both to its own success and to the nonstop surge of outsourcing contracts to China.
The day after the debate, I walked through the famous Foxconn complex in the Longhua district of Shenzhen, where some 230,000 Chinese workers, mainly between the ages of 18 and 25, turn out products sold under international brand names, from Apple and Dell to Nintendo and Sony. Another Foxconn facility not far away employs another 200,000 people; throughout China the company’s workforce numbers 1.3 million. On previous attempts to get in over the years, I had never made it past Foxconn’s front gate—not surprising given the company’s policy of stiff-arming most foreign and domestic reporters. But a new PR team at Foxconn had apparently decided that closed-door secretiveness was making the company look even worse than it otherwise would. (If only this team were in charge of Chinese government policy—regarding the press, the Internet, letting people into and out of the country, and so much more.) Immediately after hearing the allusion to Chinese-made products on TV, I e-mailed an official at Foxconn and said that so prominent a mention in American politics would be a great news peg for a visit. I was fully expecting another turndown, but to my surprise, the company agreed. The next morning, I went to the factory and was told I could roam around and take pictures of anything I wanted, as long as I did not show or mention any of the brand-name products coming off its assembly lines.
What I saw at these Chinese sites was surprisingly different from what I’d seen on previous factory tours, reflecting the political, economic, technological, and especially social pressures that are roiling China now. In conjunction with significant changes in the American business and technological landscape that I recently saw in San Francisco, these changes portend better possibilities for American manufacturers and American job growth than at any other time since Rust Belt desolation and the hollowing-out of the American working class came to seem the grim inevitabilities of the globalized industrial age.
For the first time in memory, I’ve heard “product people” sound optimistic about hardware projects they want to launch and facilities they want to build not just in Asia but also in the United States. When I visited factories in the upper Midwest for magazine stories in the early 1980s, “manufacturing in America” was already becoming synonymous with “Rust Belt” and “sunset industry.” Ambitious, well-educated people who had a choice were already headed for cleaner, faster-growing possibilities—in consulting, finance, software, biotech, anything but things. At the start of the ’80s, about one American worker in five had a job in the manufacturing sector. Now it’s about one in 10.
“Many factory managers say openly that they prefer women: women, they say, learn new jobs faster, handle high-precision work better, and pose fewer disciplinary challenges.”
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Whether you call the business history of the past 15 years the age of hedge funds, the age of Google (or its rival Facebook, or its other rival Amazon, or its other rival Apple), the age of Walmart, or even the cautionary age of Lehman Brothers and Countrywide, in no case would you call it the age of American manufacturing. Manufacturing’s share of the total American economy has fallen by about the same amount as its workforce share: it went from about 20 percent in the early 1980s to just over 10 percent now. For comparison, manufacturing accounts for some 30 percent of China’s total economy. Still, the U.S. economy is so much larger that our manufacturing sector, even in its battered condition, remains the largest in the world.
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I’m used to hearing excitement from people at American infotech companies—or from biotech innovators, or people in other enterprises who believe the future is on their side. I’m used to hearing it in China. I’ve gravitated to tech topics and to fast-growing parts of the world because I like hearing from people with big plans and dreams. And this year, for the first time in decades, I have been hearing upbeat accounts from business officials and entrepreneurs engaged in American manufacturing.
The heart of their argument is this: Through most of post–World War II history, the forces of globalization have made it harder and harder to keep manufacturing jobs in the United States. But the latest wave of technological innovation, communications systems, and production tools may now make it easier—especially to bring new products to market faster than the competition by designing, refining, and making
them
in the United States. At just the same time, social and economic changes in China are making the outsourcing business ever costlier and trickier for all but the most experienced firms.
For Americans, the most important factor is the emergence of new tools that address an old problem. The old problem is the cost, delay, and inefficiency of converting an idea into a product. Say you have an idea for—anything. (For me, the list would start with silent leaf blowers, which I’d give to all my neighbors as gifts.) Before you can earn the first dollar from the first customer, you have to decide whether the product can be built, at what cost, and how fast, so you can beat anyone else with the same idea.
For the first time in memory, I’ve heard “product people” sound optimistic about hardware projects they want to launch and facilities they want to build not just in Asia but also in the United States.
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The need to reduce costs has driven much of this work outside the United States. The possibility of saving time may bring some of it back. For instance, at Lime Lab, a small industrial-design firm in San Francisco, a design engineer named Adam Mack told me that technologies including 3‑D printing were revolutionizing the process of deciding what to build and where. Three-dimensional printing refers to computerized molding or related systems that can produce tangible objects in a matter of minutes or a few hours, on the basis of designs created on a screen. This dramatically speeds up the process of creating a prototype and then trying out variations and working out flaws.
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“Before, you could sit around and talk about something you wanted to make,” Mack said. “Now you can have a prototype of an injection-molded part in your hand the next day, and confer with factory managers about how much it would cost to build.” By making manufacturing generally more attractive and feasible, new tools will—so I heard many times—lead to more good jobs in America than we would have thought possible only a few years ago.
“A revolution is coming to the creation of things, comparable to the Internet’s effect on the creation and dissemination of ideas,” Linus Chung told me at Lime Lab, in San Francisco. (Chris Anderson, formerly of
Wired, has recently advanced a similar case in his book
Makers.) Chung is an American-born, Stanford-trained manager who now works for PCH International and is based in Shenzhen. This past June, PCH bought Lime Lab as part of an expansion into America to encourage more start-ups and manufacturing work here. “There is a whole new interest in hardware in Silicon Valley,” said Phil Baker, a product-development expert who has worked with Apple and other companies since the 1970s. “I’ve never seen a more exciting time in the hardware business.”
Why “exciting”? Let’s consider the changes affecting China, and America, and manufacturers everywhere.
The Big Picture
For the past 30 years, all of the largest forces have pushed in favor of China’s manufacturing expansion, from very low labor costs and a deliberate policy of welcoming foreign investment, to ever faster and cheaper global cargo-shipment networks, to a deliberately undervalued Chinese currency. Within the past two years, nearly all of those advantages have become more complicated. (In his accompanying article for this issue, Charles Fishman explains some of the large forces pushing in favor of America’s manufacturing renewal.) In China, wages are rising, workers are becoming choosier, public resistance to environmental devastation is growing, and the Chinese “investment led” model is showing strain.
That model has involved a kind of hyper-Keynesianism far beyond what the United States experienced even during the most government-run periods of the New Deal. China has created jobs by building factories, highways, railroads, and dams—and airports where there are no cities, and cities where there are no people. “Americans are used to thinking of ‘savings’ and ‘investment’ as absolute goods, because we’ve done too little” of both, Michael Pettis, of the Guanghua School of Business in Beijing, told me. “But there is such a thing as too much savings and investment and infrastructure, and too little consumption, all of which we see in China.” If the American public challenge is “reinvestment” of all varieties—in education, in infrastructure, in a sense of community, in everything but houses—the Chinese counterpart is a need for a comprehensive rebalancing. Indeed, Pettis’s forthcoming book on the Chinese economy is called The Great Rebalancing. Reliance on exports needs to come into better balance with domestic consumption; economic growth with environmental sustainability; political liberties with the new level of economic prosperity; and on down a long list.
Some observers inside and outside China think that the strains are too great and the system too rigid to allow the necessary rebalancing in time for the party to maintain political control. For instance, Minxin Pei, a native of Shanghai who now teaches at Claremont McKenna College in California, has been warning for more than a decade that the economic, social, and political imbalances of the Chinese system would reach a breaking point just about now—and that Communist rule would have to give way to a multiparty system. Many others contend that, on the contrary, the Communist leaders will manage somehow to address each of today’s problems just before any one becomes an outright emergency, as they have done time and again for 30 years. Whichever view proves correct, the relevant point for Americans is a convergence of trends that make operations here more attractive and feasible, just as the cost and friction of operating in China are increasing.
The Factory-Level View, From the World’s Biggest Factory
I had a more vivid sense of some of these challenges after this latest look at Chinese factories—especially at Foxconn, the world’s largest electronics maker. You learn a lot about China from its factories, of which I have now visited nearly 200—just as you would have learned a lot about the England of Charles Dickens and Friedrich Engels by seeing its factories, and the America of Theodore Dreiser and Upton Sinclair. Factories are not the only arenas for high-speed social transformation in China: its farms, from which working-age people are fleeing, and its cities, to which millions of people migrate each year, are also the settings for individual dramas and collective adjustment at a rate and on a scale that the world has never previously seen. But on this trip I spent time in factories. And what I saw underscored the ways in which the tumultuous transformation of China is complicating life for its outsourcers and exporters.
At the Foxconn plant I visited, I know firsthand only about conditions I could observe in four hours of walking around the more than one-mile-square “campus” and being taken into selected dormitories, cafeterias, training rooms, and assembly-line areas by members of the newly accommodating Foxconn PR team. One part of the visit had the unmistakable note of the staged: In the sole dormitory we entered, whose occupants were all on their shifts at work, every towel and pillow in the four-bunk room I saw was perfectly aligned. The clothes were on hangers in precise order, and there was not a scrap of extra paper or debris on desks, dressers, the floor, or anywhere else. I could only assume that this room had been specially cleaned up; other parts of the campus resembled most other parts of China in being much more casually
groomed. I’m acutely aware of all the things I did not see: conditions at night, the dorms where not four but six or eight workers live in each room, assembly lines where hazardous materials might be used or where the pace is exceptionally fast. Still, what I was allowed to see was more than a tiny keyhole glimpse—and my movement around the campus was less rather than more controlled than I’d been accustomed to on other factory visits. The scale of buzz and activity was so vast—cafeterias with thousands of people getting lunch, bus and shuttle stops with hundreds of workers waiting for a ride, coffee shops and convenience stores crowded with Foxconn patrons—that I doubted that every detail could have been orchestrated overnight. Plus, there were products to ship.
At most other big Chinese factories I’d seen, people walked around all day in uniforms—usually gray or blue coveralls for men, light-colored smocks for women. At Foxconn, people wore anti-static jackets and caps when at work on the assembly lines and shirts or vests with the Foxconn logo when in offices. But when walking to the cafeteria, going to the shops, or commuting to normal off-site apartments, where three-quarters of the workforce lives, people were dressed in the blue jeans or cargo shorts and fake Polo or NBA shirts of a normal Chinese crowd. On the lines I did see, where printed circuit boards and other electronic components were being put together in a process that combined the use of large, fancy, expensive machinery with detailed handwork, the pace and supervision seemed no looser or tighter than I’d seen at comparable sites elsewhere in China. If you are looking for the most-gruesome factory conditions in China, you don’t go to a multinational giant like Foxconn, which has to deal with Western customers and pay at least some attention to appearances and laws. You go instead to the small, ramshackle, often unregulated workshops, often away from the big cities, where conditions are as inefficient and sometimes as unsafe as they were when China was just beginning to industrialize.
Although I had heard about the Foxconn “suicide nets,” I was still taken aback to see them. Most dormitories and factory buildings on the site are five or six stories tall. Outside every upper-story window, open balcony, and other spot from which someone might plunge, the company has installed netting about 20 feet above ground level. The founder and CEO, Terry Gou, ordered the nets installed after a spate of jumping suicides in 2010; many of the upper windows also now have latches that keep them from opening fully, and some balconies have a fine mesh of jump-prevention wire. The idea, I was told by a Foxconn spokesman, was that while some suicide attempts reflect deep mental illness or depression, others are impulsive and half-thought-through, so anything that even slightly slows an attempt might deter a suicide altogether. (The peak suicide rate for Foxconn came in 2010, when it reported a total of 12 “completed” suicides at all its Chinese plants. On a per capita basis, this was below the suicide rate for China as a whole, but everyone at Foxconn recognized it as an emergency.)
But to me the most significant aspect of the visit—one my hosts were so inured to that they barely mentioned it—was the sight of the enormous throngs at Foxconn’s recruiting and new-worker training sites on campus. In a typical week, the Shenzhen Longhua facility will take on about 2,000 new employees for its own factories, and recruit and train many more for other Foxconn sites. It brings in so many people because so many keep heading out; the annual turnover rate at the plant is about 60 percent—high but not astounding by Chinese standards.
A convergence of trends make operations in America more attractive and feasible, just as the cost and friction of operating in China are increasing.
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You can draw many conclusions from this rate of churn. Anita Chan, an expert on Chinese labor conditions at the University of Technology, Sydney, said the turnover indicated some brutal realities of Chinese factory life, in ways that reflected both well and poorly on Foxconn itself. “Why do workers still go to Foxconn despite its bad reputation?” she asked, in an interview with The China Story, an Australian online journal. “I believe that it is because they know that Foxconn pays wages on time. While this may appear to be a crude view, workers at Foxconn often come from smaller companies where they have been cheated, are underpaid, or even owed wages. In this context, they know that Foxconn is synonymous with an assured income.”
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But to earn more money—or even enough money to stay ahead of fast-rising food and housing costs—the workers find that they have to put in overtime. According to Chan, “They willingly comply until they get totally exhausted and cannot tolerate the long work hours anymore. Their solution then is to quit.” Some go back to Foxconn; some go, often with a group of friends, to another factory in hopes of a better deal; some find retail jobs; some move back home or to other parts of the country. All in all, they change the labor dynamics of China’s vast factory zone, steadily increasing the cost and reducing the predictability of doing business there.
I spoke about workforce churn with Foxconn’s Louis Woo, whom I had met years earlier in Shanghai. Woo and Terry Gou had become friends in the early 1990s, when Woo was the general manager of Apple Taiwan. Four years ago, Woo accepted Gou’s offer to be Foxconn’s chief spokesman, and moved to Shenzhen. Woo told me that Gou, who turned 62 on the day of my visit, was at this stage of life increasingly conscious of the social as well as the purely industrial legacy of his work.
Terry Gou has done as much as anyone since Deng Xiaoping to shape life in China, or at least in the factory-dense southern part of the country. Although Gou is Taiwanese and Foxconn’s headquarters are in Taiwan, the company is the largest private employer in mainland China. According to Louis Woo, Gou is aware of the example of Henry Ford. Not the Ford of the assembly line and the mass-marketed Model T, whose achievements Gou has already matched, nor the elderly Henry Ford of the anti-Semitic conspiracy theories. Rather, the “welfare capitalist” Ford, who in 1914 announced a new $5 daily wage, roughly double the prevailing rate. Ford did this to reduce then-extreme turnover on his assembly lines, which was even more rapid than Foxconn’s current level, and to hasten the creation of a middle class capable of buying his cars.
Foxconn has raised basic wages four times in the past three years, in some areas doubling the starting-level pay. A typical Foxconn assembly-line worker spends 50 hours a week on the job—40 hours at base rates, and 10 hours of overtime at a time-and-a-half rate. For that, a worker typically gets about $400 a month, or about $2 an hour. During production surges, workers may put in another 10 hours of weekend overtime, for which they get double-rate pay. Six years ago, typical monthly pay in Shenzhen factories I visited ranged from $115 to $155 (the difference partly reflects the higher value of the Chinese renminbi today). Woo said that he expected the trend of rising wages to continue, and that Gou was mindful of the centennial of Henry Ford’s $5‑wage announcement, in 2014. This would reflect a calculation of long-term self-interest comparable to Ford’s: if Gou can accelerate the growth of China’s middle class, a large company like his will share in the returns. “If we have a new-generation middle class, that will fuel the need for products like those we manufacture,” Woo said.
A living wage for the laboring class would be one
more sign of progress for China, as it was for the America of Ford’s era. But it would also be part of the process that is reducing China’s advantage as a site of cheap labor—and a sign of other challenges facing Chinese employers.
Two more things about the Foxconn workers surprised me: that so many were male, and that nearly all were kids. By kids I don’t mean the 14-year-old “apprentices” a different Foxconn plant, in the northern city of Yantai, was found to have hired earlier this year. (The company apologized to the youths and their families and, according to Woo, fired one of the managers involved and disciplined a total of nine.) I mean that at factories I’d previously seen across China, the workers looked and acted like country people weathered by their rough upbringing. Most of the Foxconn employees looked like they could have come from a junior college.
“Even a few years ago, the typical worker was a farmer,” Louis Woo told me. “He or she already had a family back in the village. They came, they earned their money, and when they were able to buy some pigs or fix up their house, they went home.” The standard workers today, he said, are those people’s children. “They’ve never farmed. They don’t want to, and they don’t have to, thanks to the hard work of their parents, who were the first generation of migrant workers. They’re coming here as part of entering a bigger world.” Chinese factory bosses face the same challenge in dealing with them that Chinese political bosses face with a better-informed, more intellectually independent populace. The “shut up and look at your paycheck” approach that has worked for people who remember China’s backwardness may not work for their children.
Promising new tools are making it possible for American innovators to rapidly convert their ideas into products—and jobs.
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I noted a parallel change at some PCH factories. On my previous visit, four years earlier, virtually all of the assembly-line workers had been female. This time, all but one of the PCH factories I visited was staffed predominantly by young men. I asked the supervisor of the one all-female line why there were no men on it. “These are the more responsible jobs,” she said. (The women were handling online orders from American customers for a famous electronics brand.) She was partly joking, but many factory managers say openly that they prefer women for any job not requiring unusual strength.
