Transcript Modular Production and Technological Up

Global Chains and the modular
design of autoparts: The case of
México
Dr. Arturo A. Lara
Universidad Autónoma Metropolitana – X.
México- D.F.
This analysis focuses on the production plant network of
Lear Corporation in Mexico, and its aim is to describe and
analyze the technological up-grading process, as well as the
strategy of intra-company coordination and cooperation
(in the North American market) developed by Lear within
the framework of modular production.
CuadroI no. 11
Distribución del volumen de producción de asientos a
nivel mundial según principales empresas
(porcentajes)
Empresa
Mundial Norteamérica
Europa
Lear Corporation
Johnson Controls
Faurencia
Magna
Otros
25
24
9
*
42
22
23
25
*
25
Fuente: Elaborado apartir de Aroq Limited (2002).
Nota: * Dicho porcentaje se incluye en el rubro otros.
41
42
*
8
9
NUMERO DE PATENTES DE LAS PRINCIPALES EMPRESAS
PRODUCTORAS DE ASIENTOS
AUTOMOTRICES (1976-2002)
21
11 8
214
162
Lear Corporation
Johnson Controls
Magna International
Delphi
Faurecia
EVOLUCIÓN DE LAS FUNCIONES TECNOLÓGICAS EN
LOS ASIENTOS AUTOMOTRICES DE LEAR
CORPORATION
(Número de Patentes)
Funciones\
1981- 1986- 1991- 1996- TOTAL
1976-80
Periodo
85
90
95
02
Ajuste y
Comodidad
Personal
Búsqueda de
espacio Interior
63
7
5
2
7
42
1
1
23
25
Proceso
2
5
47
54
Seguridad
1
4
30
35
13
21
36
30
163
213
Otras Funciones
1
1
Total
8
6
6
FUENTE: Elaboración propia en base a la información del USPT.
hypotheses:
Lear-México is an autoparts company that is bringing
together an increasingly large amount of automobile
interior sub-systems and components, including seats.
This process has been made possible by:
a) the incorporation and intra-firm application of the
technological capabilities it has developed on a global
level,
b) the use of a modularization and specialization strategy
in a cohesive cluster of technological sub-systems and
c) productive and technological coordination processes on
an intra-company level.
How can we explain the evolution of Lear’s
technological capabilities, from the production of
seats to entire interior systems?
In order to answer these questions, it is necessary
to describe the interdependent nature of seat
design.
Establishing the architecture.
The steps are:
• 1.- Crate a schematic of the product.
• 2.- Cluster a rough geometric layout.
• 3.- Identify the fundamental and incidental
interactions.
Integral architecture
An integral architecture has the following
properties:
• Functional elements of the product are implemented using
more than one components (chunks).(many-componentsto-one function)
• A single component implements many functional elements.
(one-component-to-many-functions)
• The interactions between components are ill defined and
may be incidental to the primary functions of the products.
Modular: one-to.one
function/component
• One architectural feature essential for many
of the advantages associated with modular
product designs requires a one-to-one
relationship between function and
component.
Deviation from a one-to-one
relationship.
• 1.- There can be a one-to-many relationship:
Multiples components contribute to a
particular function (protection and comfort
in automobiles).
• 2.- A function can be provided by a
component that simultaneously provides
also other functions (the automobile´s body)
Deviation from a one-to-one
relationship.
• 3). There can be a many-to-many
relationship between functions and
components (the power unit of the
computer).
Function-Component Map for a Computer
Aesthetics
External Communication
Data Storage
Data Output
Data Processing
Data Input
Keyboard
Monitor
Motherboard
w/ CPU, RAM Disc Drive
Modem
Power Unit
Case
Function-Component Map for an Automobile
Control
Comfort
Aesthetics
Space
Protection
Propulsion &
Decelerarion
E ngine /
T ra ns m is s io n
Chassis /
Suspension
Wheels /
Tires /
Brakes
Body (incl.
doors &
windows
Fuente: Fixson & Sako (2001)
Seats
Cockpit
Trunk
Modularity and Outsourcing
• In theory, modularity captures the notion of
a clear division of labor between the
architect with architectural design
knowledge and designers with knowledge
of each module.
