The following article was produced by IDI, Industrial Developments International, in their recent newsletter. It is reflective of similar information I have provided in writings and talks over the last couple of years. I first learned of a probable resurgence in U.S. Manufacturing from Hal Stratton, former Chief of the U.S. Consumer Products Safety Commission during the Bush Administration, who gave a talk at my home to a group of limited government types shortly after he retired from that position and returned to Albuquerque a few years ago. The impetus, from his perspective, is that the U.S., unlike many developed countries, has product liability laws that force improved quality control on the production line. Countries like China are not yet oriented to quality control. The likelihood of a retailer like WalMart being sued for a defective baby stroller made in China is high. The costs of that kind of liability combined with the other concerns addressed in IDI’s article below seem to make a strong argument for ‘reshoring’ or ‘nearshoring’ again. Problem for places like New Mexico is… we are not a right to work state, our development policies are anti-growth, anti-business and we have a limited supply of skilled labor for manufacturing, though many could be trained… then there is a land availability problem, which many think is a funny notion considering we are surrounded by dirt… but getting water and roads to it is quite another thing! Vic
Not Made in China
U.S. Manufacturers See Advantages of Reshoring
Sleek Audio CEO Mark Krywko was like a lot of business people in the mid-2000s, wooed to China by cheap labor and manufacturing costs. For Krywko, however, the honeymoon did not last long. Repeated manufacturing glitches, delivery delays, cash tied up for months waiting for inventory to arrive and numerous trips to China every year cost him millions. Finally, after countless headaches and seeing his company on the brink of disaster, Krywko brought his operations home. Sleek Audio’s high-end earphones now cost about 50 percent more to produce, but the premium is worth the quality and consistent deliveries. Sleek Audio projects 2011 to be its most profitable year ever.
After years of U.S. manufacturers moving their operations overseas to reduce costs, changes in markets both here and abroad are beginning to swing the pendulum the other way. “Reshoring,” or shifting operations back to the U.S. from a distant country, is slowly emerging as a trend affecting manufacturing jobs, state and national economies and industrial real estate
The Offshoring Backstory
Offshoring has always been part of American history, starting in the Colonial era when almost all manufactured goods were imported from England. In the 1800s, America created its own manufacturing infrastructure in response to high import costs, and eventually led the world in manufacturing power and innovation. This dominance continued until the 1960s, when American productivity stagnated and offshore competitors emerged.
By the 1980s, America’s lack of manufacturing competitiveness prompted companies to close domestic factories and move operations to Mexico, a phenomenon known as “nearshoring.” Next came relocating to Asia, where costs were even lower. Ultimately, as in Colonial days, America once again offshored most manufactured goods.1
Offshoring momentum, however, is showing signs of reversing. In a June 2011 survey of North American manufacturers, 21 percent said they were bringing production into or closer to North America and 38 percent planned to research such a move soon. The Boston Consulting Group predicts the U.S. will undergo a manufacturing renaissance in the next five years.2
The Tide is Starting to Turn
The initial appeal of offshoring was reduced costs. Even though many companies’ transportation, duty and other costs went up and supply chain speed went down, the 30 to 50 percent reduction in labor costs more than offset the shortcomings.3 These numbers, however, are changing. Wages in China are soaring 15 to 20 percent per year.2 In 2000, hourly manufacturing wages were 52 cents; by 2015, they are projected to climb to $4.41.4 Because wage rates account for 20 to 30 percent of a product’s total cost, manufacturing in some areas of China will be only 10 to 15 percent cheaper than in the U.S. After factoring in shipping and inventory costs, the advantage is minimal.
Rising labor costs are not the only reason manufacturers are rethinking offshoring. Other considerations are:
• Increased shipping costs. In the last four years, shipping costs have gone up 71 percent because of higher oil prices and cutbacks in ships and containers.4
• Quality concerns. In an Accenture survey of 287 manufacturing companies, 46 percent said they experienced product quality problems in their offshore manufacturing and supply operations.2
• Supply chain disruptions. Offshoring expands the supply chain’s length, complexity and risk of serious interruptions. Events such as earthquakes, floods, terrorist activity, military actions and political upheaval occur more and more frequently, forcing manufacturers to develop flexible supply chains, multiple sources of raw materials and extensive contingency plans.