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The prevailing view is that women learn new jobs faster, handle high-precision work better, and pose fewer disciplinary challenges. (I am just telling you what they say.) But as the modernizing Chinese economy creates more options for women, fewer of them are choosing factory work. That leaves men.
Among the consequences is greater fractiousness in the typical Chinese factory force. In September, a Foxconn plant in Shanxi province was temporarily closed because of a late-night riot that eventually involved several thousand workers. According to Louis Woo, the riot was touched off not by worker-management tensions but by the Chinese equivalent of an ethnic-gang war in an American prison, as workers from one province took the side of a colleague who was fighting a worker from somewhere else. This is the sort of thing that happens more frequently with more men in the workforce.
Ten years ago, Chinese factory life stood comparison to the “dark Satanic Mills” of William Blake’s England in the early 1800s. Five years ago, I was struck by the parallels with accounts of Chicago packinghouse life in the 1890s. Now I see a counterpart to the American 1920s, with the first sizable generation of
moderne post-rural life. In September, after turnover surged at many Chinese factories, PCH commissioned a nongovernmental organization to do a survey of worker attitudes. I sat in on a focus group from the factory discussing the findings. It’s not the long hours we mind, most of the workers said; according to the survey, fully 80 percent welcomed an average of two or three hours of overtime a day, because of the extra pay that meant. But we still want to “have a life,” they told the survey takers. The No. 1 item on their wish list was more organized social activities on the weekends, and singles nights and mixers for all the unaccompanied young men.
China’s economic and social maturing, tumultuous or smooth as it may turn out to be, will certainly affect the world division of labor. Some very low-skill jobs may move to very low-wage economies, such as Burma, India, and parts of Africa; some will move to inland China; some will be automated or done by robots; some will stay in China, but at higher costs. But some of the next round of jobs that might have moved to China will be more attractive for producers to keep in the United States.
The New Smiley Curve
Above: Woodworking and bookbinding equipment at the San Francisco factory of DODOcase, with founders Patrick Buckley and Craig Dalton pictured in the middle (David Høgsholt)
“Geography is history,” I was told in Shenzhen by Liam Casey, the Irish-born entrepreneur, now in his mid-40s, who founded PCH 16 years ago. (The name is a sentimental allusion to the Pacific Coast Highway in Southern California, where Casey had been living until his failure to get a green card forced him to leave. I’ll say it in every article: America’s greatest strategic advantage is its openness to an outsize share of the world’s talent, and one of its greatest self-inflicted weaknesses is needlessly turning that talent away.) Casey—whose company is headquartered in Ireland and employs some 4,000 people, mainly in China, and this year will handle electronic goods with a retail value of some $8 billion—still lives in the Sheraton Four Points Hotel in Shenzhen, as he did when I met him in 2006. Everywhere he goes, he takes three iPhones with him—one on a Chinese network, one Irish, one American—and I’ve seen him use all three at once. I am several inches taller than him, but I practically needed to run to keep up with his superfast walking pace. I took this as his way of reminding himself and everyone around him that modern business is all about speed.
Here is what Casey meant by “geography is history,” and how it affects the prospects for U.S. manufacturing:
“For decades, the process of technology-enhanced globalization has been pushing manufacturing work steadily from richer countries to poorer ones. Casey has had a firsthand view of this transition. As he explained to me when I first met him, “supply chain” interactions like those between Apple and Foxconn, or other famous Western brand names and the tiny Chinese firms Casey lined up as subcontractors, brought benefits to all sides, but in a very particular way. Customers in rich countries got the benefit of cheaper products—an iPhone for $300, for instance, rather than $2,000 if it had been made at U.S. wages. Factory workers in China and elsewhere got their pay.”
But the companies involved benefited very unevenly, according to what Casey has named the “smiley curve.” This idea has become so familiar in China that the government alludes to it in the current Five Year Plan. For anyone not familiar with it, the concept refers to the sequential stages in manufacturing a product, arrayed from left to right along a U‑shaped smile. They start on the left with the corporate brand (for instance, Apple), then the product i
dea
(iPhone), then the industrial design, and on through the stages of manufacturing at the bottom of the curve—then shipment, retail, and service going up the other side. The profitability of each stage matches its elevation on the curve—which is why Chinese manufacturers, down at the bottom of the curve, get the smallest share. Globalization has thus far enriched Westerners on the high parts of the smiley curve—designers, shareholders, advertisers, other mainly white-collar professions—but has left out Western manufacturing workers.
A crucial and underappreciated step in this process, Casey and others explain, is the transition from the idea for a product to its physical incarnation, which can then be made and sold. There’s a direct analogy to the world of publishing. Even 10 years ago, having an idea for a book, a song, a political exposé or commentary, got you only so far. To spread your work or ideas beyond your immediate circle of friends required the involvement of a publishing organization. Unless you could persuade an editor, a broadcaster, or a publishing house to promulgate your views, few people would ever hear them. Writing was hard enough; “getting published” could be worse. But now, blogging software and social media of all sorts have eliminated that barrier. Publishing organizations can still provide authority and a megaphone. But more ideas from more people are now being heard by more people.
How does this apply to manufacturing? Blogging software and related technologies have made it easier for entrepreneurs in the realm of ideas to expose their products to a worldwide market test. Three-dimensional printing and related technologies are making it easier for entrepreneurs interested in making physical goods to expose their products to the worldwide market. America has more than its fair share of such potential innovators, thanks to immigration, our still-strong university and public research centers, and the financial and cultural underpinning of a start-up culture. The terrain is shifting in a way that should draw more entrepreneurs to manufacturing and let more of their ideas succeed. This should in turn foster more manufacturing work within the United States than was feasible a few years ago. Companies with the right connections to foreign suppliers and foreign markets will grow even faster.
But rather than simply shifting manufacturing work from rich countries to poorer ones, this latest technological wave should allow all regions to grow. “As business has become faster and more globally connected, that’s been good for American companies overall but bad for America’s low-skilled manufacturers,” Phil Baker, the designer for Apple and other companies, told me. “Now speed and connections allow start-ups to compete with much larger companies, and often beat them.”
Made in San Francisco“I am betting heavily on San Francisco, for its energy and creativity,” Liam Casey told me in China. He didn’t quote Jane Jacobs, but he went on to present a theory that could have come from her book The Death and Life of Great American Cities: national economies are really a collection of vibrant city economies, and cities thrive when they foster a diverse ecosystem of small enterprises whose growth is mutually reinforcing. He felt that his adopted home of Shenzhen was the engine and the success model for China. “When I came here, Shenzhen was a place to make cheap products,” he said. “Then it became a place to make products cheaply. Now, for the work we do, it’s the only place to make certain products, because of the supply base, the logistics, and the workforce.” (He said that my article about his company, “China Makes, the World Takes,” could, five years later, be redone as “Shenzhen Makes, China Takes.”) San Francisco is his model for how the new manufacturing economy would spread in America. When we spoke, he had just leased a 30,000-square-foot building off I‑280, the former home of the San Francisco Bay Guardian, and announced plans to establish major PCH operations there. “We look forward to fostering the growing community of makers in the Bay Area who seek to have a massive impact on the world through their dedication to design, brand building, and consumer experiences,” he said in a statement announcing the deal.
To put his ambitions in context, let’s consider an existing effort to boost the “community of makers” in San Francisco, a coalition called SFMade. I use it as an example of undertakings on behalf of small manufacturing in several North American cities. This example is different from Casey’s plans in its scale and its level of technology. But it is similar in its emphasis on speed as the key to manufacturing success, and its ambition to help large enterprises grow from small start-up roots.
The Bay Area might seem to display all of America’s imbalances, intensified. Tech and venture-capital billionaires on the Peninsula, hipsters in the East Bay and the city, rich naturalists in Marin, and ordinary families priced out of anything not a distant commute away. Of course, this is a caricature, but it is one that matches the prevailing rest-of-the-world view of a hollowed-out and unequal modern United States.
Into the standard American urban mix—high-end tech and finance, low-end service or tourist work, the professional class from universities and hospital complexes—has come an unlikely renaissance of small-scale manufacturing in the past five years. There is no point in comparing it with anything in China. The 400 manufacturing firms that have factories in San Francisco and are part of the SFMade coalition employ a total of just over 3,000 people, equivalent to a busy week’s intake at Foxconn’s Longhua campus. Apart from the 100-employee LeeMAH electronics firm, founded by an immigrant from China, their products are mainly medium- and low-tech: apparel, high-end food and drink, bags and accessories. This pattern will be familiar to anyone who has followed the growth of light manufacturing in Brooklyn. In San Francisco, more than 120 of the firms were founded during the past three years of overall economic distress; their employment base grew by 10.5 percent last year and 12.5 percent this year; and they have applied in their modest way the principle of drawing on a local base of skilled workers for very fast response to global consumer demand.
“Most of the companies that are here would argue that, while they are not super-duper high-tech, they are all absolutely connected to the design prowess and skilled craftworks in the city,” Kate Sofis, the executive director of SFMade, told me. The most obvious example is apparel. Like New York, Chicago, Cleveland, and Los Angeles in their periods of fastest manufacturing expansion, San Francisco has attracted a large and diverse immigrant population. “The Latino and Asian communities have a high level of apparel skills,” Sofis said. “A young designer might have high design skills but not the technical ability to realize it.” Going to Asia for production would be too slow; finding the skills elsewhere in the U.S. would be too hard. Carrying out all operations locally has allowed many SFMade companies to offer quick “mass customization”: Rather than buying off the rack, a customer can choose personalized clothing, accessories, furnishings, or furniture, mainly online. Then small factories produce the goods locally, faster than they could come from overseas. I spoke with Sofis just before she headed to a conference of the Urban Manufacturing Alliance, which promotes manufacturing in 15 other cites, from Boston and New York to Detroit and Atlanta.
I first learned of SFMade two years ago, via DODOcase, a member that is one of the city’s start-up success stories. I had bought one of the company’s iPad covers as soon as it came onto the market, because I was drawn to its distinctive retro-futuristic design. Inside, the case contains an iPad or other electronic reader. Outside, it looks like an ant
ique leather-bound book. A bamboo frame holds the electronic tablet in place and also strangely recalls the look of the page edges of a physical book.
“Back in 2010, we saw an opportunity present itself, if we could move quickly enough,” Craig Dalton, a veteran of tech start-ups who is now in his early 40s, told me in explaining the company’s history. I liked that he said “back in 2010” so matter-of-factly. The opportunity that 2010 brought was the launch of the first iPad. Liam Casey got his start making accessories for the popular electronic devices of 15 years ago. Dalton and his business partner, Patrick Buckley, did not know Casey’s story, but they saw a parallel chance.
To “design the product, and launch, and fulfill orders within one month—that meant that outsourcing to China was not ever a feasible option,” says Craig Dalton, a veteran of tech start-ups.
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“The Kindle and other e-readers were already getting noticed,” Dalton told me. “The writing was on the wall, you could say, that there was going to be this shift from ink and paper to electronics as the way people consumed information. We felt there was an opportunity to connect people to the physical experience of picking up a book, and to the soon-to-be-dying craft of bookbinding.” Buckley, who is in his early 30s, had trained as a mechanical engineer at MIT and worked in laser physics at Lawrence Livermore National Laboratory, and had grown up with several relatives who worked in New York’s publishing industry.
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He and Dalton felt they had to act fast, he told me, to get their product noticed in a field that was sure to fill up quickly. “We knew it was a very small window, and we needed to have a finished product quickly,” he said. “To figure out all the things we needed to do, and design the product, and launch, and fulfill orders within
one month—that meant that outsourcing to China was not ever a feasible option.”
When he asked friends at Levi’s, Buckley said, they told him that nine months would be a reasonable timeline to take a product from concept to delivery. “We had to do it in a couple of weeks. Nimbleness like this would be impossible with a longer supply chain.” The partners drew on local woodworking and bookbinding talent. “The resources are still here, much atrophied, but in pockets,” Buckley said. San Francisco has a long tradition of fine printing. Dalton and Buckley bought large, heavy bindery machines from printing houses and brought them into their factory.
DODOcase is a niche success, to be sure. But it has grown to 30-plus employees in two years, with 30 percent of its sales outside the United States, and its founders have broad ambitions. “If you look at brands like Levi’s and Gap and North Face that had their beginnings here in S.F., you see that a small boutique idea can grow into a global brand,” Buckley said. “It is very hard to tell ahead of time which ones will make it, but we hope to become a lifestyle brand with the recognition and scale of a Gap.”
I have learned to imagine the possibility of rapid growth. I first interviewed the founders of Google when the company had 20 employees, versus today’s 30,000, and visited Apple three years after its founding, when it had a few hundred employees rather than today’s 60,000. Big things start small.
Mr. China Comes to America
The medium-tech start-ups of SFMade (and its counterparts) are working out a strategy that combines quick response, local skills, and a global marketplace to foster manufacturing in U.S. cities. Liam Casey’s new investments in the Bay Area are designed to apply a similar model for companies several steps up the technology ladder. The purchase of Lime Lab and the opening of what he sees as an academy of high-speed manufacturing in the city could combine to bring to U.S.-based entrepreneurs, inventors, designers, and smaller companies some of the advantages now unique to Apple and a handful of other globally integrated firms—and with a greater probability than Apple’s of creating jobs in the United States.
The heart of those advantages is, again, connecting the sequential stages of the manufacturing cycle as a whole. The process naturally starts with the idea for a product. Whether the idea is practical depends crucially on how it is realized in industrial design; whether that design makes for an efficient or impractical factory experience depends on how well it is matched to process-engineering on the shop floor. Even after production begins, the design is often refined and the manufacturing process rejiggered based on real-world experience.
The closer this linkage, the faster and more efficiently an idea can be converted to tangible, marketable reality. The more evolved and responsive the feedback loop, the more precisely an organization will be able to distinguish promising projects from impractical ones. Apple has this capacity; it has teams on more or less permanent assignment to southern China to match its designers’ goals to the realities of the shop floor. But for the first time in decades, new tools are making it possible to develop this capacity for U.S. manufacturing. This means greater prospects for American innovators to convert their ideas into products—and jobs. That is what’s new, and promising. As one entrepreneur told me, asking not to be named for fear of irritating the mighty Apple, “What Apple has, internally, will now be available to smaller companies.”
In specific terms, the service that Lime Lab and a growing number of design firms can offer is a “quick iteration” way of deciding which ideas will be most practical for manufacturing. “Over the past couple of years, people have gotten used to the idea of rapid iteration in social-media firms,” Linus Chung told me. “You iterate and adapt quickly based on consumer demand. You learn to ‘fail fast.’ We’re bringing that to the hardware space.” As an illustration, he mentioned a start-up called Lark, which makes electronic sleep- and fitness-monitoring devices that are part of the broader trend toward precise, individualized indicators of health that Mark Bowden discussed recently in “The Measured Man” (July/August 2012). Lark was founded two years ago, while the overall economy was still reeling, by a Stanford-trained entrepreneur named Julia Hu. Many of its products, the latest of which is a $149.99 wristband that monitors your sleep, exercise, calorie-burning, and even degree of hydration, are now carried at Apple stores and by Best Buy and Brookstone. The electronics in this wristband are assembled in China, as are nearly all of the world’s electronics. But more of the total job growth in the company’s rise, including engineering and design work, has been in the United States than would have been the case even way back in 2009. “They started with five people, and now they have 30,” Chung, who has worked with Lark, told me. “For a company their size, you’d expect they’d need half those people in China. Now that entire team is one office in the United States.”
Fifteen additional employees here, a new urban start-up there—these are obviously not the sole answers to America’s reindustrialization. The growth of this sort of activity depends on large-scale policies: continued national investment in high technology; education to train the next generation of engineers and craftsmen; negotiations to open up markets (and protect intellectual property) around the world. The politically controversial, but right, decision to keep General Motors operating saved hundreds of thousands of manufacturing jobs from being needlessly lost.
But developments like these are an important part of the solution. Any account of a region’s growth or decline at any stage of our economic history has indicated promise when the region is full of people optimistically starting small ventures, and decline when it is not. “The real key to long-term value creation is that ongoing string of new companies,” Liam Casey told me this year, in New York, after he had met with people considering start-ups there. “That’s where you create the next wave of value, and new jobs.” American culture has long been favorable to the start-up, and the United States has captured a disproportionate share of the profits from their innovations. Shifts in technology may soon allow us to capture more of the jobs.
Small U.S. Manufacturers Give Up on 'Made in China'
in NewsFor LightSaver, the decision was simple. Neither of the founders has ever been to China, which made communicating with manufacturers difficult. Components that were shipped from the U.S. sometimes got stuck in customs for weeks. And Anderson had to spend hours on the phone to explain tweaks in the product. “If we have an issue in manufacturing, in America we can walk down to the plant floor,” Anderson says. “We can’t do that in China.” Anderson says manufacturing in the U.S. is probably 2 percent to 5 percent cheaper once he takes into account the time and trouble of outsourcing production overseas.
