Range of manufactures require range of strategies | 
             
             
               | 4.1  | 
               Traditional manufacturing industries cover a  range of degrees of sophistication. Table 4.1 (p. 58) ranks them by value added  as a percentage of final product. Unsurprisingly, the most value is added by sophisticated  industries such as manufacturing scientific equipment while the least is done  in manufacturing basic products such as petrol and flour.   | 
             
             
               | 4.2 | 
               
                  The manufacturing sector is often divided into  ‘elaborately transformed’ and ‘simply transformed’ industry, by somewhat  arbitrarily dividing the industries based on the complexity of their output. Production  and exports of elaborately transformed manufactures have grown much faster than  the simpler products. For example, the Treasury demonstrated that export  volumes have slowed across all categories since 2000 but only contracted for  ‘metals’, ‘resource-intensive’, ‘agricultural-intensive’ and ‘materials’  categories.1                    | 
             
             
               | 4.3 | 
               The more basic forms of manufacturing tend to  make more intensive use of low-skilled labour and are therefore much more  vulnerable to competition from economies such as China with plentiful cheap labour  (and lighter regulation) and economies of scale. As simpler goods have closer  substitutes in world markets, and compete more on price, they are also more  susceptible to the strong dollar.  | 
             
             
               | 4.4  | 
               Table 4.1 shows, however, that this analysis  misses some of the transformation within the manufacturing sector. Clothing is  generally regarded as a relatively simple product with relatively low value  added. However, as the table shows, clothing is no longer such a product in Australia as  clothing manufacturers here now specialise in high-end fashion and clothing for  special purposes (e.g. fire resistant clothing).
                                | 
             
             
               Table 4.1 Selected  manufacturing industries, ranked by value added as per cent of sales             
                 
                   
                        | 
                     Value added as % of total sales and service income, 2004-05  | 
                    
                   
                     Publishing  | 
                     51  | 
                    
                   
                     Medical and surgical equipment  | 
                     44  | 
                    
                   
                     Machine tools  | 
                     43  | 
                    
                   
                     Other electronic equipment  | 
                     40  | 
                    
                   
                     Recorded media  | 
                     40  | 
                    
                   
                     Telecommunications equipment  | 
                     36  | 
                    
                   
                     Professional and scientific equipment  | 
                     36  | 
                    
                   
                     Aircraft  | 
                     36  | 
                    
                   
                     Mining and construction machinery  | 
                     35  | 
                    
                   
                     Furniture  | 
                     33  | 
                    
                   
                     Clothing  | 
                     29  | 
                    
                   
                     Iron and steel  | 
                     29  | 
                    
                   
                     Aluminium smelting   | 
                     28   | 
                    
                   
                     Basic chemicals  | 
                     26  | 
                    
                   
                     Flour & cereal  | 
                     25  | 
                    
                   
                     Motor vehicles  | 
                     20  | 
                    
                   
                     Meat and meat products  | 
                     20  | 
                    
                   
                     Dairy products  | 
                     18  | 
                    
                   
                     Copper, silver, lead, zinc smelting and refining  | 
                     18  | 
                    
                   
                     Petroleum refining  | 
                     9  | 
                    
                  
               Source: derived from data in ABS, Manufacturing Industry 2004–05, Cat.  no. 8221.0, table 2.2.  | 
             
             
               | 4.5  | 
               Simple manufacturing industries are likely to  survive if they are naturally protected by high transport costs. For example,  the value of bricks and cement is low relative to their bulk and mass. Even if  overseas manufacturers are able to produce them more cheaply, freight costs  generally make imported bricks and cement uncompetitive.  | 
             
             
               | 4.6  | 
               Manufacturers of relatively basic products may  survive despite higher costs if they offer exceptional service, customised  products or very quick delivery of small orders.   | 
             
             
               | 4.7 | 
               Some Australian manufacturers may be able to  sell goods priced higher than imported versions as the Australian goods have a  better ‘brand image’. For example, they may be seen as more reliable. Meeting  Australian standards may give buyers more confidence in the domestic product.  | 
             
             
                | 
                 | 
             
             
               Further processing of raw materials | 
             
             
               | 4.8  | 
               A common argument is that Australia’s  extensive mineral resources should make it competitive in products that use  these inputs intensively, or that it should at least process them further  before exporting them.2                    | 
             
             
               | 4.9  | 
               The committee characterised this as an issue of  whether production is better located close to raw materials (or component  manufacturers) or close to markets. A committee member stated: 
                 Presumably the key factor  governing the extent to which it is viable to have further processing occur in Australia is  the relative economics of manufacturing close to your predominant consumer  market versus manufacturing close to your predominant resource input. I would  have thought that one of the problems with the latter, manufacturing close to  your resource input, is that there are other inputs .… isn’t it unrealistic to  expect that we are going to become major and powerful world fabricators of  aluminium window frames or something like that simply because we have the  bauxite to start with?3                    | 
             
