Word: problem
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...than in 2007. The key is a revamped portfolio more heavily weighted to smaller cars and crossovers, as well as to hybrids and electrics that are far more efficient than the current fleet. That's crucial because Detroit currently loses money making cars in North America. You see the problem...
...Fremont en masse to see the miracle of NUMMI. Some dismissed what should have become a model for the entire industry. True, the technology wasn't that innovative. But Toyota had made the workforce integral to improving the system. Workers were not mere labor inputs. GM had no problem understanding the just-in-time inventory system Toyota used, but executing it required a buy-in from the shop floor so that everyone was dedicated to improvement. The Toyota system, says MacDuffie, "relies on contributions from employees. It feels vulnerable, but your willingness to be open to that vulnerability is what...
...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...
...Reducing capacity could also go a long way toward solving Detroit's revenue problem. Between Detroit and the transplants, there are around 17 million units of manufacturing capacity in the U.S. In 2007 vehicle sales hit 16 million, but about 2 million of those were driven by the combination of easy credit and discount pricing. In a normal economy, the true size of the business may be closer to 15 million units. The Detroit Three simply have to generate more revenue per car and, not incidentally, a profit. Right now, the revenue gap per car is $4,000 vs. Toyota...
...Bush Administration, leery of adding yet another taxpayer bailout to its already shaky legacy, has been unwilling to step in, appoint a car czar and negotiate a solution to the problem. The incoming Obama Administration is expecting such talks to fall to it, but the automakers, especially GM, have warned they cannot wait. "I believe that we could lose General Motors by the end of this month," said Ron Gettelfinger, head of the United Auto Workers (UAW) union, which announced Wednesday that it would be willing to sacrifice job-security provisions and financing for retiree health care to save...