Dana Olson makes a living convincing small manufacturers that it pays to produce domestically. About 10 percent of the roughly 60 companies that his Minneapolis firm, Ecodev, has worked with have moved manufacturing to the U.S. or decided not to send it overseas, and another half-dozen are considering similar moves. “There’s a growing sense, with the economy doing what it’s doing, of U.S. companies wanting to produce in the United States,” says Olson. “It’s very important to them to have ‘Made in the U.S.A.’ on their label again.”
Since 2008, Ultra Green Packaging, one of Olson’s clients, has used manufacturers in China to make compostable plates and containers from wheat straw and other organic materials. By yearend, Ultra Green expects to start producing the bulk of its wares at a plant in North Dakota to cut freight costs and protect its intellectual property. “They’re infamous over there for knocking [products] off,” says Phil Levin, chairman of the 10-employee company. “All anybody needs to do is find a different factory and make a mold.”
For Unilife, moving production to the U.S. helped it win regulatory approval for an important product: prefilled syringes with retractable needles that make it almost impossible for medical personnel to accidentally stick themselves. Although the company used Chinese manufacturers for earlier offerings, syringes preloaded with medications are subject to stringent U.S. Food and Drug Administration rules. So in March 2011, Unilife began making its syringes at a $32 million, 165,000-square-foot plant it built in York, Pa. “The very thing in the U.S.A. that oftentimes we complain about—the complexity of the rules and the regulations—works for us,” says CEO Alan Shortall. “FDA compliance is the main reason we’re here.”
Even with strong Mandarin skills, Brian Bethke grew frustrated with manufacturing in China. The co-founder of Pigtronix, which makes pedals that create electric guitar sound effects, discovered that he couldn’t adequately monitor quality at Chinese factories. The original idea for the company was to develop products in the U.S. and make them in China, where Bethke was living. But after several years of finding technical glitches in as many as 30 percent of pedals, the company decided to move production to Port Jefferson, N.Y. At its small factory in a Long Island office park, the company can run multiple tests on its products and even has a guitarist play each of the 500 to 1,000 pedals it sells monthly before they’re packed and shipped.
While goods for U.S. consumers are less likely to be made in China these days, overseas production may still make sense for companies that plan to target foreign markets. “What we’re seeing is regionalization, buying stuff from manufacturers in the region where you’re going to sell it,” says Michael Degen, CEO of Nortech Systems, a contract manufacturer based in Wayzata, Minn., that has eight factories in the U.S. and one in Mexico. “It’s very noticeable. … We’ve seen movement in terms of manufacturing in country for country.”
The bottom line: Although manufacturing in China can cost a third what it does in American factories, small companies are bringing production back to the U.S.
What The Surge In Manufacturing Means For Skilled Labor
in UncategorizedJanuary, 2013
Skilled labor is at crisis-level shortages both at home and abroad, with over 10 million skilled labor jobs remaining vacant worldwide.That shortage is not likely to abate in the near term, and in fact, it’s likely to get significantly worse. A global study by McKinsey & Company predicts a need for 95 million skilled workers by 2020, while simultaneously anticipating a surplus of low-skill workers that reaches the same heady number.
From White Collar to Blue Collar
It would seem that a dramatic re-skilling is in order.
The past several decades have seen the United States and most other developed nations engaged in a breakneck race to funnel as many young people into four-year baccalaureate programs as possible. The goals for this frantic pursuit were varied, but in an era of increased automation — and increased consumption — the proverbial chickens have come home to roost.
In 2012 the U.S. boasted that a record 30% of its adult population held a bachelor’s degree. In the coming decade, it’s likely that many in that 30% will be looking to abandon the search for increasingly rare white-collar jobs and repackage their skill sets to take advantage of the need for savvy blue-collar talent.
The Push for Trade Education
Of course, some companies and educational institutions are ahead of the curve. A recent survey by ThomasNet.com demonstrates that nearly half of 1,600 manufacturing companies surveyed are having difficulty filling open positions for skilled labor. As a result, many companies are helping educators create job training programs for young people that will prepare a new generation for the demands of a skilled industrial workforce.
But these aren’t your grandfather’s trade- and tech-schools. As Ira Wolfe, owner of Success Performance Solutions, recently told Bloomberg Business News, “The trades are not just about swinging a hammer any more; they involve applying brainpower and advanced education.”
Indeed, technical education has become more specialized and demanding than ever before. At a time when highly technical machines like CNC tools are standard — and would have baffled even the most skilled workers a generation ago — working in the trades is no longer about having a strong back. Instead, it requires combining considerable technical acumen with the wherewithal to get one’s hands dirty, a sensibility that isn’t always so easy to find.
For the American manufacturing investor or owner , establishing a skills and training program for the next generation of workers is akin to sowing your seeds before the harvest season arrives. It’s necessary, it’s forward-thinking, and it just plain makes sense.
Worker Shortage? Teach Teens Manufacturing Skills
in UncategorizedA recent survey of 1,600 manufacturing companies in the U.S. shows that nearly half have openings for line workers, skilled trade workers, and engineers, but many have trouble filling the positions. The survey, released by industrial product sourcing and supplier selection website ThomasNet.com, echoes other reports of skilled labor shortages. Instead of lamenting the problem, manufacturers are helping educators establish training programs for prospective employees, says Linda Rigano, executive director of strategic services at Thomas Industrial Network, which runs ThomasNet.com. She estimates that there are dozens of similar partnerships in the U.S. and says, “we’re seeing more pop up every day.”
Training partnerships are the only way for domestic manufacturers to rebound, says Ira S. Wolfe, whose Success Performance Solutions in Lancaster, Pa., helps small businesses recruit and hire employees. Criticism that vocational training leads to exploitation of low-paid, nonunion labor is outdated and unrealistic, Wolfe says. “The trades are not just about swinging a hammer any more; they involve applying brainpower and advanced education.”
Five years ago, label and adhesives maker Tailored Label Products, which is near Britten’s high school, joined the Second Chance Partners program she attends. In 2009, TLP, which has 75 employees, turned a 2,000-square-foot office area in its facility into a classroom, taking on the cost of outfitting the space for students. Each semester, 10 to 15 students do two hours of classwork on site every day and then work as apprentices at TLP and other local factories.
At TLP they rotate through departments with a mentor, learning both unskilled and skilled tasks such as digital printing and finishing. TLP has hired two former students as full-time employees, where they can earn between $10 and $20 an hour and get medical and dental benefits as well as employer-matching 401(k), profit-sharing, and wellness plans, says Tracy Tenpenny, TLP’s vice president for sales and marketing.
Since its inception in 2000 (it grew out of an earlier program founded in 1996), 158 students have completed the 21-month Second Chance program, which has had a 90 percent graduation rate, according to Executive Director Stephanie Borowski. More than half of the graduates continue to work at one of program’s business partners, with 62 percent going on to full-time employment, 29 percent enrolling in post-secondary education, 5 percent continuing in apprenticeship programs, and 4 percent joining the military. Second Chance is funded by local school districts and the 70 Wisconsin businesses that participate, along with grants and donations.
In Pennsylvania’s Bucks and Montgomery counties, 50 manufacturing companies have formed a separate entity, BuxMont Manufacturing Consortium, which partners with two-year colleges and trade schools to hire and train their graduates. Its programs target young people interested in science and engineering and good at working with their hands, says Michael Araten, third-generation president and chief executive of The Rodon Group, a plastic components maker in Hatfield, Pa.
Although the family-owned, 100-employee business sends some of its parts overseas for assembly, it manufactures all its products in the U.S. Many of its competitors moved production off shore over the past 30 years, Araten says. Now he sees many returning due to supply chain complications and shipping expenses. “We’re in year three of what I think will be a 10-year transition back to U.S. manufacturing as a world leader,” he says.
Skilled workers at companies in the Pennsylvania consortium typically make $35,000 to $50,000 annually, plus overtime pay, health care, and employer-matching 401(k) accounts, Araten says. That future sounds pretty good to Brody Kolpin, 17, who says he “kind of gave up” on school after his freshman year at Mukwonago High School, also about 30 miles from Milwaukee, until he joined a Second Chance Partners program in September 2011.
He now works in maintenance at a Mukwonago manufacturer and is taking classes at program partner Waukesha Generac Power Systems. “I’m very mechanically inclined. I love to take things apart and see how they work and then put them back together,” he says.
FDA Reports 500 Dog Deaths From Chicken Jerky Treats
in UncategorizedJanuary, 2013
According to NBC News, “A new tally of reports filed with the FDA show the agency has received 2,674 reports of illness involving 3,243 dogs, including 501 deaths. The agency also has received reports of nine illnesses in cats, including one death.”
The FDA has reminded pet parents that jerky treats are not necessary for your dog’s diet and can be safely eliminated. The agency will continue to investigate the claims of pet deaths and illnesses.
“The agency last spring inspected five Chinese plants that made jerky treats,” NBC News reported. “Officials weren’t allowed to take samples for testing. Now, inspection reports released about the fifth site, Yantai Aska of Yantai, China, show that plant officials falsified records regarding imports of glycerin, a key component in the jerky treats. Officials with China’s regulatory agency, the General Administration of Quality Supervision, Inspection and Quarantine, suspended the firm’s export certificate as a result of the March 2012 inspection.”
Two more companies have announced recalls of these tainted products. Cadet Brand Chicken Jerky Treat Products and Publix Chicken Tenders Dog Chew Treats are being recalled because they may contain trace amounts of antibiotic residue.
According to Publix, “The UPC, located on the back right-hand corner of the product, is 41415-18527and the product comes in a 3.5 ounce bag. This product was sold in Publix grocery stores in Florida, Alabama, Georgia, South Carolina and Tennessee.”
The Publix jerky treats can be returned to the place of purchase for a full refund. For more information, call the Publix consumer relations department at 800-242-1227 Monday through Friday from 8 a.m. to 7 p.m., or visit their website.
As for Cadet, although the company was initially only requested to recall their tainted treats from retail locations in New York, it is voluntarily recalling the jerky treats worldwide. If you purchased the recalled Cadet products, call IMS Pet Industries at 800-394-4467 or file a claim here.
Wal-Mart 'Jump Start' Is an Admission There Is a Problem
in Uncategorized01/17/2013
However, to be honest, for a firm with nearly $450 billion in annual revenue, buying a mere $5 billion more a year of Made in America stuff is chump change. That will only account for about 1.5 percent of their wholesale purchases. While it is clearly not enough, the fact that America’s biggest importer has made such an announcement is very important in itself.
The Wal-Mart plan follows fast on the heels of Apple CEO, Tim Cook, announcing that some Macintosh production would be moved back to the U.S. this year. Apple has been the other iconic driver of Chinese GDP via American consumption supporting a process of declining real wages for the middle class, rising levels of long-term unemployment and a national calamity of under-employment (college grads working two shifts in retail stores).
Together, these announcements show that even top CEOs can no longer whitewash their lack of corporate patriotism with blather about the “benefits of free trade” and promises of “access to the world’s largest market” that will come to America, someday. The public has finally figured out that someday never comes. Corporate America is beginning to worry that the American public has caught on to the real source of their collective misery — a disastrously naive trade policy that benefits a growing plutocracy in China and the U.S.
In the last 18 months, I’ve seen this awareness in a completely new level of response to my lecturers about trade and China. It doesn’t matter if I’m in a college classroom, a union hall or a Tea Party meeting. Business leaders are also more attentive and I’ve had several very positive discussions with enlightened members of Congress from both parties. A somber determination is building to throw out the rascals who have negotiated the transfer of America’s wealth to Communist China. In fact, almost nobody outside of a few diehard faculty in our top business schools and their fans in the business press still holds on to the belief that America will actually benefit from a continuation of the trade policy status quo.
A lot of the credit for this awakening belongs to small group of brave, non-partisan economists, writers, bloggers, organizers, business owners, and even politicians that have been serving on the front lines of this battle. Through the dark years, they’ve worked together, despite disagreeing on many other things. They’ve often endured insults and sustained injuries in the fight for restoring American strength and prosperity. A lot of them have spoken out on the issue of workers and human rights in China as well. They have carried on, because they cared more about the real world outcomes than the beauty of theory. I’ve been proud to be a minor player in this effort and I’d like to thank a few of these daring Americans for a job very well done, but not yet finished. The following, incomplete list, provides a good starting point for those interested in learning more about trade reform.
Governor Buddy Roemer
Peter Navarro, economist, professor, writer and mentor
Ian Fletcher, economist and writer
Alan Tonelson, economist and writer
Thea Lee, labor economist
Bob Baugh, Industrial Union Council
Michele Nash-Hoff, businesswoman, writer
Richard McCormack, Manufacturing Technology News
Pat Choate, economist and policy analyst
Leo Hindrey, businessman and writer
Dylan Ratigan, TV personality and writer
Pat Mulloy, dedicated public servant, speaker
Andy Grove, visionary business leader
Peter Morici, economist, professor and writer
Ralph Gomory, mathematician, business executive, and writer
Bob Hall, writer and aspiring U.S. president
Harry Moser, businessman and advocate
Brian O’ Shaughnessy, businessman and patriot
Michael Stumo, Coalition for a Prosperous America
Clyde Prestowitz, economist, author
Den Black, American Jobs Alliance
Joel Joseph, Made in USA Foundation
Charles Blum, diplomat and consultant
Gil Kalpan, Renaissance for American Manufacturing conferences,
Beri Fox, Business Woman
Nanette Lepore & Robert Savage, Save the Garment Center
Congressman Tim Ryan (D,OH-17)
Congressman Dana Rohrabacher (R, CA-48)
Congressman Chris Smith (R,NJ-4)
And if you want more, follow:
Mike Tamulis, American Made Heroes
While I know I didn’t get e
veryon
e (sorry) and I’ve left out some really hard workers who generally don’t want publicity, you know who you are. Let’s celebrate this crack in the fortress of multinational corporate resolve and then get back to work so Americans can get back to work!
Greg Autry is the author of Death by China and serves as Senior Economist for the American Jobs Alliance and Economist with the Coalition for a Prosperous America. He has taught at the Merage School of Business, UC Irvine and is joining the faculty at the Argyros School of Business and Economics at Chapman University. You can find him on Facebook.
Reshoring: American Manufacturers Are Coming Back Home
in UncategorizedJanuary, 2013
On the factory floor, the din is overwhelming. More than 3,000 workers – half the population of Clyde – are busy testing, screwing, welding, and painting the hundreds of pieces that make up the company’s washing machines.
This is the largest washing machine plant in the world, with 30 miles (50km) of overhead conveyor belts that clatter along, carrying assorted barrel drums and metal doors.
Those carts driving by, filled with grey fabric? They have no driver. They are automated to follow an orange line on the ground.
And those LED screens at each assembly line? They monitor each worker’s productivity to the second and can give instant feedback about how to improve production.
Such details make the plant one of Whirlpool’s most productive, and it is one reason why the company, when it was looking to move production from a plant in Mexico, decided to bring jobs back to Ohio.
“There’s been a lot of focus both by the company and the employees to become more efficient, more effective,” says Whirlpool vice president Jeff Noel.
“That’s made making products in the US more competitive than it has been in the past.”
Homecoming
American manufacturing lost more than two million jobs during the recession, accelerating a decline that had begun long ago in the 1970s.
Yet since then, manufacturing has been one of the biggest drivers of job growth in the US, adding more than 500,000 jobs.
While much of that job growth could be attributable to post-recession pent-up demand, that is not the whole story.
According to the Reshoring Initiative, a group of companies and trade associations trying to bring factory jobs back to the US, about 10% of those job gains – 50,000 jobs – were created by companies bringing back manufacturing from overseas.
Last March, the GE’s chief executive, Jeffrey Immelt, wrote an article in the Harvard Business Review where he announced that GE planned to add more than 1,000 manufacturing jobs at its Louisville, Kentucky, facility – a manufacturing plant the company tried to sell only a few years ago during the depths of the recession.
“We can bring manufacturing back to the United States and be profitable,” Mr Immelt said.
There are many reasons why the corporate accounts are once again favouring the American worker.
Higher labour costs abroad, coupled with cheap natural gas as a result of the fracking boom in the US and workers who are willing to work for lower wages, have made it more economical than it once was to produce back in America.
Moreover, changing consumer behaviour means customers often want products immediately and with varying specifications, so “it’s better to be closer to your customers”, according to Mr Noel.
Finally, newer factories with increasingly automated technology require a more highly educated workforce, which the US has as a result of its manufacturing past. Besides, automation costs are roughly the same wherever in the world a company operates.
With all these factors combined, by 2015 a variety of manufacturing industries, from appliances to tyres, will find it more cost effective to produce goods in the United States, according to a recent report by the Boston Consulting Group.
This could add an estimated two to three million jobs and more than $20bn in output to the American economy – a striking reversal from years past.
But 2015 is a long way off, and some remain sceptical.
“The best data we have shows us that nothing like a manufacturing reshoring wave is happening now,” says manufacturing expert Alan Tonelson, of the US Business and Industry council.
With headwinds from Europe, dysfunctional politics in Washington, and US trade policy that continues to encourage overseas production, the growth in manufacturing job creation appears to be slowing down, Mr Tonelson adds.
And even if all of these factors were to disappear, it would be unlikely that the jobs added would ever be able to replace the more than eight million jobs that have been lost since the 1970s.
‘Family business’
For Clyde’s workers and others in the local community, Whirlpool’s commitment has allowed them to breathe easy for the first time in a while.