             
               | 4.10 | 
               The proposition was put to Mr Don Larkin, chief  executive officer of the Australasian Institute of Mining and Metallurgy, who  agreed that manufacturing was generally more likely to occur close to markets  rather than close to raw materials.4                    | 
             
             
               | 4.11 | 
               A related case is companies which need to be  close to a range of suppliers of components to avoid excessive warehousing of  inventories.5 These  companies may be slower to shift their operations to an economy with lower  labour costs, at least until the cheaper economy also has component suppliers.  However, if they do move, then the component makers may also close.                     | 
             
             
                | 
                 | 
             
             
               The way forward for traditional manufacturers | 
             
             
               | 4.12 | 
               There is now broad consensus across unions and  employers that the way forward is for Australian manufacturing to adjust to  face the global challenges rather than retreating behind protectionist  barriers.  | 
             
             
               | 4.13  | 
               For example, Mr Nixon Apple, industry and investment policy  advisor for the Australian Council of Trade Unions said: 
                 The thing that we need to keep in  mind more than anything we have done in the past is that it is about building  better manufacturing businesses. I think that with tariffs and with other  things we took our eye off the ball about what is involved in building better  businesses with the organisational capabilities and management systems to  succeed.6                    | 
             
             
               | 4.14 | 
               A similar view was expressed by Mr Gregory   Evans, director of industry policy  and innovation for the Australian Chamber of Commerce and Industry (ACCI): 
                 Recent difficulties faced by  manufacturing should not be used as an excuse to lead governments back to old,  failed policies of protectionism and intervention. The future of manufacturing  does not lie in increasing government intervention, building higher tariff  walls, providing greater subsidies or picking winners … The future of  Australian manufacturing lies with policies that strengthen the overall economy  and support competition.7 
                                    | 
             
             
               | 4.15 | 
               For many traditional manufacturers, there are  basically three strategies, although some firms will do more than one: 
                 - Offsetting labour cost disadvantages in the  existing product line by greatly improving productivity.
 
                 - Changing the nature of the product made to a  more original, sophisticated, specialised, high quality ‘niche’ or ‘boutique’ product,  that possibly cannot be made with a low-skilled workforce, and looking to  export.
 
               - Moving  the assembly line aspects of production of relatively simple manufactures to  cheaper centres overseas, while retaining the ‘cream’ in Australia. For some  companies this may mean they retain only the high value aspects such as design  and marketing domestically. For some companies this could involve specialising  in making one component as part of a global supply chain.
   | 
             
             
               | 4.16 | 
               These three strategies are discussed in turn in  the following sections.  | 
             
             
                | 
                 | 
             
             
               Improving productivity in making existing products | 
             
             
               | 4.17  | 
               There appears to be scope for Australian  manufacturers to raise their productivity in their existing product range by  adopting ‘world’s best practice’. Labour productivity appears less than half  that in much of western Europe (Table 4.2). 
                
                | 
             
             
               Table 4.2 Labour  productivity (value added per hour) in manufacturing, 2000, US = 100. 
                 
                   
                      
                       Finland  | 
                     107  | 
                        | 
                     Japan  | 
                     70  | 
                    
                   
                     United      States  | 
                     100  | 
                        | 
                     Canada  | 
                     66  | 
                    
                   
                     Belgium  | 
                     96  | 
                        | 
                     United      Kingdom  | 
                     55  | 
                    
                   
                     Netherlands  | 
                     95  | 
                        | 
                     Australia  | 
                     39  | 
                    
                   
                     Sweden  | 
                     95  | 
                        | 
                     Spain  | 
                     38  | 
                    
                   
                     France  | 
                     93  | 
                        | 
                     South Korea    (1998)  | 
                     36  | 
                    
                   
                     Germany  | 
                     88  | 
                        | 
                     Taiwan    (1998)  | 
                     27  | 
                    
                  
                  
                 Source: Groningen  Growth & Development Centre, ICOP Industry Database.8  | 
             
             
               | 4.18 | 
               However, even doubling productivity—a very  ambitious goal—would only make Australian manufacturers roughly competitive  with European and North American producers9,  who pay comparable wages and are struggling themselves in many cases.10 To compete with factories in countries such as China and Vietnam, where  wages are much lower than Australia,  productivity would need to be increased much more.11                   | 
             
             
               | 4.19 | 
               As work by the Productivity Commission shows, labour  productivity could be increased by investing in more capital equipment. The  average amount of capital per worker in the Australian manufacturing sector  increased more than fivefold between 1964–65 and 2001–02, accounting for about  half the growth in labour productivity over this period.12                    | 
             
             
               | 4.20 | 
               Australia’s relatively small domestic market  makes it difficult for Australian firms to achieve economies of scale and so  match the productivity of European and American firms. Australian manufacturers  therefore need to be exporting to achieve economies of scale. (A more cautious  approach is to seek economies of scale in just one part of the production  process, as discussed later in the section on global supply chains.)  | 
             
