OM in the News: Supply Chains and Thailand–A Year After the Flood

Disruptions in global chains have moved from an academic subject to a daily topic in the past two years. The Wall Street Journal (Oct.6-7, 2012) headline “After Floods, Businesses Still Wary of Thailand” provides a good classroom topic when you are covering Supplement 11. A year after massive floods in Thailand that disrupted the global supply chain for cars and electronics, most factories are at work again, but not always like before.

Some foreign companies—having learned hard lessons about concentrating too much of their production in one country—are shifting to other parts of Southeast Asia. Thailand’s worst floods in 50 years, coming just seven months after Japan’s earthquake and tsunami, exposed the danger of relying on narrow, concentrated supply chains. So foreign companies are hedging their bets by building facilities and finding suppliers in other regions so they can quickly resume operations if disaster hits.

Western Digital, one of Thailand’s largest foreign employers, moved some manufacturing of hard-disk drive components from Thailand to Malaysia. The company, based in Calif., also asked some suppliers to take similar steps, hoping to avoid a components shortage like last year. Western Digital now employs 25,000 people in Thailand, compared with 37,000 before the floods.

Japan’s Omron Corp. shifted some production of relays—electromagnetic switches for automobiles and motorcycles—to Japan and China. Nidec Corp., also based in Japan, moved part of its production of hard-disk-drive motors to China and the Philippines. This production “will not be coming back to Thailand,” said its president. Yet he added that Thailand has “skill and technology that overcomes other issues.”  Nidec, which suffered damage to eight of its Thai factories last year, has cut production of disk drive motors in the country to protect against another disaster.

Discussion questions:

1. How can firms avoid supply chain disruptions?

2. What can Thailand do to regain manufacturing jobs lost due to the fear of future flooding?

OM in the News: When Supply Chains Break

The new Fortune (Dec.26,2011) article “When Supply Chains Break”  (pp.29-32) ends with the following line:  “The real cost advantage may not go to the manufacturer with the nimblest supply chain but to the company with the most robust one”.  The opening line is:  “Manufacturers have spent years building low-cost global supply chains. Natural disasters are showing just how fragile those networks really are”. Sure enough, with hundreds of Hondas in the flooded plant in Thailand just floating in 15 feet of water, it is surreal to think of how we teach the lean supply chain concept.

Invented by Toyota, and perfected in the era of globalization, lean supply chains completely decentralized manufacturing. Manufacturers developed a network of suppliers whose components arrived at assembly plants at the moment they were needed. There was  no pesky inventory to manage, suppliers kept costs down by locating near cheap labor, and consumers enjoyed lower prices.

But the tsunami, earthquake, and flooding in the past year (costing  a total of  $240 billion in Japan and Thailand) have resulted in economic disruptions felt well beyond Asia. Seagate’s CEO predicts its shipments of hard drives (it has 2 plants in Thailand) won’t be normal until 2013. While the computer industry needs 175 million hard drives a year, suppliers can now put out only 125 million, a shortfall of 29%. Apple and HP have already told investors that their earnings will suffer from the floods.

It is not surprising then that manufacturers are starting to rethink their global infrastructures. “The question is”, says one industry expert, ” has the quest for lowest-cost production and hyper-lean supply chains overridden and exposed vulnerability to significant business risk?” For Seagate and many others, the answer is a resounding “yes”. Carlos Ghosn, Nissan’s CEO, said just last month: “”There is going to be another crisis”.

Discussion questions:

1. What should manufacturers do to prepare for the next crisis?

2. What other firms have been impacted, and how, by these disasters?