There has been a lot of push on the future of outsourcing lately, mostly looking at where it will stop or more importantly what happens when there is no more cheaper alternative for the global searcher. We have all seen it, product moves to country X, then as the standard of living rises there it moves to the next country that has a lower wage, and once it is done there it moves on. But once this phenomenon has swept around the globe what happens to a company that has not leaned out its process and was relying solely on the cheaper labor rate to make their product? The answer is they become extinct and the business goes to those companies with the more effective process.
Lean manufacturing is the answer to outsourcing because while your competition is spending 10 million in capital investment to save 0.30 on each part in labor, your organization has avoided the 10 million expenditure, placed it into R&D and is still seeing a 0.30 savings as a result of driving the waste out of the part. This philosophy also makes good sense in terms of plant efficiency, efficiency rates in a green field operation usually are not up to the existing plant process standards until 18-24 months following the operation’s opening ( which can be years in construction), and subsequently if you can keep a high efficiency rate in addition to the same piece price cost then your savings is actually greater. This of course does not address the decision by an organization to outsource for market penetration as a strategic move, but the costs associated with the move become exponentially higher if the domestic operational unit has a good solid lean culture in place.
In the end reliance on labor as a competitive advantage is a losing proposition for any organization, you will either fall victim to the slow bleed of inflation, the moving target of global currency fluctuation or may experience a major upset in the event of political instability within the region (volatile regions are those more prone to having lower labor rates). A continuous improvement culture is a sustainable cornerstone of your operational management strategy because innovation drives high profit, not replication of the same old idea. Outsourcing is all about cost reduction, if it wasn’t they would just open sales offices in the countries a business wants to move into. As a manufacturing unit the innovation in your processes will continue to make your operation a continued profit center, and no company will willingly close a high profit producing facility in favor of a potential green field operation that is several years behind an existing powerhouse.

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