“It’s very important for us, especially since they’re the largest manufacturer in our county,” says Kay Reiter, executive director of the Sandusky County Economic Development Corporation.
“If you look at all the suppliers that we have already locally, it’s huge.”
The hope is that Clyde can continue as it has been since Whirlpool first came to the town in 1952; as a place once described in American literature by Sherwood Anderson as the quintessential American small town.
For this community, “Made in America” is not a fading sentiment. It is a rallying cry.
“I’ve been with Whirlpool for 26 years,” says Sonny Workman, who works on the Alpha assembly line in the plant.
“My dad worked here, my aunts and uncles too. It’s the family business.”
Offshore Wind: Enormous Potential, Huge Challenges
in UncategorizedContributor
January 2013
What is clear is that we have come a long, long way from the 1980s, when Zond was developing the first big wind farm in Tehachapi,California, where 500 turbines generated a total of 40 MW. Today, the same amount of energy can be produced by approximately eight 2.5MW wind turbines.
The following table from AMSC gives one a good idea of the progress made in the last three decades, as well as the huge gains expected in the next three or four years:
The onshore resources are abundant in such locations, but they are far from energy-hungry populations. It has proved politically very difficult and costly to pass through the regulatory hoops to build transmission lines from the wind hotspots to the demand centers. For one $7 billion line being built to bring West Texas wind from to Dallas and other large cities, easement payments have ranged between $3,000 and $10,000 per acre, and there has been significant and time-consuming local opposition. Many of the high voltage transmission lines being proposed in other parts of the country to update our antiquated electricity grid could take decades to build. The federal, state, and local regulatory thicket is nearly impossible to navigate, and one failure in the process can kill the entire endeavor. This transmission constraint contributes further to the push to develop offshore.
Today, the typical onshore machine averages somewhere between 1 and 3 MW, and offshore machines are in the 3-4 MW range and getting significantly larger. The economics of offshore wind development necessitate scale. Constructing and maintaining turbines in remote and difficult offshore marine environments requires specialized technology, including specialized construction ships costing as much as $100 mm. As a consequence, the machines being built to harvest the steady offshore winds must have huge blade sweeps and big turbines to be economic.
The DOE is pushing a National Offshore Wind Strategy initiative to bring the costs of offshore wind to ten cents per kilowatt-hour for 10 gigawatts (GW – a thousand megawatts) of power by 2020, with an ultimate goal of 54 GW at a cost of seven cents by 2030. However, this won’t happen without a few major economic and technological developments. Both blades and turbines will have to get bigger and better.
Let’s start with blades. The bigger the swept area of the rotor blades, the more energy one can harness from the turbine. The relationship between the rotor size and the swept area is not linear. For instance, to increase the rotor diameter from 150 m (today’s largest blades) to 200 m (being developed by BD for AMSC’s 10MW offshore turbine) the blades will increase in length by 33%, but the swept area, which captures the wind energy, will increase by 78 (πR2) If you’re offshore then, you are looking at deploying blades that are as long as a football field. By way of comparison, a Boeing 747 is 64.4 m from wing-tip to wind-tip, less than one-third the size of a 10MW offshore turbine.
This creates an interesting economic and technological challenge. In order to make wind energy cost-effective, one has to keep initial component costs as low as possible. Sandia Labs put it very well in a 2011 report on blade manufacturing: “Wind turbine blades have near aerospace quality demands at commodity prices; often two orders of magnitude less cost than a comparable aerospace structure. Blade failures are currently (listed) as the second most critical concern for wind turbine reliability.” The experience of Suzlon was eye-opening in this regard. Blade cracking issues resulted in a six-month remediation program costing in the tens of millions of dollars.
The second step, once you have created half the blade in the mold is to take the one “clamshell” and join it to the other with special adhesives, with a spar in the middle to improve strength. Since the development of these blades is essentially a process done by hand, the two clamshells are never exactly identical opposites. Thus, the joining often has imperfections as well. Just about every blade requires fixes of one sort or another.
In looking at the issue, Sandia Labs comments: “While the design and manufacturing of blades has improved, it is not clear that it has done so at a rate necessary to ensure a 20-year design life. Many of the blade suppliers are using technologies and techniques that were developed for structures with much lower design loads and criteria. While these methods are inexpensive, they are thought to offer questionable reliability.”
Sandia points to the issue of size as likely creating more failure, all other things being equal: “thick composite laminates have an increased likelihood of hidden flaws and multiple fla
ws being groupe
d in the same local area. A number of production related flaws may occur in larger structures which are more easily avoided in smaller structures…Other factors which are more likely in larger blades include fiber waviness, large scale porosity, large resin rich areas, and resin cure variations through the thickness…Moreover…larger structures have a greater probability of a critical flaw.”
Addressing this concern that bigger may not be better, Blade Dynamics brings a different logic to the game. Their goal is to bring quality control down to the micro level. Instead of laying out the blades as two single large components which are then glued together, with a spar in the middle, they create a series of smaller structures – in a more controlled environment – which they can quality check and then join together. The clamshells are not built as whole units that are joined, but rather as a series of modular pieces which wrap around a modular central spar as they go.
BD believes this not only gives them strength and consistent and reliable quality – which is what they were at the Wind Technology testing Center to prove – but flexibility as well. With the joined clamshell approach, a blade exceeding 50 yards is exceeding ponderous to move. On land there have been cases where highway exit ramps have been built just to accommodate wind turbine blades. In the case of Blade Dynamics, the sections can be moved in any specified length. Currently, the default standard is 40 feet – the length of a standard truck container. Backed by Dow Chemical, they hope to use this technology to challenge the big and established wind energy giants (Siemens, Vestas, Enercon, Gamesa, GE, and a small number of other highly capitalized players) in the offshore frontier.
ETI’s nearly $25 mn investment in BD, announced just this week, will add more wind to BD’s sails. ETI took a stake specifically to advance development of enormous carbon fiber blades (compared with traditional fiberglass construction) of between approximately 90 and 100 yards, for turbines in the 8-10 MW range. By comparisons, the largest blades currently turning offshore are just over 80 yards long in 5-6 MW machines. The goal is to accelerate development of prototypes and put them into production by the end of next year, with a reduction in weight of up to 40%. The lower weight reduces costs throughout the rest of the system, improving overall economics. BD’s smaller D49 Blade just won recognition as The Best of the Best Blade of the Year by Windpower Magazine, among established competitors like Siemens and Vestas, so they may just have something here.
Now let’s address turbines. American Superconductor, for its part, sees a different and complementary challenge worth addressing. Bigger machines transmit more energy. However, big gusts of wind can transmit too much energy into the critical components (gearbox and generator), essentially destroying them. Gearboxes have traditionally been used to speed up the RPM from the rotor to the generator, but they are the weak link in the chain as you get larger. As a consequence, many manufacturers are going to wind turbines without gearboxes. However, torque then becomes a problem, requiring huge generators with heavy copper windings that may scale out in the 3-4 MW range. As AMSC’s Thomas Feiler puts it “you essentially have a locomotive on top of a very high tower.”
AMSC sees an advantage for their technology in this area, as their lightweight, superconducting ceramic wire can allow them to build machines which are both simpler and lighter. They are betting on their experience in designing and building electric motors for ship propulsion systems for the US Navy. For the sake of comparison, AMSC indicates in their literature that a 10 MW superconductor generator would have a nacelle-generator combination weighing approximately 420 tons, compared with a conventional direct-drive machine weighing over 800 tons. This reduction in size and weight would lower overall wind development costs, resulting in a lower overall delivered cost of electricity. They believe that the simpler more efficient design will also significantly reduce operations and maintenance costs. Modern wind turbines are designed to operate 24/7 for 20 years. A car, if designed for a similar duty cycle, would have to operate for more than 3 million miles.
Blade Dynamics and American Superconductor are two of a small number of US players competing for an industry estimated to be worth in excess of $100 bn annually until 2020, and getting even larger after that. The World Wind Energy Association estimates that there is currently 250,000 MW of installed wind capacity in operation today, growing at 15 – 20% annually.
Of this 250,000 MW, only a few thousand MW has been developed offshore, in Europe. There, 3,300 MW has been installed, 5,600 MW is under construction, 17,300 has been permitted, and an additional 115,000 MW is planned. Asia is also eyeing a huge push offshore. Pretty soon, wind developments will occur off US shores as well. The total estimated offshore wind potential for the US is 4,100 Gigawatts (GW), or approximately four times the size of the total US power system. The New England and Mid-Atlantic resource is estimated at just over 1,000 GW. There are still technical hurdles to be overcome in developing the massive blades and generators necessary to cost-effectively harness wind in the ocean. But for the wind industry, this may be the biggest prize yet to come.
Walmart to Boost Sourcing of US Made Products: Hiring 100k Veterans
in Consumer Products, Domestic Sourcing, Economy, Jobs, Made in USA, Manufacturing, Reshoring, Veterans, WalmartWalmart announced bold commitments to increase domestic sourcing of the products it sells and help veterans find jobs when they come off active duty. Speaking at the National Retail Federation’s annual BIG Show, Walmart U.S. President and CEO Bill Simon also announced the company is helping part-time associates who want to be full time, make that transition. Read more
Walmart to Boost US-Made Products
in Consumer Products, Domestic Sourcing, Economy, Jobs, Manufacturing, Reshoring, WalmartWalmart today announced bold commitments to increase domestic sourcing of the products it sells and help veterans find jobs when they come off active duty. Speaking at the National Retail Federation’s annual BIG Show, Walmart U.S. President and CEO Bill Simon also announced the company is helping part-time associates who want to be full time, make that transition.
Read more
Chinese Safety Concern Empties Distant Shelves of Infant Formula
in UncategorizedJanuary, 2013
The run is one of the odder examples of how China’s thirst for high-quality products can upend faraway consumer markets, particularly amid concerns about the quality of its food supply.
A number of recent high-profile scandals involving tainted food products in China have shaken public confidence in the safety of domestic supplies. In 2009, two Chinese milk producers were executed for selling contaminated milk powder after infant formula and other products were found to have the industrial chemical melamine. Six children died and about 300,000 became ill, provoking a nationwide panic among parents.
Last June, China’s biggest milk producer, the Inner Mongolia Yili Industrial Group, was compelled to recall six months’ worth of production.
With about 16 million births a year, China is one of the world’s largest markets for baby food and infant formula, representing around 23 percent of the $41 billion global market, according to a recent study published by Euromonitor International, a research firm in London.
Concerns about the safety of domestic supplies have led to a sharp rise in demand for imported formula among urban middle-class households, sending prices of foreign brands soaring in Chinese supermarkets. According to the United States Department of Agriculture, the retail price of a 28-ounce package of imported formula is 290 to 350 renminbi, or $46 to $56 — about 50 percent higher than most domestic brands.
Hoping to stem the loss of market share to foreign competitors — and perhaps to reap the higher margins on foreign milk — some Chinese producers are investing in plants overseas. One of China’s leading makers of baby formula, Synutra International, announced plans in September to invest about $130 million in a new milk-drying plant in the western French region of Brittany that will be operated by Sodiaal, a French dairy cooperative.
The plant, which is expected to open in 2015, will produce around 100,000 tons of “high-quality” whey and milk powder a year exclusively for Synutra, the company said.
With Chinese visitors to Australia reaching record numbers in 2012, local merchants say it is common for these travelers to stock up on formula.
“This has been happening for maybe five years,” Edward Karp, who owns Pyrmont Pharmacy in Sydney, said in an interview. “Their pilots and their flight attendants used to stay at the hotel in the other block, and they used to come in and buy cartons of baby formula to take back home for their family and friends. They used to come in in their uniforms with the trolleys, put the bags on the trolleys, and off to the airport they’d go.”
The phenomenon is not unique to Australia. Mainland Chinese visitors to Hong Kong, for example, have put such pressure on formula supplies that retailers routinely limit purchases to four cans per customer, analysts say. Thousands of Chinese households are also placing international orders for formula online, either directly or through friends and relatives living overseas.
The shortages in Australia are primarily limited to the Karicare Aptamil Gold brand of formula, which is produced by a New Zealand-based subsidiary of the French food-product giant Danone. It remains unclear why that brand is in greater demand than others, but Australia’s leading supermarket chains, Coles and Woolworths, acknowledged this week that they were struggling to meet demand.
A spokeswoman for Woolworths, speaking on the condition of anonymity in line with company policy, said that while the chain had not instituted formal rationing, it would restrict the amount that customers may buy at any one time.
“Woolworths is not a wholesaler; we reserve the right to limit the number of identical products any one customer can buy during a single visit,” the spokeswoman said in an e-mailed response to questions. “While there is no specific limit set, our stores are encouraged to use a common-sense approach to ensure stock is only sold in retail quantities.”
Alistair Bradley, the general manager of Nutricia, which produces the formula at its New Zealand factory, told the newspaper The Australian on Friday that the company was struggling to keep its products on the shelves, despite having increased production to 20,000 tons from 5,000 in 2012 to cope with growing domestic demand.
“This, coupled with food safety concerns overseas, has generated an unexpected increase in demand for Karicare and Aptamil formula,” he said. “We are currently not always able to ensure that adequate amounts.”
In Perth, on Australia’s west coast, Richard McWatt, the manager of the Superchem Family Pharmacy, said by telephone that a customer had called him on Thursday to buy 100 cans of the formula. Similar stories have been reported in the Australian news media, although it is unclear how the products are being taken out of the country without the imposition of export duties.
“Some families will buy six tins at a time and send it back to their home country, but never that many at one time,” Mr. McWatt said.
Some of the purchases, though, could be the result of hoarding by residents fearful of shortages.
Nicola Clark contributed reporting from Paris.
Made in America, Again: Bringing Manufacturing Jobs Back to The U.S. is Politically Savvy and Can Make Economic Sense.
in UncategorizedJanuary 2013
The idea is known as “reshoring.” Although Chinese wages are a fraction of U.S. labor costs, rising shipping rates, quality problems, and the intangible costs of being far from headquarters all add up. That’s why some companies have begun to rethink the manufacturing equation.
MIT Technology Review interviewed Harry Moser, head of the Chicago-based Reshoring Initiative, about the trend. Moser, a former industry executive whose family has been involved in American manufacturing for a century, says he grew up “experiencing the glory of U.S. manufacturing.” He created the initiative to help companies compare the real costs of manufacturing at home and abroad, and to track the experiences of those who are returning.
Why are people talking about reshoring all of a sudden?
It’s actually been happening over the last few years. The obvious answer is that Chinese wages are doubling every four years. The consultants who five years ago were helping people offshore are now helping them inshore. And then you have President Obama making a big deal over how to reduce imports and start making stuff again.
How much of Apple’s plan to manufacture in the U.S. is real, and how much is window dressing?
There’s a lot of speculation about that. Some people say it’s politics. From what I can tell, the units Apple produces in the U.S. won’t have as a high a margin. But it’s also true that consumers are looking for an American product. Think about GE, with its appliance park in Louisville, where they just reshored several products. They say they are going to save $400 million doing that, but then they spent maybe $100 million on advertising what they’re doing. I’ve seen their ad 20 times already. Reshoring is good for GE. Now they can be the good guys.
You’ve calculated that about 50,000 jobs have been reshored since 2010. How many of those came back for political reasons?
I’d say politics doesn’t account for more than 5 percent. Only a GE or an Apple would think about politics. For everyone else, it’s just a matter of the total cost. They never even broach the political question.
Why’d you get into the reshoring movement, and what’s your goal?
My family has been in manufacturing for 100 years. My grandfather was a foreman at Singer Sewing Machine, and my dad helped run their factory in what was then the largest building in the world, in Elizabeth, New Jersey. All that is totally gone, and I feel the need to bring it back.
The goal is to balance the U.S. trade deficit, which is $600 billion a year. That is largely due to offshoring of manufacturing jobs. Since the 1950s, about three million manufacturing jobs have been lost to imported goods. So to balance the deficit we’ll need to bring back three million jobs.
How big will the effect be on high-tech industries?
Keep in mind, the vast majority of what Americans consume isn’t high-tech at all. We need to efficiently make ladders and hammers and paper and lights. And we need to do it with the relatively unskilled workforce that we have. Since other countries are targeting high tech, we’ll never dominate it enough to balance the trade deficit.
So what types of manufacturing are coming back to the U.S. right now?
Most of the products coming back went away only recently, and often without much economic logic—it’s generally mechanical and electrical equipment that has some size and weight, such as transportation equipment, die castings, and foundries. The cost is just too high to ship those. I think appliances fit pretty well into the reshoring story, too, since you are shipping quite a lot of air.
How big a part are worries over intellectual-property theft in China playing in the reshoring story? Is that a reason to keep manufacturing close to headquarters?
People talk about it all the time, but it’s hard to quantify. It’s a much bigger problem for software, where there’s a disk you can copy, than it is when you are making a refrigerator. A refrigerator is made up of very little intellectual property and a lot of weight.
What about advanced technologies for manufacturing? Will they help the U.S. close the trade deficit?