             
               | 4.21  | 
               Even without large investments, it may be  possible to increase productivity by using existing workers and equipment more  efficiently. This process can be assisted if critical overviews of internal  capabilities are conducted. An external review may bring new ideas, and will at  least lead the firm to reflect on its current procedures.  | 
             
             
               | 4.22  | 
               One management tool to improve productivity is  ‘benchmarking’; comparing the firm’s performance at each stage of the  production process to the world’s best practice, so as to identify areas where  improvement is needed. A number of organisations offer benchmarking services. | 
             
             
               | 4.23 | 
               QMI Solutions Ltd is a not-for-profit company which  diagnoses and benchmarks around 100 small and medium enterprise (SME)  manufacturers a year.13 An improvement programme is designed collaboratively with the company to  improve performance. QMI also arranges mentoring and runs seminars.                    | 
             
             
               | 4.24 | 
               The National Manufacturing Forum was impressed  by QMI and refers to its ‘acknowledged success’ in: 
                 Driving continuous improvement  through technology diffusion, diagnostics, benchmarking and reviews. The QMI  model was seen as an effective approach to productive performance, with  potential to extend cooperatively its underlying principles to other states.14                    | 
             
             
               | 4.25 | 
               A specific area where benchmarking may improve  results is logistics. Dr Julie Wells,  director, policy and planning, RMIT   University made ‘a plea  for greater recognition of the importance of supply chain management and  logistics in the manufacturing industry’.15                    | 
             
             
               | 4.26 | 
               The UK Department of Trade and Industry has a  number of benchmarking initiatives. They offer an internet-based  self-assessment test on aspects such as innovation.16 They also have 2000 trained advisers who can assist SMEs in conducting a more  rigorous benchmarking of their performance using a database of over  150 000 companies.17                   | 
             
             
               | 4.27 | 
               The UK model seems to have influenced the  Australian Government’s Industry Statement 2007, which announced that new Australian  Industry Productivity Centres (AIPCs) would provide a: 
                 Free diagnostic service to help  businesses assess their performance against world best practice and identify  opportunities for improvement. Up to 2 000 businesses a year will use this  service.18                    | 
             
             
               | 4.28 | 
               Following from benchmarking activities,  manufacturers may then implement programmes to improve areas shown to be  deficient. A number of generic management philosophies, such as ‘quality  assurance’ and ‘lean manufacturing’, were popularised in the early 1990s, having  originated in manufacturing in the US and Japan some sixty years prior.   | 
             
             
               | 4.29 | 
               Management strategies aiming to improve the  awareness of quality in all organisational processes are broadly referred to as  ‘Total Quality Management’. Quality Assurance is an activity which provides  evidence that an organisation is applying these principles to provide adequate  confidence that the product optimally fulfils customers’ expectations.   | 
             
             
               | 4.30 | 
               Australian manufacturers use the International  Organization for Standardization’s (ISO) 9000 series of Quality System  Standards.19 This standard applies to all organisations regardless of size, industry,  product or service. This standard is designed to encourage continual process  improvement and efficiency and meet customer satisfaction by ensuring that  business process controls are in place and apply in practice.                   | 
             
             
               | 4.31 | 
               In addition to building customer confidence and  improving productivity, Professor Mark Dodgson, director of the Technology and  Innovation Management Centre, University of Queensland—appearing before the  committee in a private capacity—stated that embracing international quality  assurance accreditation improves firm capability and innovativeness. He said: 
                 The International Organisation for Standardisation’s international  accreditations are again very important. My survey showed that very few firms  actually had the basic ISO 9000, which is a bit of a worry because that is  basic entry-level stuff.20                    | 
             
             
               | 4.32 | 
               Another approach to improving efficiency comes  under the rubric of ‘lean manufacturing’ (LM). The Industry Statement 2007 refers  to LM as a ‘critical issue’ and the AIPCs intend to disseminate information on  it. TAFE courses are already being conducted on LM.   | 
             
             
               | 4.33 | 
               However, while there is much general talk about  LM, understanding precisely what it means is very difficult. Articles about LM generally  refer to a focus on eliminating waste and it is often associated with Toyota’s manufacturing philosophy  of ‘continuous improvement’ (or ‘kaizen’) and rigorous quality checks.21 While reducing waste seems an obviously sensible idea, it is not a  revolutionary new concept.                     | 
             
             
               | 4.34 | 
               The UK’s Manufacturing Advisory Service,  on which the AIPCs are partly modelled, claims to employ LM techniques in their  approach. While it refers to LM in numerous fact sheets, it provides no  tangible examples of how LM is applied in practice. This may lead to confusion  over what LM processes actually involve, as outlined by Dr John Blakemore, Blakemore Consulting  International: 
                 We go down the path of what is  called ‘lean manufacturing’, which is not the way to go. I will be very careful  here because you can argue about what these terms mean … the American  interpretation of the Japanese method is in error.22                    | 
             
             
               |   | 
                 | 
             
             
               Moving to ‘boutique’ manufactures and exporting | 
             
             
               | 4.35 | 
               Many Australian manufacturers have moved ‘up the  value chain’ to high quality, original or ‘niche’ products in the face of  challenges to remain competitive in traditional products.   | 
             
