What's holding US manufacturing back?
There has been an ongoing national conversation about bringing manufacturing back to the United States. The government, states, educators, and organizations have been pushing a resurgence through, addressing many of the roadblocks facing these organizations, including: lack of skilled labor, decreased sales, advancing lean manufacturing, integrating additive manufacturing, robotics, IoT and Big Data.
The middle-market manufacturers - primarily in the Midwest, in the range of $50-$500m in revenues, employing 10-800 people - face a unique set of challenges. While the advancement of things like 3D printing and robotics will undoubtedly change the manufacturing landscape, these manufacturers face much more basic challenges to compete - and more accurately - survive the next 3-5 years.
This isn't about the "skills gap", or "robots taking jobs", or "offshoring", or even "regulation burdens". Those challenges are further downstream for these manufacturers. Today's issues are much more fundamental. The advancements in digital technologies, communications platforms, and simply the Internet, have dramatically impacted business operations and overall competitiveness. The "blocking-and-tackling" of things like: embracing change, utilizing technology platforms, digitizing information, and fostering an innovative culture, are the true essentials for US middle-manufacturing growth. Here's a short list of those essentials:
1) Modernization of internal information infrastructure - Many manufacturers are running business operations on outdated technologies. This is not simply about having old computers, but the underlying software and systems. Whether it's running Windows 97, ERP systems circa 1989, taking orders by faxes, or managing customer data on Excel spreadsheets, this lack of having a 'modern tech stack' limits the organization's ability to leverage real-time business insights, dynamically connect with remote purchasing platforms at larger OEMs, and serves as a deterrent for younger employee candidates from taking a position at the company. Digital technology growth is exponential, so for every year a process is not modernized, the organization falls 3+ years behind. Without continual advancement and improvement, the technology gap will continue to expand to the point of no return, reducing the company's competitiveness, and overall organizational value down to physical assets and customer lists.
2) Changing long-standing internal cultures - Mid-Market manufacturers often are serving as a major employer within smaller, more rural communities, where employee turnover is low. With a large set of "lifers" leading the organization, employees cling to the Status Quo out of comfort and familiarity. This resistance to change is frequently fostered by leadership, who often are second, third, or even fourth generation owners. While this of course, doesn't apply to every private manufacturer, many leaders are not pushing a culture of continuous improvement. Platforms and processes haven't notably changed in decades, and many small changes cycle in and out - reverting back to the "old way of doing things" within a matter of months or weeks. Without a dramatic change to the culture and it's attitude towards change, the organization will quickly become obsolete.
3) Expanding the business acumen of middle managers - Many middle managers within mid-market manufacturers have advanced to their roles through hard work and a series of promotions. Often times, these managers have worked at the organization for the majority of their careers - they've not been exposed to other companies, environments, or new business processes. Many have little to no formal business, finance, sales, marketing, or operations training. The challenge becomes that key leaders are not fully capable to design, develop and implement broader strategies, to streamline operations, reduce expenses, identify new markets, and drive innovation throughout the company. Without education and exposure to new ideas, the organization remains stagnant.
4) Securing talent when located in small town USA - There is no doubt that there is a skills gap, and it's growing. But with this skills gap comes exclusivity. When there is a nursing shortage, those with an RN degree can pick and choose which hospital they want to work at, and negotiate a very competitive salary and benefits package. With the manufacturing skills gap continuing to grow, manufacturers that exist in small, remote communities, with a long commute from dense population centers, will have a harder and harder time securing the necessary talent to advance their organization. New recruitment and incentive strategies will need to be employed to secure (and more importantly, retain) necessary talent for organizational advancement.
5) Shifting business operations from order fulfillment to value added - Manufacturers have had the advantage of being a "product provider" for many decades, as demand for equipment, components, and materials has generally stayed consistent. When major offshoring occurred in the mid-80's, price pressures set in and it became challenging to compete with overseas suppliers. As the trend of on-shoring has begun, these manufacturers will have a new competitor to contend with - buyers with higher expectations. Buyers that are not simply seeking a product, but a strategic partner that will add value to their product, reduce costs, and help streamline their purchasing operations. This new level of "service" requires a change in the mentality and business strategy for manufacturers. Examining how they can add value - not simply through added product offerings, but throughout the entire supply chain and customer engagement experience. Without this, manufacturers will continue the price race to the bottom.