I see a lot of trendy over-excitement. Take 3-D printing. It’s pretty far from being a way to make auto parts. And even if we did create that market, we’d sell those printing machines to everyone. So everyone will have them. For instance, total U.S. sales of machine tools—the machines we use now to manufacture things—are $6.6 billion a year. But the use of those tools is worth hundreds of billions of dollars. So the greater value is in putting [manufacturing] technologies to use, not inventing them.
I think the return on investment of what we already know how to do—automation, training, lean techniques—is much higher than investing billions into advanced manufacturing processes. If society looks at the returns from the advanced stuff, it won’t be overwhelming.
Recall Alert: IMS Trading Corp Voluntarily Recall Cadet Brand Chicken Jerky Treat Products
in UncategorizedJanuary 11, 2013
The next manufacturer of chicken jerky dog treats joining the nationwide product recall is IMS Trading Corp, makers of the Cadet brand of dog treats.
Additionally, it remains to be discovered how extensively the chicken used to make these treats expands into other dog food production. The only way to ensure the safety and well-being of your pets is to stop feeding them foods and treats that are manufactured, sourced, or processed in China.
The melamine dog food scare in 2007, along with the Chinese government’s refusal to work with the FDA and investigators to locate the source of contamination in these treats further strengthens our position that when it comes to the health and safety of our pets, the Chinese are more concerned with their bottom line.
Memo to all IMS customers from Samuel Blachorsky, President
Can America Step Up To a Manufacturing Renaissance?
in UncategorizedJanuary, 2013
The headline case is the decision by General Electric chief executive Jeffrey Immelt to rekindle production at the enormous Appliance Park manufacturing site in Louisville, Kentucky. By doing so, the 56-year old isn’t just burying some of the legacy of his legendary predecessor, Jack Welch, but questioning the core business case that has increased profits for US manufacturers since he was in his mid-20s.
“The very scale of the place seemed to underscore its irrelevance,” Fishman writes of Appliance Park. “Six factory buildings, each one the size of a large suburban shopping mall, line up neatly in a row. The parking lot in front of them measures a mile long and has its own traffic lights, built to control the chaos that once accompanied shift change. But in 2011, Appliance Park employed not even a tenth of the people it did in its heyday. The vast majority of the lot’s spaces were empty; the traffic lights looked forlorn.”
Appliance Park is just one of countless historic manufacturing bases that have been slowly turned into ghost towns across the US. In no small way this has been because of the rise of China on the back of cheap labor which has in turn produced its own set of ghost towns. But that’s another story.
Immelt was actually trying to sell Appliance Park just four years ago but couldn’t find a buyer. Now it’s being slowly resurrected, and not just for show.
The GE boss has pumped $800 million into restarting sections of Appliance Park. The poster-child of American outsourcing conglomerates is looking at manufacturing an increasing number of products domestically.
Some of these products are new and thus need close attention. Others are currently being made in China and Immelt is ordering them home.
On the face of it $800 million may as well be measured in nickels and dimes for a company that takes in $150 billion in revenue every year. But it’s almost impossible to argue this isn’t a significant decision that says a lot about the limitations of outsourcing and the advantages of making things in America.
The argument that Fishman and Fallows deliver in separate stories, very convincingly, is that it’s not only the lower cost of US energy (shale gas), as well as the recently reduced wage burdens in the US and growing wages in China that is slowing or reversing the outsourcing boom. The argument is that there are peripheral advantages of making things in your own backyard.
Fishman tells the story of a Geospring water heater that suffered from a needlessly complicated and fiddly assembly, increasing not just the time it took to produce but also the materials that went into it.
When there’s a Pacific Ocean and language barrier between your designers and your assembly workers, cost reductions and design shortcomings are harder to identify. But if a mid-level manager knows a sharp guy called ‘Frank’ on his own floor who has a knack for finding ways of using less copper wiring without compromising the product, you could more easily identify cost savings from a materials and labor point of view. Plus, Frank might have a future beyond the assembly line.
GE has realized all these benefits in some cases and managed to pay for production in the US before factoring in shipping costs. Let me repeat that – they’re getting shipping costs from mainland China to the west coast of the US wiped out in some instances, and some, by doing their thing in the US.
Those who can remember the labor battles that resisted the outsourcing boom, a phenomenon that touched the Australia and England as much as the United States, will know these arguments are nothing new. Unions and academics were telling us organisations would become less agile and their products would be less reliable… but cheap as chips.
‘Frank’ would be replaced by someone in China who is both unrelatable and unable to offer a solution for the unacceptable number of faulty products finding their way to American shores. You can try a rival manufacturer down the road, but his workers are just as unskilled.
The conclusion we’re asked to contemplate is that US manufacturing renaissance is based on more than BHP Billiton’s shale gas, which disproportionately aids petrochemical manufacturers that use the gas as feedstock and heavy equipment makers that appreciate the cheap energy. Could this be the long-awaited realization that cheap Chinese labor was a false promise for products that are either complicated, or have the potential for innovation?
American manufacturers, beyond GE, are indeed bringing jobs home. Still, to call it a renaissance is terribly premature.
While it’s true that the American manufacturing sector outperformed the US economy in 2010 and 2011, output actually shrank in 2012. If you call that a renaissance, you mustn’t mind a gamble.
According to a joint report from the Citizens for Tax Justice & the Institute on Taxation and Economic Policy released late last year, General Electric was the second largest recipient of tax subsidies between 2008-10 – $8.2 billion to be precise. In the last three years, GE has put away profits of $36.7 billion.
This puts into perspective how much $800 million is and how much GE is contributing to US jobs, as well as government coffers. With over $16 trillion in federal debt, the prospect of more government subsidies for GE to encourage repatriation of jobs is pure fantasy.
China also owns 40 per cent of its adversary’s debt. This gives America’s chief labor manufacturing rival a crucial window to invest in upskilling its work force so the cost advantage isn’t outweighed by a skill disadvantage.
That’s far easier said than done, but China isn’t under pressure in this respect. The US is finding it hard enough to fill current positions within its borders, let alone jobs returning from a corporate foreign profit exchange program.
In the brilliant Davis Guggenheim documentary Waiting for Superman (2010), we discover how America’s education system hasn’t adapted to the differing skills sets demanded by the modern US economy.
With a still uncomfortably high unemployment rate, undermined by a lack of workforce participation brought on by worker dejection, we’re continuously told that American corporates have jobs to fill but no qualified Americans to do it.
From time to time we’ve heard excuses, like the fact that a high mortgage underwater rate has reduced workforce mobility. That’s a legitimate phenomenon.
Accord
ing to
Waiting for Superman, there will be 123 million high-skilled American jobs to fill by 2020 but only 50 million Americans qualified to do them.
It just goes to show that if a fully-fledged US manufacturing renaissance does exist, one that extends beyond the shale gas boom, Americans won’t get the larger pay checks this boom provides unless US companies are willing to pay the training costs.
Alexander Liddington-Cox is Business Spectator’s North America Correspondent.
Manufacturing in The Balance: Inexpensive Labor Has Defined The Last Decade in Manufacturing. The Future May Belong to Technology.
in UncategorizedJanuary 2013
At the turn of this century, manufacturing wages in southern China were 58 cents an hour, just 3 percent of U.S. levels. GE and many other manufacturers rushed to take advantage of so-called labor arbitrage by moving manufacturing overseas. In 2004, the Boston Consulting Group told clients the choice wasn’t whether to go offshore but “how fast.”
The strategy adopted by many multinational conglomerates, whether based in the U.S. or in Europe, was simple: substitute inexpensive labor for capital. Why invest in a machine to assemble iPhones when Chinese companies could throw half a million workers at the problem? The Internet, telephones, and affordable air travel and sea shipping made it easier than ever to coordinate labor from far away.
Partly as a result, the U.S. lost about six million manufacturing jobs—33 percent of the total—between 2000 and 2010, and China has overtaken the U.S. as the world’s largest producer of manufactured goods. But the impact extends beyond macroeconomic statistics.
In Producing Prosperity, a book published this year, Harvard Business School professors Gary Pisano and Willy Shih call offshoring of manufacturing a “grand experiment in de-industrialization.” They and others now believe that the consequences have been unfortunate because innovation is hard to separate from manufacturing in technologically advanced areas. Without understanding the details of production, you can’t really design the most competitive products. Eventually, what Immelt calls “core competencies”—such as product design and understanding of materials—are put at risk (see “Can We Build Tomorrow’s Breakthroughs?”).
Lately, however, economic trends have been turning. Wages in China’s southern cities have been rising fast and may soon reach $6 an hour, about what they are in Mexico. Boston Consulting Group—the same consulting firm that told clients to run, not walk, overseas—now says it’s time to “reassess” China and estimates that for some products, that country’s overall cost advantage could disappear by 2015.
The vanishing comparative advantage of Asian cheap labor isn’t the only reason for companies to question offshore manufacturing. Natural catastrophes can occur anywhere, but the risks of long supply lines became apparent in 2011, when the Japanese earthquake and tsunami interrupted shipments of computer chips and floods in Thailand left disk-drive factories under 10 feet of water. Meanwhile, higher oil prices have quietly raised the cost of shipping goods. And a bonanza of cheap natural gas has made the U.S. a relatively cheap place to manufacture many basic chemicals and is providing industries with an inexpensive source of power.
The kind of manufacturing in which labor costs are most important isn’t ever coming back from low-wage countries (assembling five million iPhones for a product launch can still only be done in China), but the recent economic shifts are giving companies a chance to adjust course. One major line of thinking, the one most vocally endorsed by the White House, is that the U.S. should focus its efforts on advances in the technology of manufacturing itself—the set of new ideas, factory innovations, and processes that are also the focus of this month’sMIT Technology Review business report.
The U.S. holds advantages in many advanced technologies, such as simulation and digital design, the use of “big data,” and nanotechnology. All of these can play a valuable role in creating innovative new manufacturing processes (and not just products). Andrew McAfee, a researcher at MIT’s Sloan School of Business, says it’s also hard to ignore coming changes like robots in warehouses, trucks that drive themselves, and additive manufacturing technologies that can create a complex airplane part for the price of a simple one. The greater the capital investment in automation, the less labor costs may matter.
Because manufacturing is so heterogeneous, no single technology can define its future direction. But for advanced economies like the U.S., the questions don’t change. Says McAfee: “If labor is not the differentiating factor, you need to ask, ‘What can be?’”
Manufacturing Reshoring
in UncategorizedFmr. President of the National Association of Manufacturers
January 8, 2013
“A convergence of trends makes operations in America more attractive and feasible,” Fallows wrote, “just as the cost and friction of operating in China is increasing.” He writes at length about growing discontent among Chinese workers who are demanding higher pay and better working and living conditions, while rapidly advancing technology favors nations with more advanced skill sets, such as the U.S. “For the first time in memory, I’ve heard ‘product people’ sound optimistic about hardware projects they want to launch and facilities they want to build, not just in Asia, but also in the United States.”
Fishman put some meat on the bones of that idea with an account of how General Electric is suddenly expanding its old plants at Appliance Park in Louisville, Ky. At its height in 1973, that facility employed 23,000 people. By 2011, it had bottomed out at 1,863 and GE was trying to sell off its appliance division. Now it’s headed in the other direction. In February, GE opened an all-new assembly line to make cutting edge water heaters that had previously been made in China. In March it opened another assembly line to make new high-tech French-door refrigerators. And early next year, GE will start making trendy front-loading dishwashers and matching dryers. GE will end this year with 3,600 hourly workers there, and also has hired 500 new designers.
There are many reasons for this trend: oil prices are three times what they were in 2000 making shipping costs higher; the natural gas boom has dramatically reduced the cost of running an energy intensive factory in the U.S. (gas costs four times as much in Asia); wages in China are five times what they were in 2000 and are rising 18 percent a year; U.S. labor unions are becoming more tractable to retain jobs; and U.S. productivity continues to soar.
But there’s an even more interesting reason. Because of rapidly gadget wizardry and consumer demand, the cycle life for many major consumer products like refrigerators has been shorted from seven years or so to 2-3 years. Production is more complicated and challenging, and thus harder to manage and control on the other side of the world.
“A convergence of trends makes operations in America more attractive and feasible,” Fallows concluded, “just as the cost and friction of operating in China are increasing.” Now there’s a thought to sustain you into the New Year!
Jerry Jasinowski, an economist and author, served as President of the National Association of Manufacturers for 14 years and later The Manufacturing Institute. Jerry is available for speaking engagements. January 2013
Mr. China Comes to America
in UncategorizedI listened to this question with special interest, since I was following the debate, via hotel-room TV, from the Shenzhen manufacturing zone of southern China, where many of those same iPads and iPhones are made. For the few days before the debate, I’d been revisiting PCH International, an outsourcing company I’d first written about for this magazine in 2007, in “China Makes, the World Takes.” The company’s revenues have increased more than sevenfold since then and its workforce has grown almost as fast, despite the years of global recession. This is testament both to its own success and to the nonstop surge of outsourcing contracts to China.
The day after the debate, I walked through the famous Foxconn complex in the Longhua district of Shenzhen, where some 230,000 Chinese workers, mainly between the ages of 18 and 25, turn out products sold under international brand names, from Apple and Dell to Nintendo and Sony. Another Foxconn facility not far away employs another 200,000 people; throughout China the company’s workforce numbers 1.3 million. On previous attempts to get in over the years, I had never made it past Foxconn’s front gate—not surprising given the company’s policy of stiff-arming most foreign and domestic reporters. But a new PR team at Foxconn had apparently decided that closed-door secretiveness was making the company look even worse than it otherwise would. (If only this team were in charge of Chinese government policy—regarding the press, the Internet, letting people into and out of the country, and so much more.) Immediately after hearing the allusion to Chinese-made products on TV, I e-mailed an official at Foxconn and said that so prominent a mention in American politics would be a great news peg for a visit. I was fully expecting another turndown, but to my surprise, the company agreed. The next morning, I went to the factory and was told I could roam around and take pictures of anything I wanted, as long as I did not show or mention any of the brand-name products coming off its assembly lines.
For the first time in memory, I’ve heard “product people” sound optimistic about hardware projects they want to launch and facilities they want to build not just in Asia but also in the United States. When I visited factories in the upper Midwest for magazine stories in the early 1980s, “manufacturing in America” was already becoming synonymous with “Rust Belt” and “sunset industry.” Ambitious, well-educated people who had a choice were already headed for cleaner, faster-growing possibilities—in consulting, finance, software, biotech, anything but things. At the start of the ’80s, about one American worker in five had a job in the manufacturing sector. Now it’s about one in 10.
The heart of their argument is this: Through most of post–World War II history, the forces of globalization have made it harder and harder to keep manufacturing jobs in the United States. But the latest wave of technological innovation, communications systems, and production tools may now make it easier—especially to bring new products to market faster than the competition by designing, refining, and making
them
in the United States. At just the same time, social and economic changes in China are making the outsourcing business ever costlier and trickier for all but the most experienced firms.
For Americans, the most important factor is the emergence of new tools that address an old problem. The old problem is the cost, delay, and inefficiency of converting an idea into a product. Say you have an idea for—anything. (For me, the list would start with silent leaf blowers, which I’d give to all my neighbors as gifts.) Before you can earn the first dollar from the first customer, you have to decide whether the product can be built, at what cost, and how fast, so you can beat anyone else with the same idea.
“A revolution is coming to the creation of things, comparable to the Internet’s effect on the creation and dissemination of ideas,” Linus Chung told me at Lime Lab, in San Francisco. (Chris Anderson, formerly of Wired, has recently advanced a similar case in his book Makers.) Chung is an American-born, Stanford-trained manager who now works for PCH International and is based in Shenzhen. This past June, PCH bought Lime Lab as part of an expansion into America to encourage more start-ups and manufacturing work here. “There is a whole new interest in hardware in Silicon Valley,” said Phil Baker, a product-development expert who has worked with Apple and other companies since the 1970s. “I’ve never seen a more exciting time in the hardware business.”
Why “exciting”? Let’s consider the changes affecting China, and America, and manufacturers everywhere.
The Big Picture
For the past 30 years, all of the largest forces have pushed in favor of China’s manufacturing expansion, from very low labor costs and a deliberate policy of welcoming foreign investment, to ever faster and cheaper global cargo-shipment networks, to a deliberately undervalued Chinese currency. Within the past two years, nearly all of those advantages have become more complicated. (In his accompanying article for this issue, Charles Fishman explains some of the large forces pushing in favor of America’s manufacturing renewal.) In China, wages are rising, workers are becoming choosier, public resistance to environmental devastation is growing, and the Chinese “investment led” model is showing strain.
That model has involved a kind of hyper-Keynesianism far beyond what the United States experienced even during the most government-run periods of the New Deal. China has created jobs by building factories, highways, railroads, and dams—and airports where there are no cities, and cities where there are no people. “Americans are used to thinking of ‘savings’ and ‘investment’ as absolute goods, because we’ve done too little” of both, Michael Pettis, of the Guanghua School of Business in Beijing, told me. “But there is such a thing as too much savings and investment and infrastructure, and too little consumption, all of which we see in China.” If the American public challenge is “reinvestment” of all varieties—in education, in infrastructure, in a sense of community, in everything but houses—the Chinese counterpart is a need for a comprehensive rebalancing. Indeed, Pettis’s forthcoming book on the Chinese economy is called The Great Rebalancing. Reliance on exports needs to come into better balance with domestic consumption; economic growth with environmental sustainability; political liberties with the new level of economic prosperity; and on down a long list.