             
               | 4.36 | 
               Germany  is seen as an exemplar of quality in manufacturing. Professor Dodgson  remarked to the committee that: 
                 They still have a very successful engineering and manufacturing sector …  They still export more than any other country in the world ... The quality of  the companies that you see—the BMWs of the world—is just so good … it gives  them such a distinctive advantage. At a time when the car industry is going to  hell in a hand basket in the United    States, Germany is doing really well …  because of the quality of their manufacturing and engineering.23                    | 
             
             
               | 4.37 | 
               An important part of Germany’s success in maintaining  this quality edge is its interest in new technologies. The Australian  Manufacturing Workers’ Union (AMWU) describes Germany’s: 
                 Single institute that has a budget  of $1 billion per year whose job it is to scour the world for world’s best  technology and, if it is not already located in Germany, its job is to import it  into Germany  and to place it with local manufacturers.24                    | 
             
             
               | 4.38 | 
               One of Germany’s particular strengths is  in production and export of capital equipment. This may be an area where Australia could  excel by focusing on industries where we have extensive experience, such as mineral  processing, medical and marine equipment. The question was posed during a  hearing: 
                 Can we therefore think about  producing low-volume, high-value manufactured goods, including those that might  be used in the production of high-volume, low-value manufactured goods in other  countries—for example, machine tools? Could we become the Germany of the Far East?25                    | 
             
             
               | 4.39 | 
               Dr    Wells  from RMIT, replied cautiously that: 
                 It is a very interesting question.  I guess it underpins the importance of engagement with industry in the skills  development process. Obviously, there has to be a viable business case around  it. In general terms, I would agree…. we have to locate the education and  training effort more squarely in the workplace.26                    | 
             
             
               | 4.40 | 
               Niche manufacturing tends to involve a more  skilled workforce and emphasis on design and R&D. Nanotechnology  applications are transferring from the pharmaceutical industry to the metal  products and polymers industry and will lead to more ‘niche’ products of  improved quality, longevity and functionality.   | 
             
             
               | 4.41 | 
               The Government has recognised the importance of  niche manufacturing with the Industry Statement 2007 allocating  $36 million over the next four years for CSIRO to establish a National  Research Flagship for Niche Manufacturing. CSIRO describes the new flagship’s  role as being to: 
                 Help the Australian manufacturing  industry to become more competitive in global supply chains, develop globally  competitive medical products, identify next generation fabricated devices,  capture value from new materials, help stimulate smart manufacturing  enterprises, and consider the health, safety and environmental issues of  nanotechnology research.27                    | 
             
             
               | 4.42 | 
               As, by their very nature, the domestic market  for niche goods is very much smaller than that for mass market goods, it  becomes even more important that manufacturers become more focused on  exporting.28                    | 
             
             
               | 4.43 | 
               Back in the 1970s, less than a tenth of  Australian manufactures were exported.29 Firms lacked confidence to move into overseas markets. There were therefore  likely to be ‘spill-over’ benefits to other companies from encouraging  ‘trail-blazers’ to set an example of exporting to their peers. New exporters  help promote the ‘Australian brand’ as well as their own products. Furthermore,  in a regulated financial market where a small number of domestic banks rationed  credit, it was often hard for small and medium enterprises to obtain funding to  develop new markets.                    | 
             
             
               | 4.44 | 
               For this reason, the government introduced the  Export Market Development Grants scheme (EMDG) in 1974 to assist emerging and  current exporters to promote their product in international markets. In the new  century, exporting is much more common among Australian manufacturers and the  financial system is now deregulated and highly competitive so credit  availability is much less of an issue, especially for larger companies. In line  with this change, the amount of funding for the EMDG scheme is now less  generous than it had been.  | 
             
             
               | 4.45 | 
               Currently the scheme reimburses up to 50 per  cent of expenses incurred on ‘eligible export marketing expenses’30,  above a $15 000 threshold. The scheme provides for up to seven grants to  each eligible applicant but imposes an income eligibility cap of $30 million  in the grant year (which had been reduced from $50 million in 2003). The  scheme involved around 1 300 grants, totalling $51 million (almost 40 per  cent of the total), being paid to manufacturers in 2005–06.31                   | 
             
             
               | 4.46 | 
               However, there is still a case for supporting  ‘trail-blazers’ as there are new emerging markets that need to be opened up for  Australian manufacturers.    | 
             
             
               | 4.47 | 
               By its very nature, the EMDG scheme rewards  outward-looking rather than conservative and declining companies. It also has  the advantage that by bringing grant recipients into contact with the  Australian Trade Commission (Austrade), it increases the chances that such  companies will hear about new market opportunities.  | 
             
             
               | 4.48 | 
               The scheme was praised by the manufacturing  sector, who unsurprisingly would like to continue to receive payments. ACCI’s  submission argued that the EMDG scheme helped participants: 
                 Overcome the single largest barrier to engaging in exporting - namely  access to the necessary operating capital to fund their export promotion work.32                    | 
             