• The dichotomy between integral and
modular architecture is conceptually
powerful. But the reality is not pure.
Modularity and Outsourcing
The broad ties and interconnection of interfaces
among the different modules that make up the
interior of a vehicle – a process called
modularization – have made it possible for Lear to
make a huge leap: from being a supplier of a
segment as specific and specialized as seats, to
offering the whole interior system.
Modularity and Outsourcing
• Acquired technological knowledge and the
processes involved in the manufacture of
these other modules have strengthened
Lear’s competitive capacity to extend
production to cover the whole interior
system
Lear Seating Corporation Plants In Mexico,
(1995)
Company
State Municipality
Employe
es
Outputs
Favesa (111) La Cuesta, SA de CV Chih
Cd. Juárez
2 474 Seat assemblies, foam paddings, seat covers
Favesa (V) Río Bravo, SA de CV
Chih
Cd. Juárez
1 825 Seat assemblies, foam paddings, seat covers
Favesa (VI) San Lorenzo, SA de CV Chih
Cd. Juarez
2 600 Seat assemblies, foam paddings, seat covers
Cisa Cuautitlan (Lear Seating)
Méx
Cuautitlán
Cisa Hermosillo (Lear Seating)
Son
Hermosillo
575
Cisa Naucalpan (Lear Seating
Méx
Naucalpan
135 Trim covers, seat systems
Cisa Puebla (Lear Seating)
Pue
Cuatlancingo
169 Trim covers, seat systems
Cisa Ramos Arizpe (Lear Seating)
Coah
Ramos Arizpe
Cisa Saltillo (Lear Seating)
Coah
Saltillo
Cisa Tlahuac (Lear Seating)
D.F.
Tláhuac
Source: ELM (1995). Directorio empresas automotrices.
96 Seat systems
Assembly, welding, pressing, bending, foam
processing
42 Seat covers
608 Seat covers
1 722 Metal frames, foam, pads, seat seating
Lear Corporation Plants In Mexico, 2000
n.d. Not available Information
1/
Other = devices, accesories and interiors parts
2/
W ithout information. The number is an estimated.
Sources: SECOFI-SIEM (2000); ELM (2001) and, interviews in Lear Corporation plants.
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Welding
Stamping
Molding
Injection
Harnesses
Interiors
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Trim Covers
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Other
X
X
X
X
X
Sewing
X
X
X
X
X
X
Cutting
X
X
X
Seats
Maquila
Manufacture
State
Chih
Chih
Chih
Gto
Coah
Méx
Pue
Chih
Chih
Chih
Son
Son
Son
Méx
Pue
Coah
Coah
DF
N.L.