Some observers inside and outside China think that the strains are too great and the system too rigid to allow the necessary rebalancing in time for the party to maintain political control. For instance, Minxin Pei, a native of Shanghai who now teaches at Claremont McKenna College in California, has been warning for more than a decade that the economic, social, and political imbalances of the Chinese system would reach a breaking point just about now—and that Communist rule would have to give way to a multiparty system. Many others contend that, on the contrary, the Communist leaders will manage somehow to address each of today’s problems just before any one becomes an outright emergency, as they have done time and again for 30 years. Whichever view proves correct, the relevant point for Americans is a convergence of trends that make operations here more attractive and feasible, just as the cost and friction of operating in China are increasing.
The Factory-Level View, From the World’s Biggest Factory
I had a more vivid sense of some of these challenges after this latest look at Chinese factories—especially at Foxconn, the world’s largest electronics maker. You learn a lot about China from its factories, of which I have now visited nearly 200—just as you would have learned a lot about the England of Charles Dickens and Friedrich Engels by seeing its factories, and the America of Theodore Dreiser and Upton Sinclair. Factories are not the only arenas for high-speed social transformation in China: its farms, from which working-age people are fleeing, and its cities, to which millions of people migrate each year, are also the settings for individual dramas and collective adjustment at a rate and on a scale that the world has never previously seen. But on this trip I spent time in factories. And what I saw underscored the ways in which the tumultuous transformation of China is complicating life for its outsourcers and exporters.
At the Foxconn plant I visited, I know firsthand only about conditions I could observe in four hours of walking around the more than one-mile-square “campus” and being taken into selected dormitories, cafeterias, training rooms, and assembly-line areas by members of the newly accommodating Foxconn PR team. One part of the visit had the unmistakable note of the staged: In the sole dormitory we entered, whose occupants were all on their shifts at work, every towel and pillow in the four-bunk room I saw was perfectly aligned. The clothes were on hangers in precise order, and there was not a scrap of extra paper or debris on desks, dressers, the floor, or anywhere else. I could only assume that this room had been specially cleaned up; other parts of the campus resembled most other parts of China in being much more casually
groomed. I’m acutely aware of all the things I did not see: conditions at night, the dorms where not four but six or eight workers live in each room, assembly lines where hazardous materials might be used or where the pace is exceptionally fast. Still, what I was allowed to see was more than a tiny keyhole glimpse—and my movement around the campus was less rather than more controlled than I’d been accustomed to on other factory visits. The scale of buzz and activity was so vast—cafeterias with thousands of people getting lunch, bus and shuttle stops with hundreds of workers waiting for a ride, coffee shops and convenience stores crowded with Foxconn patrons—that I doubted that every detail could have been orchestrated overnight. Plus, there were products to ship.
At most other big Chinese factories I’d seen, people walked around all day in uniforms—usually gray or blue coveralls for men, light-colored smocks for women. At Foxconn, people wore anti-static jackets and caps when at work on the assembly lines and shirts or vests with the Foxconn logo when in offices. But when walking to the cafeteria, going to the shops, or commuting to normal off-site apartments, where three-quarters of the workforce lives, people were dressed in the blue jeans or cargo shorts and fake Polo or NBA shirts of a normal Chinese crowd. On the lines I did see, where printed circuit boards and other electronic components were being put together in a process that combined the use of large, fancy, expensive machinery with detailed handwork, the pace and supervision seemed no looser or tighter than I’d seen at comparable sites elsewhere in China. If you are looking for the most-gruesome factory conditions in China, you don’t go to a multinational giant like Foxconn, which has to deal with Western customers and pay at least some attention to appearances and laws. You go instead to the small, ramshackle, often unregulated workshops, often away from the big cities, where conditions are as inefficient and sometimes as unsafe as they were when China was just beginning to industrialize.
Although I had heard about the Foxconn “suicide nets,” I was still taken aback to see them. Most dormitories and factory buildings on the site are five or six stories tall. Outside every upper-story window, open balcony, and other spot from which someone might plunge, the company has installed netting about 20 feet above ground level. The founder and CEO, Terry Gou, ordered the nets installed after a spate of jumping suicides in 2010; many of the upper windows also now have latches that keep them from opening fully, and some balconies have a fine mesh of jump-prevention wire. The idea, I was told by a Foxconn spokesman, was that while some suicide attempts reflect deep mental illness or depression, others are impulsive and half-thought-through, so anything that even slightly slows an attempt might deter a suicide altogether. (The peak suicide rate for Foxconn came in 2010, when it reported a total of 12 “completed” suicides at all its Chinese plants. On a per capita basis, this was below the suicide rate for China as a whole, but everyone at Foxconn recognized it as an emergency.)
But to me the most significant aspect of the visit—one my hosts were so inured to that they barely mentioned it—was the sight of the enormous throngs at Foxconn’s recruiting and new-worker training sites on campus. In a typical week, the Shenzhen Longhua facility will take on about 2,000 new employees for its own factories, and recruit and train many more for other Foxconn sites. It brings in so many people because so many keep heading out; the annual turnover rate at the plant is about 60 percent—high but not astounding by Chinese standards.
I spoke about workforce churn with Foxconn’s Louis Woo, whom I had met years earlier in Shanghai. Woo and Terry Gou had become friends in the early 1990s, when Woo was the general manager of Apple Taiwan. Four years ago, Woo accepted Gou’s offer to be Foxconn’s chief spokesman, and moved to Shenzhen. Woo told me that Gou, who turned 62 on the day of my visit, was at this stage of life increasingly conscious of the social as well as the purely industrial legacy of his work.
Terry Gou has done as much as anyone since Deng Xiaoping to shape life in China, or at least in the factory-dense southern part of the country. Although Gou is Taiwanese and Foxconn’s headquarters are in Taiwan, the company is the largest private employer in mainland China. According to Louis Woo, Gou is aware of the example of Henry Ford. Not the Ford of the assembly line and the mass-marketed Model T, whose achievements Gou has already matched, nor the elderly Henry Ford of the anti-Semitic conspiracy theories. Rather, the “welfare capitalist” Ford, who in 1914 announced a new $5 daily wage, roughly double the prevailing rate. Ford did this to reduce then-extreme turnover on his assembly lines, which was even more rapid than Foxconn’s current level, and to hasten the creation of a middle class capable of buying his cars.
Foxconn has raised basic wages four times in the past three years, in some areas doubling the starting-level pay. A typical Foxconn assembly-line worker spends 50 hours a week on the job—40 hours at base rates, and 10 hours of overtime at a time-and-a-half rate. For that, a worker typically gets about $400 a month, or about $2 an hour. During production surges, workers may put in another 10 hours of weekend overtime, for which they get double-rate pay. Six years ago, typical monthly pay in Shenzhen factories I visited ranged from $115 to $155 (the difference partly reflects the higher value of the Chinese renminbi today). Woo said that he expected the trend of rising wages to continue, and that Gou was mindful of the centennial of Henry Ford’s $5‑wage announcement, in 2014. This would reflect a calculation of long-term self-interest comparable to Ford’s: if Gou can accelerate the growth of China’s middle class, a large company like his will share in the returns. “If we have a new-generation middle class, that will fuel the need for products like those we manufacture,” Woo said.
A living wage for the laboring class would be one
more sign of progress for China, as it was for the America of Ford’s era. But it would also be part of the process that is reducing China’s advantage as a site of cheap labor—and a sign of other challenges facing Chinese employers.
Two more things about the Foxconn workers surprised me: that so many were male, and that nearly all were kids. By kids I don’t mean the 14-year-old “apprentices” a different Foxconn plant, in the northern city of Yantai, was found to have hired earlier this year. (The company apologized to the youths and their families and, according to Woo, fired one of the managers involved and disciplined a total of nine.) I mean that at factories I’d previously seen across China, the workers looked and acted like country people weathered by their rough upbringing. Most of the Foxconn employees looked like they could have come from a junior college.
“Even a few years ago, the typical worker was a farmer,” Louis Woo told me. “He or she already had a family back in the village. They came, they earned their money, and when they were able to buy some pigs or fix up their house, they went home.” The standard workers today, he said, are those people’s children. “They’ve never farmed. They don’t want to, and they don’t have to, thanks to the hard work of their parents, who were the first generation of migrant workers. They’re coming here as part of entering a bigger world.” Chinese factory bosses face the same challenge in dealing with them that Chinese political bosses face with a better-informed, more intellectually independent populace. The “shut up and look at your paycheck” approach that has worked for people who remember China’s backwardness may not work for their children.
Among the consequences is greater fractiousness in the typical Chinese factory force. In September, a Foxconn plant in Shanxi province was temporarily closed because of a late-night riot that eventually involved several thousand workers. According to Louis Woo, the riot was touched off not by worker-management tensions but by the Chinese equivalent of an ethnic-gang war in an American prison, as workers from one province took the side of a colleague who was fighting a worker from somewhere else. This is the sort of thing that happens more frequently with more men in the workforce.
Ten years ago, Chinese factory life stood comparison to the “dark Satanic Mills” of William Blake’s England in the early 1800s. Five years ago, I was struck by the parallels with accounts of Chicago packinghouse life in the 1890s. Now I see a counterpart to the American 1920s, with the first sizable generation of moderne post-rural life. In September, after turnover surged at many Chinese factories, PCH commissioned a nongovernmental organization to do a survey of worker attitudes. I sat in on a focus group from the factory discussing the findings. It’s not the long hours we mind, most of the workers said; according to the survey, fully 80 percent welcomed an average of two or three hours of overtime a day, because of the extra pay that meant. But we still want to “have a life,” they told the survey takers. The No. 1 item on their wish list was more organized social activities on the weekends, and singles nights and mixers for all the unaccompanied young men.
China’s economic and social maturing, tumultuous or smooth as it may turn out to be, will certainly affect the world division of labor. Some very low-skill jobs may move to very low-wage economies, such as Burma, India, and parts of Africa; some will move to inland China; some will be automated or done by robots; some will stay in China, but at higher costs. But some of the next round of jobs that might have moved to China will be more attractive for producers to keep in the United States.
The New Smiley Curve
Here is what Casey meant by “geography is history,” and how it affects the prospects for U.S. manufacturing:
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(iPhone), then the industrial design, and on through the stages of manufacturing at the bottom of the curve—then shipment, retail, and service going up the other side. The profitability of each stage matches its elevation on the curve—which is why Chinese manufacturers, down at the bottom of the curve, get the smallest share. Globalization has thus far enriched Westerners on the high parts of the smiley curve—designers, shareholders, advertisers, other mainly white-collar professions—but has left out Western manufacturing workers.
A crucial and underappreciated step in this process, Casey and others explain, is the transition from the idea for a product to its physical incarnation, which can then be made and sold. There’s a direct analogy to the world of publishing. Even 10 years ago, having an idea for a book, a song, a political exposé or commentary, got you only so far. To spread your work or ideas beyond your immediate circle of friends required the involvement of a publishing organization. Unless you could persuade an editor, a broadcaster, or a publishing house to promulgate your views, few people would ever hear them. Writing was hard enough; “getting published” could be worse. But now, blogging software and social media of all sorts have eliminated that barrier. Publishing organizations can still provide authority and a megaphone. But more ideas from more people are now being heard by more people.
How does this apply to manufacturing? Blogging software and related technologies have made it easier for entrepreneurs in the realm of ideas to expose their products to a worldwide market test. Three-dimensional printing and related technologies are making it easier for entrepreneurs interested in making physical goods to expose their products to the worldwide market. America has more than its fair share of such potential innovators, thanks to immigration, our still-strong university and public research centers, and the financial and cultural underpinning of a start-up culture. The terrain is shifting in a way that should draw more entrepreneurs to manufacturing and let more of their ideas succeed. This should in turn foster more manufacturing work within the United States than was feasible a few years ago. Companies with the right connections to foreign suppliers and foreign markets will grow even faster.
But rather than simply shifting manufacturing work from rich countries to poorer ones, this latest technological wave should allow all regions to grow. “As business has become faster and more globally connected, that’s been good for American companies overall but bad for America’s low-skilled manufacturers,” Phil Baker, the designer for Apple and other companies, told me. “Now speed and connections allow start-ups to compete with much larger companies, and often beat them.”
Made in San Francisco“I am betting heavily on San Francisco, for its energy and creativity,” Liam Casey told me in China. He didn’t quote Jane Jacobs, but he went on to present a theory that could have come from her book The Death and Life of Great American Cities: national economies are really a collection of vibrant city economies, and cities thrive when they foster a diverse ecosystem of small enterprises whose growth is mutually reinforcing. He felt that his adopted home of Shenzhen was the engine and the success model for China. “When I came here, Shenzhen was a place to make cheap products,” he said. “Then it became a place to make products cheaply. Now, for the work we do, it’s the only place to make certain products, because of the supply base, the logistics, and the workforce.” (He said that my article about his company, “China Makes, the World Takes,” could, five years later, be redone as “Shenzhen Makes, China Takes.”) San Francisco is his model for how the new manufacturing economy would spread in America. When we spoke, he had just leased a 30,000-square-foot building off I‑280, the former home of the San Francisco Bay Guardian, and announced plans to establish major PCH operations there. “We look forward to fostering the growing community of makers in the Bay Area who seek to have a massive impact on the world through their dedication to design, brand building, and consumer experiences,” he said in a statement announcing the deal.
To put his ambitions in context, let’s consider an existing effort to boost the “community of makers” in San Francisco, a coalition called SFMade. I use it as an example of undertakings on behalf of small manufacturing in several North American cities. This example is different from Casey’s plans in its scale and its level of technology. But it is similar in its emphasis on speed as the key to manufacturing success, and its ambition to help large enterprises grow from small start-up roots.
The Bay Area might seem to display all of America’s imbalances, intensified. Tech and venture-capital billionaires on the Peninsula, hipsters in the East Bay and the city, rich naturalists in Marin, and ordinary families priced out of anything not a distant commute away. Of course, this is a caricature, but it is one that matches the prevailing rest-of-the-world view of a hollowed-out and unequal modern United States.
Into the standard American urban mix—high-end tech and finance, low-end service or tourist work, the professional class from universities and hospital complexes—has come an unlikely renaissance of small-scale manufacturing in the past five years. There is no point in comparing it with anything in China. The 400 manufacturing firms that have factories in San Francisco and are part of the SFMade coalition employ a total of just over 3,000 people, equivalent to a busy week’s intake at Foxconn’s Longhua campus. Apart from the 100-employee LeeMAH electronics firm, founded by an immigrant from China, their products are mainly medium- and low-tech: apparel, high-end food and drink, bags and accessories. This pattern will be familiar to anyone who has followed the growth of light manufacturing in Brooklyn. In San Francisco, more than 120 of the firms were founded during the past three years of overall economic distress; their employment base grew by 10.5 percent last year and 12.5 percent this year; and they have applied in their modest way the principle of drawing on a local base of skilled workers for very fast response to global consumer demand.
“Most of the companies that are here would argue that, while they are not super-duper high-tech, they are all absolutely connected to the design prowess and skilled craftworks in the city,” Kate Sofis, the executive director of SFMade, told me. The most obvious example is apparel. Like New York, Chicago, Cleveland, and Los Angeles in their periods of fastest manufacturing expansion, San Francisco has attracted a large and diverse immigrant population. “The Latino and Asian communities have a high level of apparel skills,” Sofis said. “A young designer might have high design skills but not the technical ability to realize it.” Going to Asia for production would be too slow; finding the skills elsewhere in the U.S. would be too hard. Carrying out all operations locally has allowed many SFMade companies to offer quick “mass customization”: Rather than buying off the rack, a customer can choose personalized clothing, accessories, furnishings, or furniture, mainly online. Then small factories produce the goods locally, faster than they could come from overseas. I spoke with Sofis just before she headed to a conference of the Urban Manufacturing Alliance, which promotes manufacturing in 15 other cites, from Boston and New York to Detroit and Atlanta.
I first learned of SFMade two years ago, via DODOcase, a member that is one of the city’s start-up success stories. I had bought one of the company’s iPad covers as soon as it came onto the market, because I was drawn to its distinctive retro-futuristic design. Inside, the case contains an iPad or other electronic reader. Outside, it looks like an ant
ique leather-bound book. A bamboo frame holds the electronic tablet in place and also strangely recalls the look of the page edges of a physical book.
“Back in 2010, we saw an opportunity present itself, if we could move quickly enough,” Craig Dalton, a veteran of tech start-ups who is now in his early 40s, told me in explaining the company’s history. I liked that he said “back in 2010” so matter-of-factly. The opportunity that 2010 brought was the launch of the first iPad. Liam Casey got his start making accessories for the popular electronic devices of 15 years ago. Dalton and his business partner, Patrick Buckley, did not know Casey’s story, but they saw a parallel chance.
