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	<web>http://www.sociology.org/content/vol001.001/dassbach.html</web>
	<title>Where is North American Automobile Production Headed?</title> 
	<subtitle>Low-Wage Lean Production</subtitle> 
	<abstract><p>This paper examines two trends in the restructuring of
	  North American automobile production during the last 20
	  years: the export of productive activities or globalization
	  and the return of productive activities to core regions with
	  the increasing implementation of "lean" or Japanese
	  techniques. It argues that globalization failed and the
	  trend towards globalization has diminished because
	  globalization, as practiced in the late 1970s and 1980s,
	  entailed the export of Fordist techniques. While
	  acknowledging the superiority of lean production over
	  Fordism, it is argued that lean techniques will not lead to
	  the massive return of auto production to North America.
	  Instead, the most important trend in the North American
	  automobile industry over the next ten years will be between
	  the two extremes of globalization and the return of
	  production to North America and consist of the expansion of
	  production in a low wage region, Mexico, but using lean
	  techniques.</p>
	</abstract>
	<availability status="free">Copyright 1994 Electronic Journal of Sociology</availability>
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      <author>
	<name>
	  <first>Carl</first><middle>H.A.</middle>
	  <last>Dassbach</last>
	</name>
	<address>
	  <organisation>Michigan Technological University</organisation>
	  <division>Department of Social Sciences</division>
	</address>
</author>
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	<web>http://www.sociology.org/</web>
        <title>Electronic Journal of Sociology</title>
	<idno type="issn">1198 3655</idno>
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	<name><full>Athabasca University</full></name>
	<address><street>1 University Drive</street><city>Athabasca</city>
	  <province>Alberta</province><postalcode>SOG OWO</postalcode>
	  <email>mikes@athabascau.ca</email>
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	<web>http://www.sociology.org/content/vol001.001/</web>
	<date><year>1994</year></date>                 
	<idno type="VOL">1.1</idno>                    
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      <idno type="IUICODE">100.1.1.2</idno>   
      <startdate><year>1994-</year></startdate>
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<body>


<p>The North American automobile industry has been in a process 
of spatial and organizational restructuring since the early  1970's.
Restructuring has however exhibited two fairly distinct  trends so that
no clear consensus exists about the current  direction of the industry.
Some argue that automobile production  will continue its exodus from
Canada and the United States to low  wage areas, especially Mexico, with
the ratification of the North  American Free Trade Agreement (NAFTA).
Others argue that the  increasing use of microelectronics and flexible
production will  not only halt the shift of manufacturing to low wage
areas but  reverse the trend.  Activities exported to low wage areas
will  return to the core due to both the difficulties associated with 
operating in peripheral regions and a significant reduction in the 
labor costs resulting from the use of these new technologies of 
production.</p>

<p>Both of these trends have some basis in reality
because both  refer to observed tendencies in North American auto
production.  Determining which of these trends will predominate over the
next  five years is important for several reasons. There are specific 
concerns about the future of North American automobile production. 
"Mid-range" concerns about the future of the Canadian and American 
economies. Finally, there are general concerns about the global 
restructuring of production. One trend, exodus, implies a further 
deindustrialization of Canada and the United States and the  continued
growth of manufacturing in peripheral areas. The other  trend implies a
reindustrialization of Canada and the United  States and a possible
slowing in growth of peripheral  industrialization.</p>

<p>By way of an
introduction, I will briefly anticipate my  answer to the question posed
in the title: where is North American  automobile production headed? In
a word, south -- it will continue  to flee Canada and the United States
for low wage regions to the  south of the US, especially Mexico. Given
the previous discussion  of one trend in the restructuring of automobile
production,  namely, the shift of production to low wage areas, it could
be  argued that this is nothing new. North American automobile 
companies have been sourcing labor intensive and relatively 
sophisticated components from Brazil and Mexico for the last 20  years.
I will argue that the ongoing move to the south is  something new. It is
different from the earlier relocation of  production to these areas
along two important dimensions: the  sites where production is being
relocated and, more importantly,  the "organizational logic" underlying
this relocation.</p>

<p>This paper will analyze and discuss the
ongoing shift of  North American automobile production to Mexico by
comparing and  contrasting it with the two trends already identified.
The earlier  movement of production to low wage areas is part of a
larger  strategy among North American automobile producers that I call 
"transnational production." Underlying the claims about the return  of
manufacturing to core areas is a strategy derived from Japanese 
automobile companies which can be called, after Womack <i>et  al.</i>
(1990), "lean production."
I will discuss the benefits and 
limitations of "transnational" and "lean" production and then  relate
these to the shift of automobile production to Mexico,  which I call
"low wage lean production". This comparison will  demonstrate how "low
wage lean production" represents, on the one  hand, a continuation of
the trend in automobile production to  reduce labor costs through the
use of lower waged labor, evident  in transnational production, but also
a break with the  organizational logic of transnational production
because it  incorporates several aspects of the organizational logic of
"lean  production."</p>

<h2>TRANSNATIONAL PRODUCTION</h2>

<p>In response to increasing competition by the Japanese for  the low
price market, and rising production costs, in the mid- 1970's Ford and
General Motors (in North America and Europe)  embarked on a strategy of
"transnational production" (Dassbach, 1989),
"global Fordism"  (Lipietz, 1987) or "global factories" 
(Hamilton, 1981; Hill, 1990; Dicken, 1992).This strategy combined  old, established
Fordist manufacturing practices with a new  spatial distribution,
integration, and coordination of production.  
</p>

<p>Transnational production embodied three established  Fordist
manufacturing practices. One was the endeavor to increase  economies of
scale by locating similar activities at the same  site. The second was
the continuation of what Lipietz (1987: 71) calls</p>
<blockquote>
    Fordism's...division of activities into three levels: 1)
    conception, organization of methods, and engineering..., 2)
    skilled manufacturing, which requires a fairly skilled
    workforce; and 3) unskilled assembly and execution, which in
    theory requires no skill.</blockquote>

<p>The third was Fordism's shop floor
organization, namely, the  extensive and intensive use of dedicated
automation, the lack of  stringent in-process quality control, the
production of large  stocks of inventory in anticipation of possible
disruptions or  "just-in-case" inventory practices, and the restriction
of workers  to a limited number of highly specialized tasks through an 
elaborate system of job classifications.</p>