Méx
Chih
Méx
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Chih
Assembly
6 000 Cd. Juárez
1 825 Cd. Juárez
3 000 Cd. Juárez
400 Silao
20 Saltillo
138 Cuautitlan
169 Cuautlancingo
527 Cd. Juárez
798 Cd. Juárez
3 960 Cd. Juárez
190 Hermosillo
200 Hermosillo
575 Hermosillo
135 Naucalpan
215 Cuatlalcingo
413 Ramos Arizpe
1 100 Saltillo
3 000 Tláhuac
n.d. Monterrey
80 Toluca
3 176 Cd. Juárez
31 Tultitlán
243 Cd. Juárez
1 211 Cd. Juárez
1 495 Cd. Juárez
3 192 Chihuahua
1 208 Cd. Juárez
1 208 Cd. Juárez
1 208 Cd. Juárez
1 208 Cd. Juárez
1 016 Cd. Juárez
1 069 Cd. Juárez
1 981 Cd. Juárez
5 413 Cd. Juárez
Processes
Others 1/
Favesa La Cuesta - Manufacturing Operations Div. Lear
Favesa Rio Bravo - Manufacturing Operations Div. Lear
Favesa Sn Lorenzo - Manufacturing Operations Div. Lear
Lear Corporation México - Ford Division
Lear Corporation México - Ford Division
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Corporation México - Manufacturing Operations Div
Lear Mexican Trim Operations, SA de CV
Lear Corporation México, SA de CV
Lear Electrical Systems de México, SA de CV
Lear Electrical Systems de México, SA de CV
Lear Electrical Systems de México, SA de CV
Lear Electrical Systems de México, SA de CV
Lear Electrical Systems de México, SA de CV
2/
Lear Electrical Systems de México, SA de CV
2/
Lear Electrical Systems de México, SA de CV
2/
Lear Electrical Systems de México, SA de CV
2/
Lear Electrical Systems de México, SA de CV
Lear Electrical Systems de México, SA de CV
Lear Mexican Trim Operations, SA de CV
Lear Mexican Trim Operations, SA de CV
Municipality
Plant
Employees
Products
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Interior system task structure Matrix
MODULES
Instrument
panel
Seats
Doors/
Interior finishes
X
X
Seats
X
X
Other
accessories
Roof
X
X
X
X
X
X
X
Instrument panel
X
X
X
X
X
X
X
X
X
X
X
Doors/
Interior finishes
X
X
X
X
X
X
X
X
X
X
X
Roof
Electric controls
and other
accessories
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Source: Modified from Baldwin and Clark (2000): 50.
X
X
X
Flujo de suministro y fabricación de asientos e interiores en Lear Tláhuac
MEXICO
ESTADOS
UNIDOS
Lear
Lear
Cd.Juárez
USA
Ensambladoras
Lear
Cuautitlá
n
Lear
Silao
Lear
Tláhuac
Johnson
Controls
Lear
Puebla
Fabricantes de autos
Competencia
Plantas de Lear
Planta de Lear “proveedor
exclusivo”
A
Ensambladoras
B
A
C
B
D
D
E
E
Sentido de la cadena de
suministro
Fuente: Elaborado con información de entrevistas a plantas de Lear Corporation.
Contraste de los diseños integral y modular
en Lear Corporation
Diseño Integral
Proveedores
Diseño Modular
Nodos de
fabricación
Lear
Clientes
Plantas
Lear
Clientes
A
A
B
C
B
México
A
B
Plantas de Lear
Plantas de la competencia
Clientes
D
Estados Unidos
Costura/
Espuma
Bastidor/
Espuma
Cd.
Juárez
A
B
Tláhuac
C
D
Conclusions
1.- During the 1990s, Lear-México underwent an
impressive process of expansion. This company
opened numerous plants in different parts of Mexico,
increasing the number of people it employed and
diversifying its productive processes.
2.- Lear offers a successful case of a world class
supplier that went from being a specialist in the
manufacture of seats to a producer and assembler of
different components (upholstery, harnesses and
interiors) which are then distributed to the terminal
industry.
Conclusions
3.- This company has managed to orchestrate the
broadening of the range of products it offers with a
growth strategy, not only through geographical
expansion but also by improving its technological
capabilities and organizational strategy.
Conclusions
4.- The case study of Mexico reveals that the policy
of expansion and the location of Lear’s plants is part
of the process of economic and commercial
integration of this country resulting from the North
American Free Trade Agreement.
Lear’s decisions with regard to location are in
response to the search for lower salaries, the
reduction of transport costs and the needs of its main
customers (Chrysler, General Motors, Volkswagen,
etc.).
Conclusions
5.- A company that increases its size, the number of
plants it has, its technological capabilities, its human
resources and the range of products it offers is facing
up to the challenge of dealing with complexity and
uncertainty. Lear has managed to overcome these
obstacles by acting on three basic levels: 1) intracompany coordination, 2) its strategy of capability
expansion, and 3) modular design.