When he asked friends at Levi’s, Buckley said, they told him that nine months would be a reasonable timeline to take a product from concept to delivery. “We had to do it in a couple of weeks. Nimbleness like this would be impossible with a longer supply chain.” The partners drew on local woodworking and bookbinding talent. “The resources are still here, much atrophied, but in pockets,” Buckley said. San Francisco has a long tradition of fine printing. Dalton and Buckley bought large, heavy bindery machines from printing houses and brought them into their factory.
DODOcase is a niche success, to be sure. But it has grown to 30-plus employees in two years, with 30 percent of its sales outside the United States, and its founders have broad ambitions. “If you look at brands like Levi’s and Gap and North Face that had their beginnings here in S.F., you see that a small boutique idea can grow into a global brand,” Buckley said. “It is very hard to tell ahead of time which ones will make it, but we hope to become a lifestyle brand with the recognition and scale of a Gap.”
I have learned to imagine the possibility of rapid growth. I first interviewed the founders of Google when the company had 20 employees, versus today’s 30,000, and visited Apple three years after its founding, when it had a few hundred employees rather than today’s 60,000. Big things start small.
Mr. China Comes to America
The medium-tech start-ups of SFMade (and its counterparts) are working out a strategy that combines quick response, local skills, and a global marketplace to foster manufacturing in U.S. cities. Liam Casey’s new investments in the Bay Area are designed to apply a similar model for companies several steps up the technology ladder. The purchase of Lime Lab and the opening of what he sees as an academy of high-speed manufacturing in the city could combine to bring to U.S.-based entrepreneurs, inventors, designers, and smaller companies some of the advantages now unique to Apple and a handful of other globally integrated firms—and with a greater probability than Apple’s of creating jobs in the United States.
The heart of those advantages is, again, connecting the sequential stages of the manufacturing cycle as a whole. The process naturally starts with the idea for a product. Whether the idea is practical depends crucially on how it is realized in industrial design; whether that design makes for an efficient or impractical factory experience depends on how well it is matched to process-engineering on the shop floor. Even after production begins, the design is often refined and the manufacturing process rejiggered based on real-world experience.
The closer this linkage, the faster and more efficiently an idea can be converted to tangible, marketable reality. The more evolved and responsive the feedback loop, the more precisely an organization will be able to distinguish promising projects from impractical ones. Apple has this capacity; it has teams on more or less permanent assignment to southern China to match its designers’ goals to the realities of the shop floor. But for the first time in decades, new tools are making it possible to develop this capacity for U.S. manufacturing. This means greater prospects for American innovators to convert their ideas into products—and jobs. That is what’s new, and promising. As one entrepreneur told me, asking not to be named for fear of irritating the mighty Apple, “What Apple has, internally, will now be available to smaller companies.”
In specific terms, the service that Lime Lab and a growing number of design firms can offer is a “quick iteration” way of deciding which ideas will be most practical for manufacturing. “Over the past couple of years, people have gotten used to the idea of rapid iteration in social-media firms,” Linus Chung told me. “You iterate and adapt quickly based on consumer demand. You learn to ‘fail fast.’ We’re bringing that to the hardware space.” As an illustration, he mentioned a start-up called Lark, which makes electronic sleep- and fitness-monitoring devices that are part of the broader trend toward precise, individualized indicators of health that Mark Bowden discussed recently in “The Measured Man” (July/August 2012). Lark was founded two years ago, while the overall economy was still reeling, by a Stanford-trained entrepreneur named Julia Hu. Many of its products, the latest of which is a $149.99 wristband that monitors your sleep, exercise, calorie-burning, and even degree of hydration, are now carried at Apple stores and by Best Buy and Brookstone. The electronics in this wristband are assembled in China, as are nearly all of the world’s electronics. But more of the total job growth in the company’s rise, including engineering and design work, has been in the United States than would have been the case even way back in 2009. “They started with five people, and now they have 30,” Chung, who has worked with Lark, told me. “For a company their size, you’d expect they’d need half those people in China. Now that entire team is one office in the United States.”
Fifteen additional employees here, a new urban start-up there—these are obviously not the sole answers to America’s reindustrialization. The growth of this sort of activity depends on large-scale policies: continued national investment in high technology; education to train the next generation of engineers and craftsmen; negotiations to open up markets (and protect intellectual property) around the world. The politically controversial, but right, decision to keep General Motors operating saved hundreds of thousands of manufacturing jobs from being needlessly lost.
James Fallows is an Atlantic national correspondent. His latest book, China Airborne, was published in May.
The Case For and Against ‘Made in the USA’
in UncategorizedJanuary 7, 2013
Perhaps this idea isn’t all that new; it’s just a timely reminder that we can become more strategic with our spending.
My father-in-law announced to the family several years ago that he was only interested in giving and receiving gifts that were made in the U.S. Frustrated by the prospect that we’re no longer globally competitive in many manufacturing sectors, he insisted we avoid items made in China — or anywhere else for that matter.
That year he gave each family member an envelope with a crisp, uncirculated Franklin ($50) for Christmas. Thankfully, the Treasury still prints those here in the U.S.
Most of us made an honest effort but found the exercise quite taxing. It’s hard enough to find just the right gift, and then you find that it has been manufactured elsewhere.
Perhaps this issue requires deeper thought and more critical analysis. On a monthly basis we hear of wild swings in unemployment numbers. The rates for new claims go up; then they go down. But basically the rates have hovered around 8 percent for far too long.
There is no argument that creating and saving jobs is in our best interest. The hard question is which jobs to save and, most importantly, discovering the jobs to be created through entrepreneurial exploits.
There are a fair number of critics — even economists — of this “buy American” push who claim there’s nothing American about it. Their contention is that we should buy American only so long as it’s the best price and not simply to create or sustain jobs.
Economics tries to take consumer emotion out of the equation and keep things simple. There is a supply and demand curve applied to the manufacture of a particular good that identifies the likely quantity of demand at a particular price point. And the incentive to producers is in the anticipated profit margins gleaned through efficiencies and their manufacturing capacity.
And in the end, the economics will argue that each economy would be better off producing and manufacturing those products for which there is a competitive advantage. These advantages include an abundance of ingredients, such as access to raw materials, labor, technology and transportation.
We’re really talking about product differentiation when we promote “made in America” through a campaign meant to create or save jobs. And this is squarely a marketing function. If we can feel better about ourselves because we’re helping our fellow citizens by buying certain items, then we can argue for a premium — just as we would for purchase of a product that comes with a better warranty or in one’s favorite color.
But how long will this work? Is this truly sustainable in the long run?
David R. Henderson, who is an economist at the Hoover Institution, explained it this way in an interview with John Stossel:
“Almost all economists say it’s nonsense. And the reason is: We should buy things where they’re cheapest. That frees up more of our resources to buy other things, and other Americans get jobs producing those things,” Henderson said.
Since we are competing globally, it makes no economic sense for us to continue manufacturing products that are no longer viable in the global marketplace. Americans need to continue to create jobs based on innovation and new ideas.
“A huge part of the history of mankind is an increase in the division of labor. And that division of labor goes across national boundaries,” Henderson said.
Whether you believe spending $64 on products “made in America” will make a difference for job creation, I believe more meaningful jobs will be created in our economy as the result of innovation and entrepreneurial endeavors. I wonder how I’ll spend this year’s crisp new Franklin.
Is There Any Hope For America? Absolutely!
in UncategorizedJanuary 2013
Is the U.S. finished? It’s awfully tempting to think so. Political dysfunction, crushing debt, a bad economy and a sinking middle class are not exactly signs of vigor. Two failed wars have dealt huge blows to its reputation and prestige. Not to mention the gun culture and the junk food and the [fill in your favorite example of American pathology here].
But if the U.S. were a stock, I’d buy it. Despite the gloomy news, its future is looking brighter than it has in years. One reason is the new energy revolution, a phenomenal reversal of fortune that nobody foresaw. The country is awash in cheap new supplies of unconventional oil and gas that are being unlocked with new technologies. This unexpected bonanza is rocket fuel for the economy.
It’s also creating millions of new jobs – not McJobs but the kind of well-paid industrial ones that are supposed to have disappeared forever. “These jobs include people working on rigs in Pennsylvania or North Dakota, manufacturing equipment in Ohio or Illinois, and providing information-technology services in California or legal services to royalty owners nationwide,” energy expert Daniel Yergin wrote in The Wall Street Journal.
The energy jobs of the future were supposed to be green. But it turns out they’re brown. In case you think that’s a bad thing, here’s good news: Greenhouse-gas emissions have plummeted as clean natural gas replaces dirty coal.
Cheap, reliable, abundant energy is helping to fuel another big trend – reshoring, the opposite of offshoring. The China advantage is disappearing fast, and the U.S. is on the verge of a manufacturing renaissance. A recent report by the Boston Consulting Group (Made in America, Again) concludes: “Within five years, rising Chinese wages, higher U.S. productivity, a weaker dollar, and other factors will virtually close the cost gap between the U.S. and China for many goods consumed in North America.”
Dozens of leading U.S. companies have already set up new operations back home. It’s even possible that your next computer will be made in America. Last month, Apple CEO Tim Cook said the company will start making one of its new computer lines in California. “There are skills associated with manufacturing which have left the U.S.,” he told NBC, and he wants to see “a concerted effort” to get them back.
Conventional wisdom says the sun is setting on America’s reign as the world’s only superpower. Maybe so. But this sun will be setting for a long, long time. U.S. economic and military power remain unparalleled. It has the most inventive, entrepreneurial and open culture the world has ever seen, with the greatest concentrations of research and brainpower. It has the ability to recruit the best talent from around the globe. Sure, it has problems. But who doesn’t Would you rather put your bet on Europe? Or China, whose ruling class of kleptocrats and their spoiled Ferrari-driving offspring are facing a combustible mix of labor and peasant revolts on top of a demographic crisis? No thanks.
Last month, the U.S. National Intelligence Council painted a picture of the global mega-trends that will shape the world between now and 2030. These include food, resource and water shortages, and wrenching technological change. But the answer to the question “Is America finished?” is a resounding No. Although the U.S. will have to share the power, it will remain “first among equals” for years to come. “No other power would be likely to achieve the same panoply of power in this time frame under any plausible scenario.”
America is much more than the sum of its cartoonish politics – luckily for Americans, and for us.
US Tariff Bill To Cut Manufacturers' Costs
in UncategorizedTax-News.com
January 3, 2013
The package includes provisions from more than 2,000 bills introduced in the House and Senate during the Miscellaneous Tariff Bill (MTB) process. By eliminating tariffs on selected items until December 31, 2015, it hopes to provide temporary tax relief “to help US manufacturers better compete, expand, and create jobs.”
The MTB is a bipartisan, bicameral process developed over nearly 30 years. On March 30, the Ways and Means Committee and the Senate Finance Committee simultaneously commenced the 112th Congress MTB process and invited Congressional members to introduce temporary miscellaneous tariff bills for consideration and inclusion in the MTB legislation.
It was required that each bill would be non-controversial. If a domestic manufacturer or member objected to a bill, it was eliminated. The bills were scored by the Congressional Budget Office (CBO) and were each required to cost under USD500,000 per year. As a consequence, nearly 170 House members and Senators submitted more than 2,000 single bills to be considered through the process, which were then compiled into a single MTB.
Commenting on the legislation Camp said: “This legislation reflects a transparent, bipartisan effort to lower costs for US manufacturers. The bill has broad support, and it has received extensive public comment.”
Levin added that “the MTB helps make US manufacturers more competitive in the global market by reducing input costs. This bill has undergone an extensive vetting process with input from the administration, the International Trade Commission and the public.”
Brady said that “suspending duties temporarily on products such as manufacturing inputs is an essential step in helping to make US manufacturers more competitive and creating US jobs,” while McDermott hoped that the “bipartisan action on this trade bill is a harbinger of things to come on the trade agenda in 2013.”
The National Association of Manufacturers has already pointed out that all existing duty suspensions on over 600 products expired on December 31, 2012. It said that “passage of a new MTB is vital to avoid the re-imposition of import taxes on manufacturing inputs unavailable in the US,” and that “without a new MTB, US manufacturers will have to pay new taxes on these essential inputs, further adding to the cost of manufacturing in America.”
Promoting Made in U.S.A., But Very Carefully
in NewsDecember 2012
But many companies are stepping gingerly, avoiding sweeping claims and spelling out what “Made in the U.S.A.” means for their products. Consumers are more shrewd about how few consumer goods actually are made in the United States, leaving companies less wiggle room about the origin of products.
The Whirlpool Corporation, for example, specified in full-page print advertisements this year that 80 percent of its appliances “sold in the U.S. come from our U.S. factories.” Despite its deep American roots, the 101-year-old company — which makes Maytag, Amana, KitchenAid and Jenn-Air products — has, like other corporate giants, moved some manufacturing abroad.
As a result of its centennial celebrations last year, some consumers have urged the company to talk more about its American origins, said William Beck, a senior marketing director at Whirlpool, which spent $57.4 million in 2011 on advertising, according to Kantar Media, a WPP unit.
In recent months, the appliance giant has been underlining its American factories, and noting in its overall brand advertising that it employs about 22,000 workers (15,000 of them at its manufacturing plants), and spends $7.4 billion annually on operating and maintaining its factories in Iowa, Ohio, Oklahoma and Tennessee.
But Whirlpool, whose ad drew a full-page rebuttal from the International Association of Machinists and Aerospace Workers accusing it of shutting factories in the United States, said nostalgia and similar sentiments do not drive its sales. “Whirlpool’s key differentiating points are quality and innovation,” said Mr. Beck, and “the icing is that, hey, we’re made in the United States.”
Whirlpool does not share its market research, but other market studies show that customers increasingly take note of where a product is made. Perception Research Services International, in a September study, found that four out of five shoppers notice a “Made in the U.S.A.” label on packaging, and 76 percent of them said they would be more likely to buy a product because of the label.
While shoppers, especially those over 35, say they want to help the economy by buying United States-made goods, “the motivating factors actually may be quality and safety,” said Jonathan Asher, executive vice president of Perception Research Services. The company, which is based in Teaneck, N.J., surveyed 1,400 consumers last summer. “People are paying attention in categories that are ingested like food, medicine and personal care products, but less so in electronics, office supplies and appliances,” he said.
In a separate study, the Boston Consulting Group found that 80 percent of consumers surveyed said they would be willing to pay more for “Made in the U.S.A.” products than for those carrying a “Made in China” label.
They would pay the biggest differential for items like baby food and wooden toys, and a smaller percentage for electronics, apparel and appliances, said Kate Manfred, director of the group’s Center for Consumer and Customer Insight in the Americas, which released the study in mid-November.
“Safety and quality, and keeping jobs in America, are the important factors,” she said.
Bixbi, a Boulder, Colo., pet treat provider, has relied on safety to increase sales. The company, which started in 2008 amid revelations of tainted dog food ingredients imported from overseas, sells dog treats made from locally raised chickens and other animals.
“Our sales have grown 600 percent each year,” said James Crouch, who founded the small company with his brother, Michael. “Locally sourced is a key advantage.”
But for all the talk about American-made goods, Bixbi is one of the few clients that have adopted “Made in the U.S.A.” marketing, said Dave Schiff, co-founder of Made Movement, a Boulder advertising firm that handles the Bixbi account.
“Some customers think that the American-made label may just be window dressing and companies can be reluctant to use it,” Mr. Schiff said. He and two colleagues started their firm in April to enlist client companies that manufacture in the United States.
Classifying goods as American-made can be dicey, he discovered, because many products have parts that are made outside the United States. To generate interest in such products, as well as a revenue stream, his firm in July started a Made Collection Web site to sell American-made goods.
But finding goods manufactured in the United States for the Web site has been a challenge, Mr. Schiff said. Many items on the Web site are expensive, like a $225 dress shirt from Hamilton, the Houston company that makes Made in America apparel that competes with brands like Levi’s Vintage Clothing and Orvis, which also capitalize on manufacturing in the United States.
Companies are keenly aware that highlighting American-made credentials can backfire after the experience of the apparel maker Ralph Lauren. Renowned for its American nostalgia, Lauren provided uniforms for the 2012 United States Olympic team that were made in China. That resulted in threats of a boycott by some angry consumers.
Some companies like Exxel Outdoors, which makes camping, hunting and fishing equipment, have considered, then rejected, marketing their American-made credentials. Exxel makes two million sleeping bags annually at its Haleyville, Ala., factory.
“We do manufacture in the United States, but there are a lot of variables, like where the components are made. Some of ours come from abroad, so it could be confusing,” Harry Kazazian, the company’s chief executive, explained.
“Simply using the Made in the U.S.A. label is not enough,” said Jaynie L. Smith, chief executive of Smart Advantage, a consulting firm based in Fort Lauderdale, Fla.
“Companies can be foreign owned,” said Ms. Smith, who wrote “Relevant Selling,” a book about corporate sales strategy. “But they need to say that ‘We are still on your soil. We create jobs. We make quality products, and we’re delivering them quickly.’ ”
An Eyes Wide Open Look at U.S. Manufacturing
in UncategorizedCo-author, ‘Death by China’
Senior Economist, American Jobs Alliance
December 31, 2012
As the quote above illustrates, her arguments fly in the face of the current U.S. business school paradigm which seems to be: Leverage America’s R&D and capital to create great consumer products, manufactured abroad — usually China — in order to maximize shareholder return. In this mindset capital is not king, but God, bearing no allegiance to any nation, community, firm or employee. As academics, we teach our business leaders: The fate of individuals is not your concern — unless they are CEOs or stockholders — as competing with third-world wages and standards will actually do them good. In this curriculum the only thing that matters is getting the biggest number on the left side of the equation next quarter, even if the ironic long-term consequences of this short term thinking may be the subjugation of the capitalist system that created it to a foreign and avowedly communist regime.