<p>To these, transnational
production added several new  elements. One was a new spatial
distribution of manufacturing  operations. Similar or related activities
were not simply  concentrated at some site to exploit economies of scale
but  concentrated at those sites in the world which enabled companies 
to exploit economies of scale in conjunction with some local  advantage
such as R &amp; D experience, specialized labor skills,  manufacturing
expertise and, most importantly, pools of low wage  labor. In other
words, where Fordism tripartite division of  activities was previously
articulated nationally and  organizationally as a division between
activities in the same  nation, region or city, transnational production
articulated this  division globally. Perhaps the first to identify this
trend was  Stephen Hymer (1979: 157-158) when
he wrote in 1971:</p>
<blockquote>
    A regime of multinational corporations would tend to produce
    a hierarchical division of labor between  geographical
    regions corresponding to the vertical division of labor in
    the firm. It would tend to centralize high-level decision
    making in a few key cities in the advanced countries,
    surrounded by a number of regional subcapitals, and confine
    the rest of the world to lower levels of activity and
    income.</blockquote>

<p>The second was the administrative integration and 
coordination of spatially dispersed activities through 
telecommunications networks. Specifically, the emergence of 
transnational production was both accompanied by, and made  possible
through, a massive expansion of high speed data  processing and
communications links within enterprises. These  telecommunications
systems enabled North American auto firms to  quickly and easily share 
R &amp; D performed at different sites in  the world, transmit manufacturing
specifications and product  modifications instantaneously from
development to manufacturing  centers, specify rates of output at
manufacturing sites around the  world and, most importantly, monitor and
control the globally  dispersed activities of the enterprise from a
central site.  Activities were materially integrated through the
transhipment of  large quantities of components from production site to
final  market where they were assembled into vehicles.</p>

<p>Concretely,
transnational production's assumed different  guises depending on its
geographical scope. If production was  dispersed and integrated
throughout a "region" such as Europe or  North America, this was
referred to as "regionalization." If  production was dispersed and
integrated across different  geographical regions such as Europe, North
and South America or  Asia, this was referred to as "globalization."
Central to both  "regionalization" and "globalization" was a common
product  designed to be sold in all or most of the markets where its 
components were manufactured.<endnotenumber>1</endnotenumber> Perhaps the
best known, but by no  means the only,<endnotenumber>2</endnotenumber> 
examples of such products were "world cars" such  as the Ford Escort,
Ford Fiesta and GM J-car. These small, four  cylinder automobiles, were
sold, albeit at different market  levels, in most of the countries where
the components were  manufactured.<endnotenumber>3</endnotenumber> By the
late 1970s, it appeared that transnational  production represented the
future of automobile production and  North American companies expanded
and strengthened their  transnational networks.<endnotenumber>4</endnotenumber>
</p>

<p>By the mid-1980's however, <i>internal</i> and
<i>external</i> limitations in the organizational logic 
of transnational  production
became evident.  External limitations took the form of  inadequate
infrastructural support for advanced manufacturing  activities in
peripheral countries and the failure to develop the  expected levels of
local demand for vehicles. Auto companies in  peripheral regions found
it extremely difficult to locate the  supplies, replacement parts, and
maintenance/repair technicians  for their advanced, 
imported machinery. 
<endnotenumber>5</endnotenumber> 
Because peripheral  markets failed to develop the anticipated
levels of demand for  world cars,<endnotenumber>6</endnotenumber>  local
assembly facilities never ran at capacity,  thus raising costs and
further undermining sales. Globally, weak  sales in peripheral markets,
though relatively small compared to  total production, resounded through
the entire system. Total  production never achieved the anticipated
volumes and this served  to raise overall production costs.</p>

<p>The
internal limits of transnational production merely  reflected the
internal limits of Fordism as practiced by U.S. auto  companies. In
exporting production to low wage regions, auto  companies also exported
Fordist practices.  As a result, the  problems confronting North
American plants were replicated and, to  a certain extent, exacerbated
in foreign plants. Like North  American plants of the early 1980s,
foreign plants were  inflexible. Technically, inflexibility was a
consequence of the  use of dedicated automation. Socially, inflexibility
was the  result of the reproduction of a system of rigid job 
classifications which restricted workers to a limited range of 
activities (Katz, 1985). For example, Ford's
Mexico City plant had  as many separate job classifications, 150, as
Ford plants in the  United States and Canada (Shaiken, 1987).<endnotenumber>7</endnotenumber> Foreign plants also 
experienced the same quality problems as
American and Canadian  plants which were compounded by larger than
average production  runs. Fordism's lack of stringent in-process quality
control,  combined with large production runs because components were 
manufactured for export, meant that foreign plants could produce  large
stocks of defective components. In many cases, these defects  were only
discovered at remote assembly sites months after they  had occurred.
</p>

<h2>LEAN PRODUCTION</h2>

<p>While the limitations in
transnational production forced  auto companies to reappraise this
strategy, the success of  Japanese automobile companies in North America
and Europe  undermined the organizational logic of transnational
production.  By the mid-1980's, several Japanese companies had
established  "transplants" in these markets and were successfully
building  vehicles comparable in quality and price to those built in
Japan  (Rowand, 1983; Hoerr, 1989).
Ironically, in the U.S., Japanese  companies such as Toyota or Mazda
were building cars with U.S.  workers, some unionized, in plants that
American companies had  abandoned a few years earlier. The success of
the transplants was  mainly due to the fact that the Japanese had
successfully  recreated their distinctive organization of production, or
"lean  production," in these overseas markets 
(Institute of Social Science, 1990; Womack,
<i>et al</i>. 1990; Kenney and Florida, 1993).</p>

<p>There are several important differences between the 
organizational logic of lean production and Fordism. One is shop  floor
organization in terms of the actual social organization of  production
<i>and</i> labor-management relations. According to Kenney and Florida
(1988: 131-133),
the shop floor organization of lean production:</p>

<blockquote>
     replaces the fundamental characteristics of Fordism
     -functional specialization, task fragmentation, and assembly
     line production - with overlapping work roles, job rotation,
     team-based work units, and relatively flexible production
     lines... Work organization is based on self-managing teams.
     Work roles are assigned to groups of workers, who then
     reallocate them internally.... Multi-skilling is absolutely
     essential for this strategy to be successful.... Rotation
     within teams allows workers to familiarize themselves with
     various aspects of the work process...This rotation scheme
     extends to the entire plant. Workers subsequently master the
     different tasks and grasp the interconnectedness among
     them.</blockquote>


