That tide is turning, though. Currently with our high unemplyment rate, and the fact that China is experiencing high inflation, at some point those jobs will have to come back here
Not to get too far off topic, but as a design engineer that is responsible for getting new deigns into production in plants around the world, I?ll honestly say there?s more to the outsourcing of manufacturing jobs from America than just cost of labor.
Simply put, America?s manufacturing plants are not competitive.
Years ago factories were kept filled with guys (and some girls) that came in from the rural farm areas that at least had some common mechanical aptitude. Those folk don?t really exist in large numbers anymore. Or at least they have no desire to work for minimum wage in a factory.
Now you get illegal aliens (bless them for wanting a better life) that always just nod and sheepishly mutter ?Yes, yes.? When you ask them if they understand what you just explained to them, or the high school dropouts that can?t keep a job at McDonalds. I?m not embellishing here, these are specific cases I?ve seen more than once. People straight in off the streets that literally don?t know how to use a screwdriver.
At the same time the mid level workers in American factories are all just a bunch of whiners. Every time I go to one of our factories in rural Minnesota I hear the same thing from at least one or another of them, without fail. First they complain about how hard and challenging the new version of this or that product is to assemble and how they wish we hadn?t changed it? ?then I hear them complain about how they went to buy this or that at the store the last night and could only find ones that were made in China.
Don?t even get me started on the unions. Last time we had a big on-site pow-wow, set up and paid for by the head of the factory to drum up ideas for how to reduce assembly costs and improve quality, a fellow engineer had a grievance filed against him because he proposed a couple of productivity improvements that would enable them to reduce the number of workers needed on the line.
It?s not just the factories fault either. Most of America?s manufacturing companies are run by people that have never actually set foot on an assembly line. They like to read books about Japanese work philosophies (like A3s, Kaizens, Lean Manufacturing and the like) but then they try and ram-rod those Japanese notions into an American mindset, with poor results.
Really briefly, A3s at Toyota are meant to be a one page document, printed on a sheet of A3 sized paper, that only gives the high level review of a problem and/or solution. Keeping it to A3 size and having it printed on paper means that only the most basic information is conveyed and you have to *physically* get up and walk to the person that owns it to read it. Thereby facilitating conversation with that person that may be able to help you with your problem. The company I work for has grabbed this notion and decided to make the whole system electronic. So people can search it from any company computer and don?t even have to bother with knowing who or which project was responsible for the previous issue?
?Kaizen? in Japanese means ?continuous improvement.? The idea that everyday, every shift, every hour employees work on trying to make their jobs better and more effective with as much attention paid to that as to the actual job they are expected to do. Day in, day out; month in, month out; etc they try and find ways to make their work more productive as a matter of doing their jobs. In America, companies have taken hold of this ?Kaizen? philosophy with both hands, only they hold events over the span of a few days or maybe up to a week, where we try and solve a specific problem. Usually by having employees stop what they are doing, move offsite, and work on just that problem it until the session is over (problem solved or not.) Often not thinking about it again after returning to their real responsibilities?
Lean manufacturing in Japan has to do with trying to evaluate the entire process of assembly to eliminate large sums of waste from the factory by looking at the big picture and outright eliminating the large cost wastes within a factory that do very little to make a good product. By eliminating the ?sacred cows? savings on the order of hundreds of thousands to millions of dollars per factory per year can be obtained. In America the craze amongst large manufacturing companies is to force their office workers to try and do this. Coming up with new ways to use fewer staples and the like?
America deserves to lose its manufacturing. And I say that as a proud citizen that would like to see us be competitive as much as I?d like to not have to fly half-way around the world to get my projects into production.
Ah..., anyway off the soapbox... when is this phone releasing again?
-Suntan