One of the things that American companies did a lot of during the past thirty years was outsource manufacturing. But not only did they outsource manufacturing, they outsourced even the design of the manufacturing tooling and equipment and facilities. Now it’s claimed that the United States has lost critical skills and could no longer bring those manufacturing jobs back onshore even if we wanted to do so.
One thing I want to point out is that manufacturing is hard. I was the manufacturing manager for two different small computer companies as well as designing the manufacturing processes for another computer company. Making sure you get quality product out to the customer in a timely manner is not easy. You have supply chain that has to be coordinated so that all the parts in the right numbers come together at the same time, you don’t want to have lots of components hanging around not bringing in revenue, that’s how you lose money. You must design procedures for how the systems will be assembled and imaged with firmware, and how they will be tested. You have to make sure that the final result is packaged in a way that can get to the customer without shaking to pieces.
And if you don’t know how to manufacture, you don’t know how to design.
That was the problem I ran into with the last computer company where I had anything to do with manufacturing. They had completely outsourced their hardware design and manufacturing. There was only one person on staff who knew anything at all about manufacturing, and that was me, and I’m not a hardware designer, I’m a software / firmware designer who happens to understand hardware, and they had not hired me to do manufacturing, they’d hired me to write software. They didn’t even *know* that they needed someone who understood hardware and manufacturing to make sure that the hardware could be manufactured in a cost-effective manner and arrived at the customer site ready to use. As a result they made rookie mistakes. A drive controller board ended up being more than 12 layers of copper and weighed as much as your average girl gym barbell, when it could have been half that thickness (and a quarter of the production price) with a little optimization for manufacturability. Various jumpers to connect to the front panel and to disk drive lights had identical connectors so that the assembly people could not tell at a glance which jumper went into which connector. None of the cables had positive retention, which, given that the motherboard to disk controller cable was heavy and hanging upside down from the disk controller board (which was horizontally plugged into the backplane), meant that the cable was invariably falling out when the system was subjected to vibration during shipping, leading to a system that was basically dead on arrival when it arrived at the customer site. Various things were very hard to screw together into systems, when competitors like Dell were creating snap-together servers that required no tools at all in order to assemble them. I came up with procedures and tests to make sure everything got assembled correctly, but it was a struggle. I also got a connector with positive retention spec’ed *finally*, months after I’d remarked that the connector was *not* going to stay put, because a machine arrived at a beta customer site, didn’t work, got shipped back, and I showed them that the machine was fine once I plugged that cable in. It took that disaster before they finally listened to me at all on these things, because they just didn’t understand manufacturing and didn’t understand how their hardware was basically unmanufacturable as designed.
Eventually I got so frustrated dealing with people who just didn’t “get” manufacturing that I quit that job and moved on. The company eventually ended up going out of business — because they did not know how to design a quality product that could be manufactured for a competitive price.
Which brings me to my point: When you outsource your manufacturing, you’re eventually outsourcing your design too, because you simply can’t “do” design utterly divorced from the question, “how do I manufacture this widget?”. And once you’ve outsourced your design team to China, bringing that skill set back here to the United States in order to bring manufacturing back here to the United States is a mission impossible. You basically have to re-develop those skills from scratch — and we’re talking skills that take decades to develop, this is stuff you learn via hard knocks and passed-down wisdom from older workers, there are no books, there are no courses that teach you how to do this stuff.
In short: In those fields where we’ve outsourced everything to the Chinese, including, now, the design in large part (because they’re the ones with the manufacturing expertise to design for manufacturability, we don’t know how to make anything in the USA anymore), we’re fucked. It will take literally decades to bring any of that back to the USA, and would require some government subsidies and protections in the meantime to keep those companies in business while they learn how to manufacture again. And we can’t do that subsidy/protection thing anymore like we did in the past, because WTO, NAFTA, you name it.
The United States still manufactures some stuff, of course. We still make cars, for example, as well as most of the components for building cars. We build high-value microchips here too. But all of that is now becoming highly automated, requiring fewer and fewer workers. Which means that if you’re a manufacturing worker who was laid off during the Great Recession… well, sorry, guy. Your job went away, and it’s not coming back. That’s all the answer that our political establishment has for that laid-off worker. And that’s not an answer they’re willing to accept.
Thus Donald Trump. But more on that later.
– Badtux the Manufacturing Penguin
Read Full Post »