<p>The basic organizational unit on
the shop floor is not the  isolated, individual worker found under
Fordism but rather the  work team. Teams are headed by an hourly paid
team leader and  consist of four to eight workers. The emphasis within
work teams  is on group identification, worker involvement, and job 
flexibility. To insure flexibility, lean plants have replaced the  150
or so rigid job classifications of Fordist plants with one 
classification for production workers and one, or perhaps two, for 
maintenance workers. Workers are cross-trained and regularly  rotated to
different jobs. Unlike traditional plants, most workers  in lean plants
are also responsible for performing routine  maintenance on their
equipment.</p>

<p>Workers in these plants have a far higher degree of
control  over both their working conditions and final products than in 
conventional plants. They are constantly encouraged to make  suggestions
to improve their job, associated jobs or finished  products and these
suggestions are regularly implemented. A system  of signal lights or, in
Japanese, <i>andon</i> board, enables  workers to summon help if they
are experiencing difficulties with  their work. There are few quality
inspectors and quality control  is the responsibility of the workers.
One of lean production's  most radical breaks with Fordism is empowering
workers to stop the line if they are experiencing difficulties with
their work which  cannot be resolved without assistance or if there are
significant  problems in quality. Workers who stop the line are not
upbraided  or punished by management. Instead, line stoppages are viewed
by  management as an indication of worker involvement and as a means  to
uncover and resolve difficulties.</p>

<p>Through the use of techniques
originally developed by  Demming and subsequently refined in Japan
during the 1950s, lean  producers achieve far more stringent in-process
quality control  than Fordist firms. Hence, there are fewer
manufacturing defects.  Lean production is also far more flexible than
Fordism. Socially,  flexibility is the result of the lack of rigid job
classifications  and the ability of workers to perform a variety of
tasks.  Technically, flexibility results from the fact that lean
producers  avoid the use of dedicated automation. In fact, unlike
Fordist  firms who often implement new types of automation without 
considering whether workers are replaced or just converted into  machine
attendants, lean producers eschew the use of automation  unless it truly
displaces at least one worker (Monden, 1983).
</p>

<p>Lean producers have also recast labor-management relations  in
the automobile industry by replacing traditional adversarial  relations
with relations of cooperation and consensus. This has  entailed
eliminating many of the privileges and perquisites  accorded to
management in traditional plants, requiring managers  and workers to
wear the same company uniform, and adopting an  "open door" policy where
workers are free to go to any level of management with a problem or
complaint. Lean producers stress that management and workers are
partners in the firm. As such, both parties will share in the profits
resulting from improved  production as well as the employment and salary
reductions  occasioned by downturns.</p>

<p>A second, and perhaps more
important <endnotenumber>8</endnotenumber> difference between  lean
production and Fordism is the organization of the enterprise. 
Historically, Fordism has internalized or incorporated previously 
external activities within the enterprise. Internalization enabled 
Fordist firms to eliminate market transactions between suppliers, 
capture or eliminate intermediate profits and extend their span of 
control over an ever wider range of activities 
(Chandler, 1977).  This strategy proved to be extremely successful,
and highly  profitable, as long as sales were expanding (1950-1970), but
 internalization also had severe and unanticipated limitations  which
only became apparent with a protracted downturn in sales. 
</p>

<p>First, as companies increased in size, more and more 
administrative, or "non-value adding," workers were needed to 
coordinate and control the various activities.<endnotenumber>9</endnotenumber>
Barring massive  lay-offs, these administrative workers became a fixed
overhead  which had to be carried.  Second, daily control and
coordination  of activities became increasingly difficult as the number
of  administrative layers multiplied.<endnotenumber>10</endnotenumber> 
Third, connective bargaining  and the standardization of wages raised
wage costs to the same  level in all the activities controlled by the
enterprise (Katz,  1985). Finally, companies
even abandoned Sloan's basic principle  that the cost of internally
supplied components had to be  competitive with externally supplied
components in order to keep  their component divisions working
(Dassbach, 1989).</p>

<p>Where the organizational logic of Fordism
has been to internalize, the organizational logic of lean production
has been to externalize. Instead of creating a giant, integrated, 
enterprise, each lean producer has created their own cooperating 
network, in Japanese, <i>keiretsu</i>, of banks, sales and export 
companies, and several layers of quasi-independent and independent 
subcontractors and suppliers 
(Cusumano, 1985; Smitka, 1991; 
Sheard, 1983; Hill, 1989).
With the exception of
banks, the  companies in these networks fall into one of four general 
categories: firms which were originally departments in the main  company
that were "spun off" into independently operating companies, companies
in which the main firm had an equity interest of at least 20%,
companies in which the main company had an equity  interest of less than
20%, and finally, totally independent suppliers 
(Cusumano and Takeishi, 1992).
The coordination 
and integration of activities
in these networks is achieved through a  complex set of mechanisms which
include, in addition to partial ownership of suppliers by the main
firm, the movement of personnel between main firm and suppliers, the
exchange of R &amp;D and, most importantly, trust (Smitka, 1991; 
Wright, 1990; Asanuma, 1989;  Reich 1988). <endnotenumber>11</endnotenumber></p>

<p>These networks have several important consequences for the 
organization of the enterprise. One is that lean firms produce a 
significantly smaller portion of their components in-house than  Fordist
firms.</p>


<table cellpadding=0 cellspacing=0 align=center
<caption>TABLE 1 - PERCENTAGE OF IN-HOUSE PRODUCTION AT LEAN (JAPANESE)</caption>
<thead>
<tr valign="BOTTOM">
<th>Year</th>
<th>Nissan</th>
<th>Toyota</th>
<th>GM</th>
<th>Ford</th>
</tr></thead>

<tfoot><tr><td colspan=4>Source: Cusumano, 1985: 190.</td></tr></tfoot>
<tbody>
<tr><td>1965</td>
<td>32%</td>
<td>41%</td>
<td>50%</td>
<td>36%</td>
<td></td></tr>
<tr><td>1970</td>
<td>29%</td>
<td>35%</td>
<td>49%</td>
<td>39%</td>
<td></td></tr>
<tr><td>1975</td>
<td>22%</td>
<td>30%</td>
<td>45%</td>
<td>36%</td></tr>