6) Understanding and leveraging marketing - Back 20, 30 and even 40 years ago, manufacturers built their business on handshakes and relationships. With the expansion of online sales, automated purchasing, and even Amazon.com, marketing plays a much bigger and more impactful role when it comes to revenue growth. Since many of these companies have solely utilized marketing as a department for brochure creation and website updates, the lack of strategic resources keep this department from helping advance and grow the organization. Marketing is inherently communications - identifying where customers are, what they want, new opportunities within the market, new or underserved markets, how information flows through the company and how the customer experience can be leveraged as a differentiator. Even traditional branding, messaging, positioning, and promotions play a part, but not without a clear strategic plan in place. If manufacturers don't start embracing the concept of marketing, they will continue to fall by the wayside.
7) Understanding how to use business data to make strategic decisions - Everyone talks about "big data", but what about using the data you have at hand now to make better business decisions? Manufacturers have reams of data - including product usage, field performance, customer orders, past purchase history, and much more. Yet, an overwhelming amount of companies simply look at the P&L each quarter and see if sales are up or down, and push the sales force to increase numbers the next go-around by 10%. By examining the financials - where and how money is made, understanding margins, looking at seasonality, regionalization of purchases, and customer mix - new opportunities for building business and increasing sales can be discovered. With the identification of those opportunities, new marketing, sales, packaging, pricing, and product strategies can be employed, keeping the company cash flow humming. Even with the purchase of a data analytics platform, organizational leaders need to know the right business questions to ask to leverage that investment.
Manufacturing is the backbone of the US economy. The "American Dream" was born from entrepreneurs seeking and developing new solutions and products to serve the market. American industrialists had an unmatched drive to see an opportunity in a market and capitalize on it. Mid-market manufacturing isn't dead yet - we simply need to bring back the entrepreneurial spirit and business savvy from which US manufacturing was born.
By Andrea Olson, MSC - CEO of Prag'madik
Follow @ManufacturingGL and @NellWalkerMG
Ultium Cells LLC/Li-Cycle: Sustainable Battery Manufacturing
Ultium Cells LLC - a joint venture between General Motors and LG Energy Solutions - has announced its latest collaboration with Li-Cycle. Joining forces the two have set ambitions to expand recycling in North America, recycling up to 100% of the scrap materials in battery cell manufacturing
What is Ultium Cells LLC?
Announcing their partnership in December 2019, General Motors (GM) and LG Energy Solutions established Ultium Cells LLC with a mission to “ensure excellence of Battery Cell Manufacturing through implementation of best practices from each company to contribute [to the] expansion of a Zero Emission propulsion on a global scale.”
Who is Li-Cycle?
Founded in 2016, Li-Cycle leverages innovative solutions to address emerging and urgent challenges around the world.
As the use of Lithium-ion rechargeable batteries in automotive, industrial energy storage, and consumer electronic applications rises, Li-Cycle believes that “the world needs improved technology and supply chain innovations to better recycle these batteries, while also meeting the rapidly growing demand for critical and scarce battery-grade materials.”
Why are Ultium Cells LLC and Li-Cycle join forces?
By joining forces to expand the recycling of scrap materials in battery cell manufacturing in North America, the new recycling process will allow Ultium Cells LLC to recycle cobalt, nickel, lithium, graphite, copper, manganese and aluminum.
“95% of these materials can be used in the production of new batteries or for adjacent industries,” says GM, who explains that the new hydrometallurgical process emits 30% less greenhouse gases (GHGs) than traditional processes, minimising the environmental impact. Use of this process will begin later in the year (2021).
"Our combined efforts with Ultium Cells will be instrumental in redirecting battery manufacturing scrap from landfills and returning a substantial amount of valuable battery-grade materials back into the battery supply chain. This partnership is a critical step forward in advancing our proven lithium-ion resource recovery technology as a more sustainable alternative to mining, " said Ajay Kochhar, President, CEO and co-founder of Li-Cycle.
"GM's zero-waste initiative aims to divert more than 90% of its manufacturing waste from landfills and incineration globally by 2025. Now, we're going to work closely with Ultium Cells and Li-Cycle to help the industry get even better use out of the materials,” added Ken Morris, Vice President of Electric and Autonomous Vehicles, GM.
Since 2013, GM has recycled or reused 100% of the battery packs it has received from customers, with most current GM EVs repaired with refurbished packs.
"We strive to make more with less waste and energy expended. This is a crucial step in improving the sustainability of our components and manufacturing processes,” concluded Thomas Gallagher, Chief Operating Officer, Ultium Cells LLC.