• Delivery time. Physical separation between regional supply and regional demand can make it difficult to respond to customer needs quickly and maintain quality and cost efficiency.2
Industries Looking Toward Home
Reshoring makes more sense for certain product categories than others. Household appliances, construction equipment and other products that require less human labor and are made in modest volumes are good candidates for U.S. factories.2
Others likely to relocate U.S. market production are:
• Furniture
• Transportation goods
• Computers and electronics
• Electrical equipment
• Plastics and rubber products
• Machinery
• Fabricated metal products
Together, these industries could add $100 billion to the U.S. economy and lower the non-oil trade deficit by 20 to 35 percent, according to Boston Consulting Group.6
The Reshoring Alternative: Nearshoring
While signs of reshoring are unmistakable, some experts say it is too soon to declare a definite trend. One reason is nearshoring, which offers cheaper labor while keeping production close to U.S. customers. From Mexico, goods can be delivered to the U.S. in one or two days compared to 21 days by overseas. Other advantages are: being in or close to the same time zone as U.S.-based customers for easier communications and coordination; a well-educated, skilled workforce; lower manufacturing costs; and patent and intellectual property protection.7
The news in Mexico, however, is not all favorable. Access to domestic parts and materials, security, drug-related violence, crime, border delays and difficulties persuading managers to relocate are challenges companies face doing business south of the border.
States Poised to Benefit
U.S. manufacturers who move operations back on home soil obviously look for the best locations. Factors influencing their decisions include real estate costs, labor costs, union concessions, workforce skills, state incentives and subsidies, and real estate development partners with experience in the geographies being considered. IDI, for example, has completed inventory and build-to-suit projects in several southern states with low-cost labor including Alabama, Georgia, Mississippi, North Carolina, South Carolina, Tennessee and Texas. These markets are particularly attractive as manufacturing hubs for the U.S. market8 and some could become among the least expensive production sites in the industrialized world.2
If the reshoring trend plays out in a big way, it could create up to three million U.S. jobs in coming years.6 With the “multiplier effect,” where every manufacturing job can create up to eight ancillary and support jobs downstream in logistics, retail and services, America’s employment picture could improve greatly.2
The U.S. Becoming an Offshoring Destination
Shin Uran, president of Kajima Building & Design Group, Inc. and sister company to IDI, says his company is working with more Japanese manufacturing companies planning to locate facilities in the U.S. than he has seen in over 10 years. A key factor is the large gap in financial exchange rates. “With the value of the yen so high,” he says, “…it has become increasingly necessary for these companies to produce their goods in the U.S. in order to remain competitive.”
This trend is apparent across industries, according to Takayuki Oto, marketing manager for Kajima Building & Design Group. “We have seen a significant increase in all manufacturing sectors and are currently working with Japanese firms in printing, food and beverage, automotive supply and heavy equipment manufacturing.”
1 “A Brief History of Offshoring and Its Relationship to Manufacturing Productivity,”
by Dr. Dean F. Poeth, P.E., C.Mfg.E., 2007.
2 “Is U.S. Manufacturing Coming Back?” by Lisa Harrington, inboundlogistics.com,
August 2011.
3 “Outsourcing and Offshoring,” enotes.com.
4 “Made (Again) in the USA: The Return of American Manufacturing,”
by Nin-Hai Tseng, finance.fortune.cnn.com, June 29, 2011.
5 “New Tire Plant Set for South Carolina,” by Jeff Bennett, The Wall Street Journal, October 7, 2011.
6 “Manufacturing Jobs to Shift from China to US, Report Says,”
by John D. Boyd, The Journal of Commerce Online October 7, 2011.
7 “Manufacturing in Mexico: Nearshoring and the Aerospace Industry,”
collectron.com, March 30, 2011.
8 “‘Reshoring’ Manufacturing: Which States Could Win,”
businessclimate.com, October 4, 2011.
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