<tr><td>1979</td>
<td>26%</td>
<td>29%</td>
<td>43%</td>
<td>36%</td>
<td></td></tr>
</tbody>
</table>


<p>While lean firms
produce fewer parts in-house, they still control,  via their networks, a
far greater proportion of component production than Fordist firms.</p>              

<table cellspacing=0 cellpadding=2 width=350 align=center>
<caption>TABLE 2 - IN-HOUSE, GROUP AND TOTAL PRODUCTION, NISSAN AND TOYOTA,  1965 - 1983</caption>
<thead>
<tr align="CENTER" >
<td></td>
<th>Nissan</th>
<th>Nissan</th>
<td></td>
<th>Toyota</th>
<th>Toyota</th>
<td></td></tr>
<tr align="CENTER" >
<td>YEAR</td>
<td>In-house</td>
<td>Group</td>
<td>TOTAL</td>
<td>In-house</td>
<td>Group</td>
<td>TOTAL</td></tr></thead>
<tbody>
<tr align="CENTER" >
<td>1965</td>
<td>32%</td>
<td>54%</td>
<td>86%</td>
<td>41%</td>
<td>74%</td>
<td>95%</td></tr>
<tr align="CENTER" >
<td>1970</td>
<td>29%</td>
<td>52%</td>
<td>81%</td>
<td>35%</td>
<td>66%</td>
<td>91%</td></tr>
<tr align="CENTER" >
<td>1975</td>
<td>22%</td>
<td>50%</td>
<td>72%</td>
<td>30%</td>
<td>73%</td>
<td>100%</td></tr>
<tr align="CENTER" >
<td>1979</td>
<td>26%</td>
<td>70%</td>
<td>96%</td>
<td>29%</td>
<td>74%</td>
<td>100%</td></tr>
<tr align="CENTER" >
<td>1980</td>
<td>26%</td>
<td>73%</td>
<td>99%</td>
<td>29%</td>
<td>76%</td>
<td>100%</td></tr>
<tr align="CENTER" >
<td>1981</td>
<td>26%</td>
<td>71%</td>
<td>97%</td>
<td>28%</td>
<td>75%</td>
<td>93%</td></tr>
<tr align="CENTER" >
<td>1982</td>
<td>26%</td>
<td>74%</td>
<td>100%</td>
<td>26%</td>
<td>70%</td>
<td>96%</td></tr>
<tr align="CENTER" >
<td>1983</td>
<td>26%</td>
<td>78%</td>
<td>100%</td>
<td>26%</td>
<td>73%</td>
<td>99%</td></tr></tbody>
<tfoot><tr><td colspan=5><b>Source</b>: Cusumano, 1985: 190.12.</td></tr></tfoot>
</table>




<p>Another consequence of these networks -- a higher output   per
employee ratio <endnotenumber>13</endnotenumber> -- is evident in 
Table 3.</p>

<table width = "90%" cellpadding=0 cellspacing=0 align=center
<caption>TABLE 3 - OUTPUT AND EMPLOYMENT AT FORDIST AND LEAN 
AUTOMOBILE MANUFACTURERS, 1989</caption>
<thead>
<tr>
<th>FORDIST FIRMS</th>
<th>Country of Origin</th>
<th>Passenger Car Production</th>
<th>Employees</th>
<th>Vehicles per Employee</th></tr>
</thead>
<tbody>
<tr><td>General Motors</td>
<td align="CENTER">USA</td>
<td align="CENTER">5,523,134</td>
<td align="CENTER">775,100</td>
<td align="CENTER">7.1</td></tr>
<tr>
<td>Ford</td>
<td align="CENTER">USA</td>
<td align="CENTER">4,060,586</td>
<td align="CENTER">366,641</td>
<td align="CENTER">11.1</td></tr>
<tr >
<td>Volks-wagen</td>
<td align="CENTER">Germany</td>
<td align="CENTER">2,713,671</td>
<td align="CENTER">250,616</td>
<td align="CENTER">10.8</td></tr>
<tr >
<td>Peugeot-Citreon</td>
<td align="CENTER">France</td>
<td align="CENTER">2,320,266</td>
<td align="CENTER">159,100</td>
<td align="CENTER">14.6</td></tr>
<tr >
<td>Renault</td>
<td align="CENTER">France</td>
<td align="CENTER">1,755,510</td>
<td align="CENTER">174,573</td>
<td align="CENTER">10.1</td></tr>
<tr >
<th>LEAN FIRMS</th></tr>
<tr>
<td>Toyota</td>
<td align="CENTER">Japan</td>
<td align="CENTER">3,330,380</td>
<td align="CENTER">91,790</td>
<td align="CENTER">36.3</td></tr>
<tr >
<td>Nissan</td>
<td align="CENTER">Japan</td>
<td align="CENTER">2,289,123</td>
<td align="CENTER">117,330</td>
<td align="CENTER">19.5</td></tr>
<tr >
<td>Honda</td>
<td align="CENTER">Japan</td>
<td align="CENTER">1,604,430</td>
<td align="CENTER">71,200</td>
<td align="CENTER">22.5</td></tr>
</tbody>

<tfoot><tr>
<td colspan=6><b>Source:</b> Constructed from Dicken 1992, Table 3.1, p.50 and Table 9.5: 290.</td></tr></tfoot>
</table>




<p>In 1989, the best Fordist firm, Peugeot Citroen produced 14.6 
vehicles per employee while the worst lean firm, Nissan, produced  19.6
vehicles per employee. This does not mean, as is generally  assumed,
that productivity in either individual firms or the  Japanese auto
industry as a whole is higher than North American or  European firms or
the North American or European industry as a  whole,<endnotenumber>14</endnotenumber> 
only that a smaller share of the labor in automobile  production
is directly employed in the main firms. Hence, lean  firms have lower
operating overhead which is especially important  during periods of
depressed sales.</p>

<p>A third consequence of these networks is the ability of lean 
producers to maintain wage differentials across different  activities,
especially between component manufacture and final  assembly. Where
Fordist internalization combined with connective  bargaining led to an
equalization of wages across all the  activities incorporated into the
enterprise, networks in the  Japanese auto industry maintain a hierarchy
of wages across  productive activities. This is due to the fact that
different  activities occur in firms of different sizes and the most 
important variable in determining wage rates, as shown in 
Table 4, is firm size (Cusumano 1985,Smitka 1991). <endnotenumber>15</endnotenumber>
</p>