Let me be clear that Can American Manufacturing Be Saved? is no emotional, xenophobic rant against trade. Nash-Hoff views trade as a tough playing field that Americans used to rule and can win on again. The book starts with a gritty history of U.S. manufacturing and its associated politics. It accepts no sacred cows as it turns over all the rocks and exposes the good, bad and ugly in four centuries of American industry, unions, and politicians. The author happily skewers the intransigent labor leaders, complicit managers, and naïve politicians of the last century who guided American manufacturing into a period of ludicrous union contracts and built our Kafkaesque regulatory environment.
That said, Nash-Hoff is quick to remind cynics that just because the pendulum may have swung too far, it doesn’t mean that we want to be living in the 19th century again either:
Lessons Learned From 100% Made in USA House
in UncategorizedDecember 27, 2012
Now, about a month from completion, the three-bedroom house on the Conway Chain of Lakes stands as a pioneering lesson in the challenges, costs and limitations of building a made-in-America house. The couple have cataloged their construction story at buildtheusa.us.
Two rules were imposed on the job: All products had to be made in the U.S., though not necessarily by a U.S. company. And all workers had to be legal residents of the country. The point, the Gents said, was to support jobs in the U.S.
In some cases, the workers were employed by companies with plants on American soil but with global headquarters elsewhere; it is a mistake, Greg Gent said, to assume that a U.S. company manufactures all its products in the States, or that companies marketing their U.S. presence actually manufacture their wares domestically.
“We started checking all the products, and then [contractor] John [Carr] did, and then John got the subs to,” he said. “No one tried to sneak anything by.”
The ashen porcelain tiles that cover the floors throughout the two-story house were made in the United States, though the supplier is a subsidiary of Italy’s Florim Ceramiche SpA. The shingles were similarly manufactured in the U.S. by a business owned by a French corporation.
Carr, president of Belle Isle-based JPC Construction Inc., said the biggest challenge was finding legal workers in a market abandoned by many crews after the housing slump started five or six years ago. An increase in production-home construction during the past year has left skilled workers in high demand, he added.
Difficulties finding the right workers, plus rain delays, added at least three weeks to the job. And ensuring the house was built with U.S. products, materials and labor added several more weeks.
Subcontractors were dutiful about the made-in-America mission. Carr said his father-in-law, Russ Willis, did the electrical work in the house and discovered a low-voltage surge-protector box marked “Made in the USA” that, upon closer inspection, had components within it from Canada and Mexico as well as the U.S.
Part of the home’s soffits were manufactured by a company that had just started purchasing its supplies from China, so an earlier product batch built in the U.S. had to be tracked down and used.
Carr, who used his cellphone camera to document where products had been manufactured, estimated that the additional cost of wrapping the house in a virtual American flag was about $2,500 to $3,000, or about 1 percent of the overall cost of construction. Two of the project’s seemingly least-expensive items — screws and nails — were responsible for driving much of that higher tab, because they cost about four times as much as their foreign-made versions.
“I’d like to change to do this entirely” with other houses, the contractor said. “But you’ve got the competition. My clients now say they’d like to do this, but there’s the cost.”
Greg Gent is able to recite the origins of almost every part and product used in building the house, from the suppliers of sand and limestone in Lake Wales to the cement company in Sumterville. The item he is most excited about, however, is the Pawleys Island handcrafted rope hammock from South Carolina.
Unable to find a ceiling fan manufactured on U.S. soil, he said he and his wife are holding off on ordering any. Maybe someone in this country will start manufacturing them again, he said.
Apple to Move Mac Mini Production to America: Report
in TechnologyDecember 27, 2012
A report from the Taiwanese tech publication DigiTimes, quoting sources in the upstream supply chain, said Apple is set to move its Mac Mini production lines back to the U.S. “Currently, Foxconn has about 15 operating bases in the U.S., and the company reportedly plans to start recruiting workers in 2013 for new automated production lines,” the report said.
Foxconn, the Taiwanese manufacturing company that makes the iPhone handset, among other Apple components, would be responsible for handling the establishment of production, DigiTimes reported. The Mac Mini offers third-generation Intel Core processors, an integrated memory controller that connects 1,600MHz memory directly to the processor, Intel HD Graphics 4000, either a 500GB or 1TB 5,400rpm hard drive and up to 256GB of flash storage in a solid-state drive instead of a traditional hard drive.
According to a DigiTimes research report, Apple’s Mac Mini shipments are projected to rise 30 percent to 1.8 million units in 2013, up from 1.4 million units in 2012. Apple upgraded the Mac Mini in October, which now includes four USB 3.0 ports in addition to its Thunderbolt, High Definition Multimedia Interface (HDMI), Secure Digital Extended Capacity (SDXC), Gigabit Ethernet and FireWire 800 ports.
The Mac Mini is available with a 2.5GHz dual-core Intel Core i5 with Turbo Boost speeds up to 3.1GHz, 4GB of memory and a 500GB hard drive for $599; a 2.3GHz quad-core Intel Core i7 with Turbo Boost speeds up to 3.3GHz, 4GB of memory and a 1TB hard drive for $799; and a 2.3GHz quad-core Intel Core i7 with Turbo Boost speeds up to 3.3GHz, OS X Server, 4GB of memory and two 1TB hard drives for $999.
Earlier this month, Apple CEO Tim Cook told NBC news anchor Brian Williams that Apple will, in fact, be moving the production of one of its Mac lines to America, a move that will cost the company approximately $100 million.
In the interview, Cook’s first since he took the helm as CEO in mid-2011, he also said the company plans to build a data center in Texas, in addition to existing data centers in North Carolina, Nevada and Oregon. Cook declined to state specifically where the computers would be made, however.
“We’ve been working for years on doing more and more in the United States,” Cook told Williams. “When you back up and look at Apple’s effect on job creation in the United States, we estimate that we’ve created more than 600,000 jobs now.”
What Mac to be 'Made in USA'? Maybe Mini, perhaps Pro?
in UncategorizedDecember 26, 2012
Elmer-Dewitt notes that Cook mentioned a $100 million investment and that a Bloomberg source, Dan Luria, estimated that such a sum would add up to a factory employing about 200 workers and turning out about a million units of whatever product per year. (Luria studies factory operations as a labor economist at Michigan Manufacturing Technology Center in Plymouth, Mich.)
“Only the Mac Pro and Mini sell fewer than 1 million per year,” Elmer-Dewitt says. And here’s why he casts his lot with the Pro: It’s heavier than the Mini, and thus more expensive to ship from overseas; Pros are, he says, “easier to build and customize than any other Apple product;” and Cook has indicated that Apple will be making a new Pro in the coming year.
So which Mac will bear the “Made In USA” label? That, of course, remains to be seen. It’s interesting, though, to play armchair CEO/COO and begin pondering such logistical questions.
Manufacturing “Insourcing” to Gather Steam in 2013
in NewsIn the wake of the BP drilling rig failure in the Gulf of Mexico almost 18 months ago, costing untold billions of dollars in penalties and losses, this unfortunate incident has added to the importance of “ultimate responsibility” by the “front line” installer and ultimate user.
Added to these changing circumstances are both escalating and time consuming overseas transportation costs, plus the shrinking of direct labor costs that have actually dropped in the U.S., but quintupled in China during the last 10 years. In the case of high technology, the imbalance has even grown tighter as the cost of labor in finished goods have continued to be less important as part of the total price picture.
But what surprised me most in the Atlantic Monthly article is the fact that GE, universally derided as the “champion of outsourcing,” has taken a leadership role in reopening production facilities in the U.S.
Although dismissed by some as a public relations gesture, due to CEO Jeff Immelt’s previous collaboration as the White House chief of non-existing domestic job creation, the GE “insourcing turnaround is primarily due to the rapid need for constant product innovation, and the shift to “just-in-time” inventory control. This is made almost impossible by today’s multi-month delivery time and the volume of purchases necessary from abroad to achieve a satisfactory cost preference. Other major American multi-nationals are indicating a similar predisposition.
When viewing America’s 2013 domestic production expansion through the prism of “insourcing” rapidity, trade deficit shrinkage. and setting new export records, especially in energy, heavy machinery, military equipment, technology and agriculture, guarded optimism has entered the picture. But it still leaves in doubt economic direction, so heavily colored with questionable politico-economic leadership emanating from Washington, D.C.
Is Manufacturing Making A Comeback In The U.S.?
in UncategorizedAs a whole, the sector is looking up. The Institute for Supply Management’s PMI (Purchasing Manager’s Index — an indicator of manufacturing health) showed positive growth in October for the second straight month as orders increased, production improved, and export demand remained static.
Hidden within those statistics are two curious and surprising success stories.
Automotive manufacturing, once a crucial tentpole in America’s industrial economy, is poised for a surprising (if slow) comeback. Industry analysts are cautiously optimistic about the sector after stronger year-to-date sales, healthier inventory levels, more favorable credit conditions and improved consumer sentiment have boosted demand for American light-vehicle manufacturing.
Chrysler capped off its best October in five years, with sales rising 10% despite the three-day disruption of Hurricane Sandy. (Ford, for example, despite estimating that the storm cost the industry 20,000 to 25,000 sales, reported a small sales increase.) With gas prices declining and consumer sentiment rising, experts expect automotive manufacturers to experience gains into 2013.
The second and even more surprising growth sector is computer and electronics manufacturing. Apple recently announced plans to invest $100 million in building more of its Mac computer components in the United States. Chinese PC giant Lenovo announced in October that it would break ground on a manufacturing center in North Carolina. The facility, Lenovo said, “will be capable of turning out some of Lenovo’s newest and most innovative products, such as the recently announced ThinkCentre M92p Tiny desktop and ThinkPad Tablet 2.”
The facility is expected to create only 115 jobs initially, a tiny fraction of the 2.7 million manufacturing jobs the U.S. has lost to China in the last 10 years alone. But it’s a start. Reasons to shift manufacturing back to the U.S. are many; the “landed cost” — the cost of moving goods from factories to their destination — is rising owing to increasingly expensive fuel and logistics needs. Also rising is the cost of Chinese labor. While still low by Western standards, wages are creeping up in China as they fall stateside.
Both changes are too new and too undeveloped for a pronouncement of recovery just yet, but the attendant factors — increased cost of shipping, rising foreign labor costs, falling wages at home and growing consumer demand — give prognosticators every reason to be cautiously optimistic. Though a victory lap may be premature, it’s possible these could be the first signs of a return to the American industrial economy of decades past.
R-CALF USA – USDA Prepares to Expose the U.S. to an Unnecessary and Avoidable Risk of FMD
in UncategorizedDecember 18, 2012
According to Iowa State University, swine are a “special concern” for FMD because they are more susceptible to the disease than other species of livestock. The United Kingdom also identifies pork meat from FMD affected countries, especially bone-in pork or with lymph glands attached, as bearing a higher risk for transmitting the disease.
Brazil is not a country recognized as FMD free by either the U.S. or the World Organization for Animal Health (OIE), yet both the U.S. and the OIE claim that Santa Catarina, the second most southern state in Brazil, is free of the disease.
Santa Catarina borders Argentina, which also is a country not recognized as FMD free. In 2011, Paraguay, which borders Brazil, reported an outbreak of FMD and a Brazilian journalist reported that after the outbreak, Paraguayan cattle were crossing freely into Brazil along a 254-mile stretch of the border and further reported no inspection crews at two border crossings.
“Our only means of preventing the introduction of FMD into the United States from raw Brazilian pork will be immediate notification by Brazil in the event of another FMD outbreak in that country,” said Max Thornsberry, D.V.M. and Chair of R-CALF USA’s Animal Health Committee.
But therein lies the rub.
Thornsberry said the fact that Brazil took two years before notifying the U.S. on December 7, 2012 that it had detected a cow with bovine spongiform encephalopathy (BSE) that had died in 2010 clearly demonstrates that developing countries like Brazil are not in the same league as the United States in preventing, detecting and reporting dangerous livestock diseases.
“The U.S. faces a real risk of introducing FMD from Brazil and USDA must start to realize that its system of relying upon foreign countries to prevent disease spread and introduction is badly broken.
“The USDA’s goal of free trade at any cost will soon cost the U.S. cattle industry much more than we can withstand and both cattle ranchers and consumers will suffer,” Thornsberry concluded.
# # #
R-CALF USA (Ranchers-Cattlemen Action Legal Fund, United Stockgrowers of America) is a national, nonprofit organization dedicated to ensuring the continued profitability and viability of the U.S. cattle industry. For more information, visit www.r-calfusa.com or, call 406-252-2516.
12 Days of Christmas & Holiday Giveaway – DAY 12
in UncategorizedWelcome to Day 11 of our Fabulous
12 Days of Christmas & Holiday Giveaway
Please help us in thanking our wonderful members and sponsors of our our daily giveaways. This would not have been such a success without the generous contributions of our corporate members and sponsors.
Now, on to our last giveaway of the year…
Today’s giveaway includes 16 prizes, valued at over $1,000!!
Rules for each day/entry:
(1) Comment at the bottom of this BLOG
(2) Enter via Rafflecopter widget below.
It may seem overwhelming at first, but its really quite easy.
(3) Are you on GOOGLE+? Give us a “+” up on the right hand corner of this blog. Not necessary to enter, but while you’re here… ;-)
It will help us rank higher on GOOGLE!!
(3) SHARE (via Facebook) blog link on your wall.
The more you share this link, the better your chances are to win.
Giveaway begins at 12PM EST
Giveaway will run for 24hrs only
One winner will be chosen at random.
Name of winner will be posted at 6pm EST.
Winner will have 24hrs to get in touch with us;
otherwise prize will go to runner up.
Today’s retail value of all 16 prizes is about $1,000
That’s $1,000 worth of American Made gifts you won’t have to spend a dime on!
We want to keep our giveaways flexible and allow our readers to enter in whatever ways they are most comfortable. There are a LOT of entry options below, but don’t be overwhelmed. The FACEBOOK likes are required, the Twitter follows are not… however, the more entry options you complete, the more chances you’ll have to win.
This giveaway will close at 12pm EST on 12/21. The winner will be randomly selected, verified for correct entry participation, and notified by email.
Now, let’s have some fun and win some prizes!!!
12 DAYS OF PRIZES
DAY 12
12 Days of Christmas & Holiday Giveaway – DAY 11
in UncategorizedWelcome to Day 11 of our Fabulous
12 Days of Christmas & Holiday Giveaway
Rules for each day/entry:
(1) Comment at the bottom of this BLOG
(2) Enter via Rafflecopter widget below.
It may seem overwhelming at first, but its really quite easy.
(3) Are you on GOOGLE+? Give us a “+” up on the right hand corner of this blog. Not necessary to enter, but while you’re here… ;-)
It will help us rank higher on GOOGLE!!
(3) SHARE (via Facebook) blog link on your wall.
The more you share this link, the better your chances are to win.
Giveaway begins at 12PM EST
Giveaway will run for 24hrs only
One winner will be chosen at random.
Name of winner will be posted at 6pm EST.
Winner will have 24hrs to get in touch with us;
otherwise prize will go to runner up.
Today’s retail value of all prizes is over $800.
That’s over $800 worth of potential American Made gifts you won’t have to spend a dime on!
We want to keep our giveaways flexible and allow our readers to enter in whatever ways they are most comfortable. There are a LOT of entry options below, but don’t be overwhelmed. The FACEBOOK likes are required, the Twitter follows are not… however, the more entry options you complete, the more chances you’ll have to win.
This giveaway will close at 12pm EST on 12/20. The winner will be randomly selected, verified for correct entry participation, and notified by email.
Now, let’s have some fun and win some prizes!!!
12 DAYS OF PRIZES
DAY 11
Foxconn Begins Manufacturing Amazon Smartphone
in UncategorizedDecember 18, 2012
Perhaps the most surprising part of the report relates to the price of the supposed device. The report claims that Amazon’s smartphone will be offered for a price somewhere in the range of $100 to $200. If true, such a low price point would be consistent with the company’s strategy of bringing customers into its e-commerce ecosystem over profit margins on its hardware. Despite the success of the Kindle line of devices, the company barely breaks even on every Kindle Fire $159.00 at Amazon device produced.
But, contrary to the high profit margin strategy of Apple, Amazon CEO Jeff Bezos apparently believes in a different approach. In October, in a statement accompanying Amazon’s third quarter results, Bezos said, “Our approach is to work hard to charge less. Sell devices near breakeven and you can pack a lot of sophisticated hardware into a very low price point.”
The Asia-based news source also claims the device is scheduled to be launched some time in the second or third quarter of 2013, which might allow the handset to compete, give or take a few months, with the release of an updated iPhone, assuming Apple hews to its usual release schedule.
Last month, Digitimes reported that Foxconn was producing phones for Amazon and Microsoft.