OM in the News: Taking Nerf Guns Away From China

The Nerf N-Strike Elite Hyperfire

Nerf guns. Monopoly board games. G.I. Joes. Some of Hasbro’s  bestselling toys are getting pricier as the U.S. implements stiff tariffs on Chinese imports. So Hasbro, and others like Barbie maker Mattel, are negotiating with suppliers and considering design changes. The threat of new taxes on toy imports comes amid a long-term shift in the industry away from China, spurred by rising labor costs in that country. Manufacturers have spent years trying to make fewer toys and games in China by relocating to factories in other countries, including Vietnam and India.

Across industries, U.S. companies have been diversifying their supply chains, prodded in part by tariffs implemented during both the Trump and Biden administrations, writes The Wall Street Journal (Nov. 18, 2024). Makers of everything from steel and semiconductors to auto parts are rejiggering supply lines to source components from other countries. Sharpie and Yankee Candle maker Newell Brands, for example, is moving more factory work to the U.S.—the desired result of the tariffs.

Hasbro’s current target is for roughly 20% of its U.S. sales to come from China-made products within four years, down from about 40% today. The challenges the company has faced in achieving a long-held goal underline the pressure facing toy makers. While lower-cost locations are easy to find, switching to a new factory with similar product-quality and safety standards can be a challenge in the toy industry.

Unlike in some industries, automation has yet to make major strides in parts of the toy-making process. Assembly for many toys still relies on skilled workers to put together the latest action figure or hand-paint details. Shifting to a different country requires training a new generation of craftspeople. Smaller factories in South and Southeast Asian countries also might not produce enough units to easily replace Chinese facilities.

Hasbro’s shift away from China is part of a $750 million cost-cutting push that includes negotiating lower prices from suppliers or changing designs to make them cheaper to build, such as Jenga blocks that now use a single type of wood. The change lowered costs and had the added benefit of making the pieces slide more smoothly out of a Jenga tower. Meanwhile, the Chinese government has been pushing for the country to graduate from being a hub for lower-cost work, such as toy making.

Classroom discussion questions:

  1. What other products have been moving away from China?
  2. Have the tariffs been successful?

OM in the News: Hasbro to Phase Out Plastics From Packages

Hasbro Inc. — known for its plastic dolls, Transformers and Mr. Potato Heads — is vowing to cut down on the plastic components used to package those products, reports Industry Week (Aug. 20, 2019). The toy company will start phasing out plastic from new packaging, including elastic bands and shrink wrap, starting next year, with a plan to eliminate virtually all plastic from packages for new products by the end of 2022. The company has not yet announced a plan to cut down on plastic usage in the toys themselves, though it will soon announce steps involving more sustainable materials.

The packaging switch will only apply to new products. About two-thirds of Hasbro’s product portfolio is new each year. “Something already designed and on the shelf we’re not taking off the shelf, but everything we’re putting into the marketplace going forward” would get the new packaging where it makes sense, said Hasbro’s CEO. The new packaging costs will be about the same for the company.

There are some places Hasbro won’t be able to replace plastic, because of health and regulatory rules. For example, packaging for Easy Bake Oven ingredients will remain wrapped in plastic to keep the food tamper-proof and fresh. So far, Hasbro hasn’t been able to find an alternative.

Consumer companies are facing an increasing backlash to single-use plastics, with major corporations from PepsiCo to Procter & Gamble vowing to cut back.

Classroom discussion questions:

  1. How is this an OM issue?
  2. Why is packaging so important to Hasbro?

Teaching Tip: Time & Motion and Monopoly Sets

There is no question that we crave more decent-paying factory jobs in this country. But to keep things in perspective, most of us (and our students) would probably not enjoy making our living with these jobs. Today’s Fortune (Feb.7, 2011, pp. 80-81) lists the “100 Best Companies to Work For”, with Hasbro ( the toy and game maker) ranked #59. In a world of ruthless outsourcing, the Hasbro plant in Springfield, Mass., is an anachronism. Even though more of its Monopoly, Scrabble, and Mousetrap games are now made in Southern China, Hasbro employees are deeply loyal to a company that just committed to $40 million in capital upgrades to keep their US plant’s assembly lines going.

But in a humorous article (not as yet on-line), Fortune reporter David Kaplan goes to work at Hasbro  to see why the company is so beloved. He lasts a day, as a sort of George Plimpton in overalls– a cog in the assembly line for Monopoly boxes. Here is his tale:

“I’m at the back end of the assembly line, doing quality control. On a conveyor belt that mercilessly keeps advancing to my left comes open Monopoly box after Monopoly box. My dual task–every 1.81 seconds–is to place a plastic bag of dice and game tokens in a tray, while also ensuring that each box includes a container of 12 hotels and 32 houses, instructions, and a shrink-wrapped stack of money. I know just how Lucy and Ethel felt when they couldn’t keep up with the chocolates at the candy factory–except I can’t stuff the accumulating boxes in my bra….Who knew you could get motion sickness on an assembly line?”

Kaplan last only 4 minutes before vomiting.  But Hasbro’s 600 employees, with average seniority of 21 years, seem to have mastered the manual dexterity, automatous concentration, and the need for a refined inner-ear. How many of us could do so for 21 years?  The Fortune piece provides a good chance to discuss job enrichment and enlargement in Ch.10.