<table cellpadding=2 cellspacing=0 align=center width="80%">
<caption>TABLE 4 - JAPANESE AUTO INDUSTRY WAGES BY FIRM SIZE, 1983 (AS A PERCENTAGE OF WAGES IN THE LARGEST FIRMS)</caption>
<thead>
<tr>
<th align="CENTER">Size of Firm</th>
<th align="CENTER">Number of Firms</th>
<th align="CENTER">Number of Employees</th>
<th align="CENTER">Wages</th></tr>
</thead>
<tbody>
<tr align="CENTER" >
<td align="CENTER">4-9</td>
<td align="CENTER">31,972</td>
<td align="CENTER">31,972</td>
<td align="CENTER">42%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER">
<td align="CENTER">10-18</td>
<td align="CENTER">27,697</td>
<td align="CENTER">27,697</td>
<td align="CENTER">52%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER">
<td align="CENTER">20-29</td>
<td align="CENTER">27,301</td>
<td align="CENTER">27,301</td>
<td align="CENTER">54%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">30-49</td>
<td align="CENTER">645</td>
<td align="CENTER">25,261</td>
<td align="CENTER">59%</td>
<td align="CENTER"></td></tr>

<tr align="CENTER" >
<td align="CENTER">50-99</td>
<td align="CENTER">689</td>
<td align="CENTER">47,644</td>
<td align="CENTER">61%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">100-199</td>
<td align="CENTER">384</td>
<td align="CENTER">52,364</td>
<td align="CENTER">68%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">200-299</td>
<td align="CENTER">151</td>
<td align="CENTER">36,812</td>
<td align="CENTER">64%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">300-499</td>
<td align="CENTER">125</td>
<td align="CENTER">47,975</td>
<td align="CENTER">81%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">500-999</td>
<td align="CENTER">119</td>
<td align="CENTER">83,525</td>
<td align="CENTER">83%</td>
<td align="CENTER"></td></tr>
<tr align="CENTER" >
<td align="CENTER">1000+</td>
<td align="CENTER">95</td>
<td align="CENTER">318,139</td>
<td align="CENTER">100%</td>
<td align="CENTER"></td></tr>
</tbody>
<tfoot><tr><td colspan=4>Source: Adapted from Smitka 1991: 101.</td></tr></tfoot>
</table>



<p>A fourth
consequence of these networks is that they permit  an externalization of
development costs and the associated  overhead. The uneasy and
distrustful relationships between Fordist  firms and their suppliers
have led auto companies to design  components in-house and then convey
precisely detailed drawings  and specifications to their suppliers. As a
result, Fordist firms  are forced to carry most of the engineering and
design costs as  well as the associated overhead. In lean networks,
suppliers  perform this function in addition to actually manufacturing
the  parts (Helper, 1990; 1991). In 1988, for
example, suppliers developed 80% of the parts purchased by Toyota
(Smitka, 1991). As  a result, main firms are freed from a considerable
portion of the  cost burden and overhead of product design.</p>

<p>The
final two differences between the organizational logics  of Fordism and
lean production are interrelated. One is inventory  practices, which
directly impacts on component quality, and the  other, which is a
consequence of inventory practices, is the  spatial distribution of
production. Fordism's inventory practices  have been characterized as
"just in case" while lean production's  inventory practices have been
characterized as "just in time."  Fordist companies have historically
tended to produce and store  large stocks of components "just in case"
of disruptions in  supplies due to strikes, transport problems, shortage
of  materials, etc. As already noted, production of large stocks of 
parts combined with lax in-process quality control often led to  large
runs of defective parts. These large runs of parts also  meant that
considerations of proximity between component producers  and main
company were not extremely important. If a supplier  provided a 60 day
supply with each delivery, the supplier could be  located anywhere in
the country, if not the world, hence,  transnational production. The
only requirement was that deliveries  arrived at the proper intervals.
</p>

<p>Under a "just in time" system, suppliers produce components  in
small batches and deliver these to the main company as needed,  often as
frequently as two or three times a day. These parts are  then assembled
into vehicles almost immediately. Not only does  "just in time" reduce
the capital and the amount of storage space  devoted to intermediate
inventories but it also quickly reveals  any manufacturing defects so
that these can be rectified before  the next batch arrives. Because JIT
operates on the basis of  frequent deliveries, spatial proximity becomes
a paramount  consideration. Suppliers must be relatively close to the
main  company, if not clustered around the main company as in the most 
extreme case of Toyota City in Japan.</p>

<p>To a large extent, the
successful transplantation of lean  production to North America and
Europe by Japanese automobile  companies was at the heart of arguments
that the shift of  production to low wage countries would halt. While
proponents of  this view may not use the term lean production, they
suggest that  the emulation and spread of these methods in the core
regions will  halt and eventually reverse the flight of production to
low wage  areas for three reasons 
(Womack, 1987).
First, lean production  drastically reduces labor content and this, in
conjunction with  political and economic instability of low wage
regions, diminishes  the lure of low wage areas. Second, the newly
industrializing  countries have neither the skills nor the
infrastructure to  support the new manufacturing technologies and
techniques. Third,  it is logistically "desirable", especially for
just-in-time  production, to have the majority of manufacturing
operations not  only located in a given market but in proximity. Some
even assert  that manufacturing activities expelled from North America
over the  prior 20 years will eventually return 
(Castells and Tyson, 1988; Junne, 1987; Drucker, 1986; Lawrence and Litan, 1987; Sanderson, 1987).
Whether expelled activities will return is
unclear, but  there is wide consensus that the diffusion of lean
techniques,  especially in automobile production, will result in a
spatial  restructuring and a new geography of production in North
America.  North American automobile producers will abandon the previous 
pattern of geographical dispersion and adopt a spatial  distribution
more akin to the regional concentration in Japan.  Restructuring will
occur largely by abandoning older sites in  Michigan, California and the
Northeast and moving to new  greenfield sites in the Midwest 
(Hill, 1987; Ishi, 1988; Mair <i>et al</i>., 1988; Storper and Scott, 1989; 
Rubenstein, 1992).</p>

