Word: detroits
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...senior lecturer Steven Spear, a lean-manufacturing specialist who has worked on production lines at both a Detroit Three and a Toyota plant, says the problem worsened over the years as products and manufacturing inevitably got more sophisticated. Merely upgrading a Toyota, he says, requires 300 man-years of engineering. No single manager can ever understand it. "Figuring out products, markets, customers, designs, systems - what's inherent about anything complex is that it becomes impossible. You can't design it perfectly," he says. What matters, he argues, is swarming problems from every direction to create high-speed, low-cost discovery...
...Management in a Mess Detroit's corporate culture is obviously complicit in the industry's deterioration, just as it was guilty of creating an unparalleled manufacturing system decades earlier. The Detroit approach has been plan-command-control, stemming from that original control freak, Henry Ford. At GM, a management hierarchy that had been created by GM's master planner, Alfred P. Sloan, in the '20s - GM's first and most successful restructuring - was still functioning in the '80s. Management's job was to create the products, design the production system and provide solutions if there were problems. Everyone else followed...
...Failing to cure themselves of the Not Invented Here disease, Detroit's bosses resorted to Hail Mary attempts to fix what were long-term issues. "They were constantly looking at buy, sell, hire, fire, looking to be rescued from their predicament," says Spear. On the buy side, GM CEO Roger Smith acquired Hughes Aircraft, EDS and a 50% stake in Saab. His successors bought the Hummer, 20% of Korea-owned Suzuki and 20% of Fiat with the obligation to buy it or pay to get rid of it. (The latter course was chosen, at a cost of $2 billion...
...there were the occasional hits that demonstrated Detroit's deep pedigree in engineering and design. Chrysler, desperately surviving on a government-guaranteed loan, created the minivan in 1984. That same year, it launched the first modern sport-utility vehicle, the Jeep Cherokee. Throughout it all, Detroit kept its dominance of the hugely important pickup-truck market - and does so to this...
...want to build. They have to build them because they have a fixed cost structure to amortize," says Nick Gidwani, a former auto-industry investment banker with Sankaty Advisors and now head of the startup auto-sales website CarZen. Particularly after the post-9/11 sales slump, Detroit got addicted to this strategy and used it to move plenty of SUVs...