             
               | 4.49 | 
               Some argued for the eligibility cap to be  restored to the previous $50 million or even raised beyond this.33 The committee heard that some high-tech and advanced manufacturers would only  be able to undertake international promotional activities exceeding  $15 000 per annum after their turnover exceeded the cap. However, ACCI  agreed with a recent Austrade review supporting the current threshold.34 The Austrade review had concluded that: 
               
                 Larger firms already have more  export experience, have more ability to fund export promotion from their own  resources, and have lower expectations about the benefits generated by  increased export promotion.35                   | 
             
             
               | 4.50 | 
               Since 1997, the EMDG scheme has had a limited budget for each year. Therefore, in years  with high demand, successful applicants are paid only a proportion of  the reimbursement for which they would normally be eligible (a process known as  ‘modulation’) in order to keep total spending within the overall budget.   | 
             
             
               | 4.51 | 
               This process may substantially reduce the  incentives to increase export marketing arising from the scheme, as it means  firms have to decide on their promotional spending without knowing what  proportion of the spending will be reimbursed. Both ACCI and the Austrade report suggested a ‘smoothing arrangement’  whereby in years of low demand the unspent commitment may be carried forward to  cover high demand years.36 This would reduce the frequency and extent of modulation but would still leave  some uncertainty for companies about whether their spending will be fully  covered.                     | 
             
             
               | 4.52 | 
               There were also some criticisms of the burden on  applicants of proving that the promotional activity undertaken actually  resulted in an increase in exports, but this has subsequently been addressed.37                     | 
             
             
               | 4.53 | 
               Aside from marketing, another way an Australian  manufacturer may win a contract over a foreign rival is by offering faster and  better after-sales service such that the ‘whole-of-life’ cost of a domestic  product is lower even when the initial purchase cost of the domestic good is  higher than for an imported product. An example of offering extensive service  is the Australian aluminium shipbuilder Austal, the world’s largest builder of  fast ferries, who provide assistance when the ferry arrives in the home port  and continue to provide repairs and maintenance.  | 
             
             
                | 
                 | 
             
             
               Global supply chains | 
             
             
               | 4.54 | 
               A large  proportion of world trade now takes place within, not between, industries. The Industry  Statement 2007 notes that: 
                 Traded goods are now just as likely to be intermediate goods as finished  products, often sold between affiliates of the same multinational enterprise.38                    | 
             
             
               | 4.55 | 
               This  trend has occurred with an increase in the global concentration of  manufacturing companies. The Industry Statement 2007 refers to some estimates  that only 500 firms account for 70 per cent of global trade, and that 40  carmakers in the 1980s have consolidated into 14 firms now.39                     | 
             
             
               | 4.56 | 
               The Industry  Minister’s forward to the Industry Statement 2007 refers to ‘the concentration  of trade in global supply chains’ as one of ‘the challenges of the global  market’.40                     | 
             
             
               | 4.57  | 
               The  growth in global supply chains reflect a rethinking of how multinational  corporations can most efficiently produce goods, driven in part by reductions  in trade barriers. Whereas in the past, all stages of the production process  were replicated in each economy (often to be inside tariff walls), now the  production process is divided into stages, with operations in each economy  specialising in the stage in which they have a comparative advantage and  producing for the global market. This allows much greater economies of scale in  each stage.  | 
             
             
               | 4.58  | 
               The  Department of Foreign Affairs and Trade described the new process as follows: 
                 Companies are seeking to locate different stages of production in  countries with the lowest cost structure. As a result, there is growing  dispersion of production processes - with assembly operations migrating to  relatively low-wage countries, and the production of components taking place in  higher-wage countries.41                     | 
             
             
               | 4.59  | 
               There  are three ways in which Australian entities might be involved in global supply  chains;
                
                 - Leading  a supply chain with overseas firms contributing some links (Figure 4.1, p. 71).  The committee heard an example of an Australian‑controlled supply chain  where Australian wool is sent to Italy for spinning and the yarn is  then returned to Australia  to be made into high-quality merino knitwear for sale in international markets.42 With Australia  making up less than 1 per cent of the global economy, Australian-led global  supply chains are likely to remain uncommon.
 
                
                               | 
             
             
               
                 Figure 4.1 Australian  supply chain 
                                                               | 
             
             
               |   | 
               
                   - As part of one multinational company’s global  operations (Figure 4.2). For example, a global manufacturer might have one  component of its global products made in its Australian subsidiary. An example  is NEC, whose Australian operations are one of five R&D centres in NEC’s  global network, and produce the digital subscriber line (DSL) product for sale  around the world.43 Australian manufacturers are more  likely to participate if we have a skilled, well-educated workforce and  efficient work practices.
 
                      | 
             
             
               | 
                  Figure 4.2 Link in  global supply chain 
                  | 
             
             
               |   | 
               
                   - As a supplier of a component to the supply  chains of a number of international supply chains (Figure 4.3).
 
                   | 
             
             
               