<h2>LOW-WAGE LEAN PRODUCTION</h2>

<p>Although some manufacturing complexes have developed in the  United
States and Canada around Japanese transplants as well as  newer plants
built by North American producers, the relocation of  automobile and
component production to Mexico appears to be a far  more significant
trend for the future of North American automobile  production. Mexico
has been integrated into both Ford and GM's  transnational production
systems since the mid-1970s, but only  recently become an important site
for automobile production by  North American companies. Engine exports,
mainly to Canada and the  U.S., which hovered around 400,000 a year in
the early 1980's,  increased to 1.3 million between 1985 and 1989
(Shaiken, 1990).  Vehicle exports grew from
14,000 to 186,000 between 1981 and 1989  (Shaiken, 1990) and, over the
next three years, more than doubled,  reaching a figure of 393,000 in
1992 (Werner, 1993).</p>

<p>The most
important reason for this growth in Mexican  production is the lure of
low wages. Although advanced production  technologies reduce the amount
of labor required for production, reducing wages costs <i>still</i>
remains of fundamental  importance for auto production. Why?  Because
labor costs still  represent approximately 20% of total costs. For
example, in an  advanced engine plant direct labor costs only represent
10% of the  cost of manufacturing an engine but indirect labor costs for
 maintenance and repair account for another 12% so total labor  costs
amount to approximately 22% of manufacturing costs 
 (Shaiken, 1987). In assembly, 
total labor costs are of a similar
magnitude - 20% of costs. No mathematical wizardry is required to see
the  benefits of labor costs of $1.55 an hour in the north of Mexico, 
or even of $5.50 an hour in Mexico City versus $30 an hour in the 
United States (Flint, 1991).
Auto producers, as already noted  under the
discussion of transnational production, were cognizant  of Mexico's
lower labor costs in the 1970's but the tremendous  growth of Mexican
production since the mid-1980s is rooted in the  organizational logic of
lean production.<endnotenumber>16</endnotenumber></p>

<p>Most of the
recent Mexican plants, like most of the Japanese  transplants in the
United States, are greenfield sites. Mexican  greenfield sites, like
greenfield sites in Japan and the United States, <endnotenumber>17</endnotenumber> 
shift production from urban centers to rural areas in  order to take
advantage of lower labor costs and a more tractable  work force. 
According to Middlebrook (1991), wage costs in the  north of Mexico
are markedly lower for two reasons: the general  level of wages is lower
than in Mexico City and seniority-based  fringe benefits are lower
because the labor force in the northern  plants consists of new workers.
 Workers in northern Mexican are  more tractable for several reasons. 
They have little experience  in industry and industrial conflict and,
unlike workers in Mexico  city who are organized into militant
"democratic unions," these  workers are organized by the CTM
(Confederation of Mexican  Workers) which has "close ties to the
government" and a "generally  cooperative attitude towards management"
(Middlebrook, 1991: 279).</p>

<p>Unlike the older workers and militant unions in Mexico city 
which resisted the implementation of lean techniques, the CTM 
affiliated unions in the north wholeheartedly embraced lean  techniques
such as rotation, multi-tasking, work teams and the  elimination of both
seniority based promotions and restrictive job  classifications. As a
result, many of the new Mexican plants have  the same flexibility as the
best lean plants. In addition, the  normal work shift in these plants is
9.5 hours versus 8 hours,  which means less overtime pay. 
(Middlebrook, 1991; Shaiken, 1990).</p>

<p>Finally, unlike the previous tendency among auto producers  to
export old equipment and manufacture outdated models for sale  in
peripheral markets,<endnotenumber>18</endnotenumber> most of the newer
component and assembly  plants in Mexico are close to "state of the art"
(Shaiken, 1993). 
For example, GM's Deltronics plant in Matamoros, is
housed in a  modern air conditioned factory and employs 4,000 workers to
assemble 3 million radios a year (Flint, 1991).  The body shop at  the
Ford plant in Hermosillo was "designed, fabricated and tested"  by Mazda
of Japan and contained modifications based on Mazda's  production
experience with a similar model which were not  incorporated into its
own body shop
(Shaiken, 1990). The tools  used in Ford's
Mexican engine plant are on par with tools used in  American and
Canadian plants (Haigh, 1992; Shaiken, 1987). Where  previously Mexican
production was for local sales or American  companies manufactured "gas
guzzling models" for export to the  U.S.,<endnotenumber>19</endnotenumber>
Mexican operations now export a majority of their  component production
and approximately 40% of vehicle production  (Werner, 1993).</p>

<p>Perhaps the most important plant for the future of  automobile production in
Mexico is Ford's Hermosillo plant.  Hermosillo represents the most
advanced assembly plant in all of  North America, and maybe the world,
with the best quality of the  80 plants, including Japanese plants and
transplants, examined by  Womack
<i>et al</i>. (1990: 87). Like NUMMI, the GM-Toyota 
venture, which enabled GM to learn lean production from Toyota, 
Hermosillo enabled Ford to learn lean production from Mazda.
<endnotenumber>20</endnotenumber> But  unlike NUMMI which merely replicated 
existing Japanese
practices,  Hermosillo is striving to move beyond these. In Hermosillo,
Ford  has not only eliminated all classifications among assembly line 
workers, leaving two categories in the plant, assembly worker and 
maintenance technician, but eventually plans to eliminate these. 
Hermosillo will then have one job classification and workers will 
rotate between assembly and maintenance jobs. Even more  incredible,
Ford has managed to implement a modified version of  "just in time",
called "one-day-at-a time" for the production of  the first car at
Hermosillo, the Tracer, despite the fact that 65%  of the components
came from Japan.<endnotenumber>21</endnotenumber></p>

<p>While the search
for low cost labor is the fundamental force  in the relocation of
automobile production to Mexico, other  factors have also contributed to
Mexico's growing attractiveness  as a site for component production and
final assembly. For  example, auto makers have found that Mexican
workers are highly  motivated and capable of learning advanced
production techniques  
(Chappell, 1991; Eden and Molot, 1993). At GM's Ramos Arizpe plant,  the workers have "taken
to quality programs with a near-religious  zeal...[and] quickly mastered
Japanese-style manufacturing  techniques to become GM's No. 1 plant,
setting company quality  records" (Baker, Woodruff and Weiner, 1992:
100).<endnotenumber>22</endnotenumber> In the last  few years, the Mexican
domestic market for automobiles has boomed.  After stagnating since the
early 1980s, annual domestic sales grew  over 20% a year between 1988
and 1992 (Chappell, 1991) thus providing auto makers
with a rapidly growing local  market.</p>

