I've always been a huge Simpsons fan, even if the show has gotten less funny in the past few years (flame away on that topic, if you must). The beginning of the this week's episode made me chuckle a bit.
For those who can't see the video (those darned oppressive masters of the corporate firewall!), it's an intro to a histrionic news piece – with Kent Brockman – about a coming total eclipse being the end of the world.
In the clip I extracted here from Hulu.com, the fall of industry is illustrated by a group of robots building a car on an assembly line. At the end of the line, a robot stamps “Made in America” on the hood and the car promptly falls apart.
So, it's not really a slam on all American cars (or shouldn't be). Well, the Simpsons producers and writers probably meant it as such. It should really be a slam against companies who had “visions” of a “lights out factory” where robots dominated and people were an expense that wasn't needed or wanted. Compare that to Toyota, a company that wasn't as automated as, say, General Motors, and invested more in people and their shop floor “kaizen” and problem solving skills…
As this excellent article points out:
By the late 1980s, GM's chairman, Roger Smith, had figured out that his company had something to learn from the Japanese. He just didn't know what it was. He poured billions into new, heavily automated U.S. factories – including an effort to build an experimental “lights out” factory that had almost no hourly workers. He entered a joint venture with Toyota to reopen an old GM factory in California, called New United Motor Manufacturing, Inc., or NUMMI. The idea was that GM managers could go to NUMMI to see up close what the “secret” of Toyota's assembly system was. Smith also launched what he promoted as an entirely new car company, Saturn, which was meant to pioneer both a more cooperative relationship with UAW workers and a new way of selling cars.
None of these was a bad idea. But GM took too long to learn the lessons from these experiments – good or bad. The automation strategy fell on its face because the robots didn't work properly, and the cars they built struck many consumers as blandly styled and of poor quality. NUMMI did give GM managers valuable information about Toyota's manufacturing and management system, which a team of MIT researchers would later call “lean production.” But too many of the GM managers who gained knowledge from NUMMI were unable to make an impact on GM's core North American business.
Anyway, I've probably over-analyzed a short video that gave me a sad chuckle.
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