                 Figure 4.3 Supplier to global supply chains  | 
             
             
               | 4.60  | 
               The  committee heard of a Newcastle  problem-solving company for engineering and manufacturing, CCI Pope, which  solved a problem for the Rolls Royce jet engine manufacture and has now embedded  itself in a huge global chain.44 This third aspect is the focus of the rest  of this section.                    | 
             
             
               | 4.61  | 
               A  number of submissions, from both industry and trade unions, referred to the  need for Australian companies to integrate into global supply chains. The Australian  Industry Group (Ai Group) and AMWU respectively wrote: 
                 The fate of many firms will depend on securing a place in international  supply chains. Trade is increasingly concentrated around a relatively small  number of international supply chains.45  
                 A major outcome from this process must be… Australian firms becoming  part of the new supply chains … in this region.46                   | 
             
             
               | 4.62  | 
               The Treasury  was comfortable about Australian manufacturing moving from autonomous  manufacturing to a role within a global supply chain: 
                 In global manufacturing there is a move towards greater specialisation.  So maybe, instead of Australia  trying to produce a whole range of cars which are sold in Australia, the  automotive industry could concentrate on producing one model which is sold  around the world. It might not even be a whole car; it might be that we  concentrate on producing transmissions or something … It might be that  Australia’s input is to be the design centre.47                    | 
             
             
               | 4.63  | 
               Ford Australia gave  an example of just this process, describing its: 
                 Enhanced role as an engineering and design ‘centre of excellence’ for  the Asia Pacific and Africa region …. Ford  Motor Company recently awarded this significantly expanded team the lead role  for the design and engineering of a new global light commercial vehicle to be  sold in more than 80 markets worldwide.48                    | 
             
             
               | 4.64  | 
               The  motor vehicle industry offers scope for many Australian firms to enter global  supply chains. Austrade estimates that there are approximately 200 Australian  companies that supply components to the four Australian vehicle producers for  their export models.49                    | 
             
             
               | 4.65  | 
               While  many witnesses stressed the importance of involvement in global supply chains, Australian  firms have so far not been extensively involved in them. The Industry  Capability Network (ICN) estimates that of the world’s largest 500 companies: 
                 Less than 20 … use Australia  as a significant product development, technical or production centre for a  global business operation.50                    | 
             
             
               | 4.66  | 
               Professor Dodgson outlined the supply chain innovation challenge: 
                 There are now many mechanisms that these firms use to advertise and to  promote the access of those firms into their supply chains and they can do  that. But the challenge is to continue to innovate, to continue to be ahead of  the other potential supply chains, which could be in Brazil, South Africa or wherever. That is  where the links and the improvements in managerial capability—the more  strategic approach—would help.51                    | 
             
             
               | 4.67  | 
               The AMWU  was very sceptical about the model of Australian manufacturers supplying to  global chains: 
                 This supply chain argument about simply offshoring it is doomed to  failure. In our view, you cannot keep the cream of manufacturing, you cannot do  the R&D and the prototyping here and hope that you can keep it here.52  
                  
                 We need critical mass to maintain supply chains, build clusters,  innovate successfully, win export markets and enjoy a balanced economy.53  
                  
                 It is extremely hard to export a single automotive component in the  absence of a supply chain here. It is much easier to get into the Toyota supply chain if  you are already in the domestic supply chain of Toyota here and you have the aggressive  backing of Toyota.54                   | 
             
             
               | 4.68  | 
               The  AMWU also highlighted its concern that many companies running global supply  chains are not Australian-owned: 
                 The decisions about where the investment goes and where the economies of  scale are being taken by companies in Detroit, Tokyo and elsewhere … When the  boards sit down in Tokyo and Detroit, they will make decisions based on the  government support and investment climate in the country.55                    | 
             
             
               | 4.69  | 
               A  number of agencies (see Appendix H) help involve Australian entities in global supply chains through various  programmes, including Austrade, the ICN and Invest Australia.   | 
             
             
               | 4.70  | 
               Austrade  supports exporters in general, including those exporting components to global  supply chains. The committee heard mixed views on the effectiveness of  Austrade’s operations. Ai Group could not fault them,56 while the AMWU called for a review of the agency because it did not think Austrade  was concentrating enough on helping Australian firms become involved in big,  international procurement programmes.57                   | 
             
             
               | 4.71  | 
               Austrade  does not see its role as organising major project teams. They act as an export  facilitator and an international project ‘spotter’, which they can do with  relative ease given their international market presence.58                    | 
             
             
               | 4.72  | 
               In  contrast, the Global Opportunities programme announced in the Industry  Statement 2007 will apparently pro-actively form consortia of Australian  businesses for large international projects. This programme will ‘target more  than 30 large international projects each year, with a combined value of at  least $16 billion’.59 Project teams will be drawn from DITR,  Austrade and the ICN to identify the most promising projects. The Industry  Statement 2007 states: 
                 Consortia of Australian businesses will be formed to pursue these  opportunities, giving SMEs the chance to forge new links with Australian and  international businesses.60                   | 
             