<p>Two political changes have been especially important in  making
Mexico the new center of North American automobile  production: the
rescinding of a series of restrictive governmental  decrees in 1989
which regulated the Mexican auto industry for the  previous 20 years and
NAFTA. Under these decrees, i.e., prior to  1989, imports of assembled
vehicles into Mexico were forbidden, a  domestic content of at least 75%
was required for all cars sold in  Mexico, and manufacturers were
restricted to a few car lines. As a  consequence, most of Mexican
production was isolated from U.S. and  Canadian production.  In 1989,
these restrictions were replaced  with two new requirements: imports
could not exceed 15% and later  20%, of domestic sales and companies had
to export a certain  dollar value for every $1.00 they import: $2.50 in
1989 and 1990,  $2.00 in 1992 and 1993, and $1.75 in 1994.  This meant
that U.S.  companies, in particular, could begin importing cars and 
rationalizing model lines across North America 
(Baker, 1989; Downer, 1991; Eden and Molot, 1993).
Where the 1989 decree 
liberalized conditions for companies already in Mexico, NAFTA 
restricted access to Mexico and also insured that Mexico would not 
become an off-shore assembly platform for foreign companies  seeking to
penetrate the North American market.  NAFTA placed a  ten year
moratorium on new entrants into the Mexican auto industry  and
restricted duty free access to North American markets to  vehicles with
at least a 62.5% North American content (Eden and  Molot, 1993).</p>

<p>Womack <i>et al.</i> (1990: 265) have
predicted that there  will not be a large-scale relocation of North
American automobile  production to Mexico.  Instead, Mexican production
will be limited  to low cost entry vehicles and larger vehicles and
trucks will be  imported from the U.S. and Canada to Mexico.  Mexican
production  of several larger and more expensive models such as the Buck
 Century, Chrysler LeBaron, Dodge Ramcharger and new Dodge truck  has
already disproved this prediction 
(Berg, 1992). Already, over  75,000
U.S.<endnotenumber>23</endnotenumber> and 24,000 Canadian (Eden and Molot,
1993: 298) auto  jobs have been shifted to Mexico and, as producers
continue with  their plans to close American and Canadian factories,
more jobs  will be shifted to Mexico despite protests by the UAW and CAW
(Kerklewich, 1993).</p>

<p>The fundamental motive for the shift in North American  vehicle production
to Mexico remains the same as with  transnational production, the lure
of low wage labor.  But the  recent shift to northern Mexico differs
from transnational  production insofar as it incorporates the
organizational logic of  lean production. At the same time, the growth
of Mexican  automobile production shows is that the reality of lean
production  is unlike the "theory" of lean production. Theoretical
discussions  of lean production often assert that it will result in the 
retention of manufacturing jobs in the core areas by enabling  companies
to profitably build automobiles using high wage labor. area.  In  reality, North
American auto companies have come to a different  conclusion: if
"high wage lean production" can be profitable,  "low wage lean
production" can be even more profitable.<endnotenumber>24</endnotenumber>
</p>
</body>


<endnotes>


<endnotetext><num>1</num><p>In low wage regions, this entailed an
additional assumption  that rising incomes due to increasing industrial
employment would  increase demand for these vehicles.</p></endnotetext>

<endnotetext><num>2</num><p>Similar models in U.S. and Canada 
became a standard practice 
following the US - Canada "Auto Pact" in 1965. For details, see 
Dassbach (1989: 397-400, 455).</p></endnotetext>

<endnotetext><num>3</num><p>For example,
the Escort was marketed as a low priced car in The  U.S., a mid-level
car in central Europe and an upper mid-level car  in Spain and Brazil.
Likewise, the Fiesta and variants of the  J-car were sold at different
market levels in different countries.
</p></endnotetext>

<endnotetext><num>4</num><p>The foregoing discussion draws 
on the detailed
discussion of  transnational organization at General Motors and Ford
found in  Dassbach (1989: Chapters 9 and 10) and a theoretical
discussion  found in Dassbach (1989: Conclusion - Part III).</p></endnotetext>

<endnotetext><num>5</num><p>Shaiken (1987) reports that this 
problem existed in a country 
relatively close to the United States, Mexico, as late as 1987.</p></endnotetext>

<endnotetext><num>6</num><p>See Storper 
(1990: 427) for a discussion of
"what went wrong."  Ironically, the "political maintenance" of the same
factors which  attracted auto companies to these markets, namely, low
wages,  proved to be the crucial factor in limiting demand.</p></endnotetext>

<endnotetext><num>7</num><p>There is very little information 
about Ford's shop floor 
organization in these plants and almost none about General Motors 
plants in Brazil and Mexico. When I asked GM's Director of 
International Labor Relations,  Mr. Ralph E. Deeds, about the  number of
job classifications in GM's Mexican and South American  plants, he was
unable to give me a definite number but replied  "more than we would
like." When asked why this system was  replicated in these countries, he
responded that it  was "accepted  thinking" at the time. (Telephone
interview with Ralph E. Deeds,  February 10, 1993).</p></endnotetext>

<endnotetext><num>8</num><p>
I say "more important" because even though the social  organization of
lean production may formally differ from that of  Fordism, lean
production does not represent a radical break with  Fordism at the level
of the shop floor.  In other words, viewed  from the shop floor, lean
production, is <i>not</i> "post-Fordism"  but rather "super-Fordism."
Here, I have merely discussed the  formal differences between the shop
floor organization of lean and  Fordist production without arguing for
the substantive  similarities. The substantive similarity between
Fordism and lean  production was first suggested by Dohse, Jürgens and
Malsch (1985)  and discussed in depth in Dassbach (n.d) and 
Wood (1993).</a>
</p></endnotetext>

<endnotetext><num>9</num><p>For example, between 1948 and 1970 the
number of hourly workers  at the Ford Motor Company increased by
approximately 50% while the  number of salaried workers increased by
125% (computed from data  supplied by The Ford Motor Company).</p></endnotetext>