             
               | 4.73  | 
               The  ICN, a non-government organisation, has a more specific focus on business  partnerships for accessing global supply chains.61 ICN may be approached by international  companies working on major projects, or be informed of them by Austrade. The  ICN diagnoses the technical needs of the project and then scan their  ‘capability register’62 seeking those that meet project requirements.  Although the ICN informs manufacturers of bidding opportunities, neither it nor  Austrade are involved in assembling a bid for a project.                   | 
             
             
               | 4.74  | 
               The ICN  also administers the Supplier Access to Major Projects (SAMP) grants programme,  which provides funds for specialist consultants to work with project developers  in identifying supply opportunities for capable and competitive Australian  companies. Funding is provided for major projects of national or regional  economic significance and has recently been expanded to participation in major  projects overseas.63                    | 
             
             
               | 4.75  | 
               ICN’s  submission (the only specific evidence received on SAMP) stated: 
                 ICNL estimates that under SAMP, Australian companies have won contracts  worth around $1.6 billion for work that might otherwise have gone to overseas  competitors.64                    | 
             
             
               | 4.76  | 
               The  Global Opportunities programme will include the existing SAMP Global programme,  and supplement it with a new co‑operative programme providing $254 million over  ten years. It appears the new programme will use more resources than the ICN’s  capability network database, including conducting regional fora seeking  capability and interest in joining in joint bids for large overseas projects.   | 
             
             
               | 4.77  | 
               Invest  Australia encourages foreign companies to invest in Australia. The benefits of foreign  investment are likely to be maximised when foreign investment takes the form of  direct investment in ‘greenfield’  sites.65 This is most likely to involve technology  transfer and training for Australian workers and offers the most prospect of  the Australian operation being part of a global supply chain.66 It appears that Invest Australia now has a  more targeted approach to foreign direct investment attraction with the bulk of  promotion activities occurring in the high and medium high technology exports.67                   | 
             
             
                | 
                 | 
             
             
               Conclusions | 
             
             
               | 4.78  | 
               The  committee notes that Australian manufacturers are adopting varying strategies,  depending on the nature of the goods they produce, to adjust to a global  marketplace where proximity to raw materials is of less importance.  Some Australian manufacturers are naturally  protected by transport costs and others are staying competitive by slashing  costs, raising productivity, achieving economies of scale by entering export  markets, increasing quality and/or offering superior service. Mass low‑value manufacturing  is moving offshore or being replaced by more innovative ‘niche’ manufacturing.   | 
             
             
               | 4.79  | 
               The  committee supports ‘benchmarking’ and the use of diagnostic audits and various  management tools to improve business weaknesses identified through it. Firms analysing  their deficiencies is a positive step towards productivity and efficiency  gains. The committee therefore endorses the diagnostic analysis that the AIPCs  are proposing to offer and hopes that the SMEs will be exposed to well-founded  manufacturing-based methodologies suitable for their business type.  | 
             
             
               | 4.80  | 
               Australian  manufacturers have adopted a greater focus on exporting. The main government  support for exporting is the Export Market Development Grants scheme. The  committee heard proposals to increase the cost of this scheme by raising the  eligible turnover cap of $30 million. However, the committee supports the  recent decision of the Government to lower this cap to ensure that the main  beneficiaries of the scheme are the smaller firms less able to bear the costs  of marketing themselves.  | 
             
             
               | 4.81  | 
               A  problem with the EMDG scheme is that even applicants with strong applications are  not sure how much they will be reimbursed when they are deciding on promotion  spending, which limits the incentive the scheme provides to undertake  additional marketing. The suggestion to allow a smoothing arrangement whereby  unspent scheme monies could be carried over into future years would reduce this  uncertainty. Increasing the budgeted amount for the scheme would reduce  the uncertainty further, by increasing the probability that eligible applicants  would receive their reimbursement even in years with high demand.  | 
             
             
               | 4.82  | 
               Participating  in global supply chains is increasingly important as a means for manufacturing  to remain viable and a number of government programmes are designed to  facilitate this. However, complementary policies must be adopted to link newly  arrived foreign multi‑nationals to domestic producers, to gain true economic  benefit from this strategy.   | 
             
             
               | 4.83  | 
               After  the following chapter on ‘new’ manufacturers, there are further recommendations  applying to all manufacturers covering engagement with researchers, innovation  and government assistance packages.  | 
             
             
               | 4.84  | 
               Recommendation 5The committee regards benchmarking  as a vital activity of the nascent Australian Industry Productivity Centres and  recommends that the Government ensure the Centres are adequately resourced to  provide this service to a wide range of companies across Australia.  | 
             
             
               | 4.85  | 
               Recommendation 6
                 The committee recommends that the  Government increase the amount budgeted for the Export Market Development  Grants programme each year and, in line with a recent Austrade review, allow  the carry forward of any unspent budgeted funding to be used in future  programme years of high applicant demand.  | 
             
           
       
                             
                        