<endnotetext><num>10</num><p>I have discussed these 
problems at GM in-depth in Dassbach 
(1989; Chapter 10).</p></endnotetext>

<endnotetext><num>11</num><p>A good overview and
interesting characterization of the auto 
<i>keiretsu</i>as a <i>Shicksalgemeinschaft</i> (destiny-
sharing-body) can be found in 
Shimokawa (1985).</a>
</p></endnotetext>

<endnotetext><num>12</num><p>Some
of the totals exceed 100% because these are estimates  based on payments
to suppliers. There are no comparable figures  for American firms and
the best estimate of extent of component  production that they control
are the figures above.</p></endnotetext>

<endnotetext><num>13</num><p>As noted after the
chart, the output to employee ratio is not  intended to be a measure of
productivity.  Instead, it illustrates  the relationship between
employment, as constant overhead, and  output.  <i>Ceteris paribus</i>,
the higher the output to employee  ratio, the lower the "break-even
point," or number of units which  the enterprise must sell to realize a
profit.</p></endnotetext>

<endnotetext><num>14</num><p>There is some indication that lean
production results in higher  productivity than Fordist production, but
certainly not of the  order that would be revealed by simply dividing
the output of lean  firms by their total number of employees. Cusumano
(1985) reports  that in 1983 the aggregate productivity of the Japanese
automobile  industry, main companies plus suppliers, was 8.7 vehicles
per  worker while the aggregate productivity of the American industry 
in 1981, the last year for comparable data, was 5.9 vehicles per 
worker.</p></endnotetext>

<endnotetext><num>15</num><p>Wage differential between
subcontractors and main firms is  also found under Fordism.  However, in
lean production this  hierarchy of wages is formally and consciously
part of the logic  of organization while under Fordism it is largely
informal and  unconscious.</p></endnotetext>

<endnotetext><num>16</num><p>
Gruben (1990) argues, using econometric analysis, that wage  differentials between
NICs and Mexico are an important factor in  explaining the growth of
Mexican production after 1985. Prior to  1985, Mexican wages in dollars
were higher than NIC wages. After  the 1985 devaluation of the Peso,
Mexican wages (in dollars) were  lower than NIC wages. Since then,
Mexican wages have declined even  further due to additional devaluations
while NIC wages have  increased with the continued weakening of the
dollar against these  currencies. Clearly, labor cost differentials as
well as  geographical proximity to the major North American markets are 
factors in explaining the increasing presence of Japanese  companies in
Mexico and may explain a preference among American  companies for Mexico
over NICs. Still, I maintain that wage  differentials only provide
further support for the basic trend to  Mexico and do not, by
themselves, explain it.</p></endnotetext>

<endnotetext><num>17</num><p>On Toyota City, in
Japan, as a greenfield site, see Cusumano  (1985: 180).  On Japanese
transplants in the US as greenfield  sites see Ishi (1988); Rubenstein
(1992: ff250) and Perrucci (1994).
</p></endnotetext>

<endnotetext><num>18</num><p>For
example, for a long time Volkswagen only produced the  Beetle in Mexico
and Brazil even though these cars were no longer  sold in the
industrialized nations. Volkswagen's most recent  plans, on the other
hand, call for the production of current  models in its plant in Puebla,
Mexico for export to the United  States and Canada.</p></endnotetext>

<endnotetext><num>19</num><p>This allowed American companies to sell these models, but due 
to the fact that they were "captive imports," they were not  averaged
into CAFE (corporate average fuel economy) figures.</p></endnotetext>

<endnotetext><num>20</num><p>For details on the cooperation between Ford and Mazda to  design
and build the Hermosillo plant, see Haigh (1992).</p></endnotetext>

<endnotetext><num>21</num><p>
On the "one-day-at-a time" system, see Shaiken (1990, ff.39)  On
industrial relations and work organization, especially the plan  to
eliminate all classifications at Hermosillo, see Shaiken (1990,  Chapter
3).</p></endnotetext>

<endnotetext><num>22</num><p>According to Flint (1991: 79) Ramos
Arizpe averages 1 defect  per car, the lowest rate of any GM plant.
Baker, Woodruff and  Weiner (1992: 100) also report that singing groups
at the plant  have recorded "odes to quality management."  In <i>Plante
Mia</i>,  workers sing "Ay, dear assembly plant with your people so
united  and responsible...."</p></endnotetext>

<endnotetext><num>23</num><p>Telephone conversation with the UAW
Research Department, July  5, 1994.</p></endnotetext>

<endnotetext><num>24</num><p>While
Mexico's attractiveness has been somewhat tarnished in  the last year by
economic stagnation, political unrest in Chiapas,  uncertainty about the
upcoming elections and the healthy  performance of North American
companies, these conjunctural  phenomena, I maintain, do not undermine
the fundamental,  structural lure of Mexico, namely low wages and a
highly motivated  work force, for North American and foreign automobile
companies.</p></endnotetext>
</endnotes>

<references>

<p>Asanuma, B. (1989) "Manufacturer-Supplier Relationships in Japan 
and the Concept of Relation-Specific Skills." <i>Journal of 
Japanese and International Economics</i>, 3: 1-30.</p>

<p>Baker, S. (1989) "A Free-for-all for Carmakers South of the 
Border," <i>Business Week</i>, October 16: 32.</p>

<p>Baker, S., D. Woodruff and E. Weiner (1992) "Detroit South." 
<i>Business Week</i>, March 16: 98-103.</p>

<p>Berg, P. (1992) "Nationality Dubious, Origin Murky." <i>Car and 
Driver,</i> June 1992: 164-165.</p>

<p>Castells, M. and D'Andrea Tyson, L. (1988) "High Technology Choices 
Ahead," in Sewell and Tucker (eds.) <i>Growth, Exports and Jobs 
in a Changing World Economy</i>. New Brunswick: Transaction 
Books: 55-95.</p>

<p>Chandler, Jr., A. D. (1977) <i>The Visible Hand</i>. Cambridge, 
MA: Belknap Press.</p>

<p>Chappell, L. (1991) "South of the Border." <i>Automotive News</i>, 
April 1: 20-21.</p>

<p>Cusamano, M. (1985) <i>The Japanese Automobile Industry</i>. 
Cambridge, MA: Harvard University Press.</p>

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