                          | 1  | 
                          The Treasury, Submission no. 21, p. 3. An updated version appears as Table 2.3 in  Chapter 2 of this report. Back  | 
                        
                        
                          | 2  | 
                           This question was examined in a two-part  report by the House of Representatives Standing Committee on Industry, Science  and Resources, published as Of Material  Value (March 2000) and Getting a  Better Return (September 2001). They concluded that ‘there appears to be  strong potential for enhanced value-adding in Australia’. Back  | 
                        
                        
                          | 3  | 
                          Mr L Tanner MP, Transcript, 28 August 2006, p. 34, and 29 August 2006, p. 53. Back | 
                        
                        
                          | 4  | 
                          A similar conclusion was reached by the Industry  Statement 2007; ‘there is also a trend to locate manufacturing and product  development activity close to final markets – which in our region means North Asia and India’, Department of Industry,  Tourism and Resources (DITR), Global  Integration: Changing Markets. New Opportunities, Background papers, no. 4,  p. 7. Back | 
                        
                        
                          | 5  | 
                          This is discussed in House of  Representatives Standing Committee on Employment, Workplace Relations and  Workforce Participation, Shifting Gears,  December 2006, p. 16. Back | 
                        
                        
                          | 6  | 
                          Mr N Apple, Australian Council of Trade Unions, Transcript, 22 November 2006, p. 20. Back | 
                        
                        
                          | 7  | 
                          Mr G Evans, Australian Chamber of Commerce and  Industry (ACCI), Transcript, 2 March 2007, p. 18. Back | 
                        
                        
                          | 8  | 
                          This database is compiled by a  renowned research centre at the University of Groningen, Netherlands. The PC  uses their data in Trends in Australian  Manufacturing,August 2003. An  alternative calculation estimates labour productivity in Australian  manufacturing as 60 per cent of the US level in 2003 (but falling over  time); Dolman, B., Parham, D. and Zheng, S. 2007, ‘Can  Australia Match US Productivity Performance?’, Productivity Commission Staff Working Paper, Canberra, p. 28. Back | 
                        
                        
                          | 9  | 
                          The difficulty of bridging the  productivity gap with the US  is discussed by Dolman, Parham and Zheng, 2007, who attribute much of the gap  to ‘fundamental factors of history and geography, including Australia’s  remoteness from large markets and its pattern of settlement’. Back | 
                        
                        
                          | 10  | 
                          There is limited scope to reduce labour  costs given the need to compete with the booming mining sector for workers. In  any case, for many manufacturers labour is not the dominant cost. Labour  accounts for around 10–30 per cent of the total value of production for most  Australian manufactured goods, compared to over 60 per cent for many services.  Labour accounts for a higher proportion in some industries such as ceramics and  footwear; around 15 per cent for car manufacturers and a much lower proportion  in industries such as coal, petrol, and leather products (where raw materials  is overwhelmingly the major cost). Back | 
                        
                        
                          | 11  | 
                          In 2005 the hourly wage for an Australian  worker in manufacturing was almost twice that of a similar worker in South  Korea, almost four times that for a worker in Taiwan, 28 times that for a  worker in mainland China and over 40 times that for a worker in India. Source:  IMD, World Competitiveness Yearbook 2006. Back | 
                        
                        
                          | 12  | 
                          PC, Trends  in Australian Manufacturing, August 2003, pp. 156–7.  Back | 
                        
                        
                          | 13  | 
                          It was established by the Queensland  Government, CSIRO and the Queensland University of Technology as the Queensland  Manufacturing Institute in 1993. Back | 
                        
                        
                          | 14  | 
                          National Manufacturing Forum, Exhibit, no. 22, p. 26. Back | 
                        
                        
                          | 15  | 
                          Dr J Wells, RMIT University, Transcript, 28 August 2006, pp. 26–7. Back | 
                        
                        
                          | 16  | 
                          The department also uses the results from  this as a way of measuring the overall performance of the manufacturing sector. Back | 
                        
                        
                          | 17  | 
                          Further information is available at <http://www.benchmarkindex.com.bi> Back | 
                        
                        
                          | 18  | 
                          DITR, Global  Integration: Changing Markets, New Opportunities, May 2007, p. 8. Back | 
                        
                        
                          | 19  | 
                          The latest is AS/NZS ISO 9001:2000 Quality  Management Systems – Requirements Standard. Back | 
                        
                        
                          | 20  | 
                          Prof M Dodgson, private capacity, Transcript, 19 October 2006, p. 16. Back | 
                        
                        
                          | 21 | 
                          The committee witnessed the Toyota production line at  the Altona plant. Japanese management practices in general became very  fashionable in the 1990s, ironically just as the Japanese economy went from  outperforming western economies to barely growing at all. Back | 
                        
                        
                          | 22 | 
                          Dr J Blakemore, Blakemore Consulting  International, Transcript, 29 August 2006, p. 47. Back | 
                        
                        
                          | 23 | 
                          Prof M Dodgson, private capacity, Transcript, 19 October 2006, p. 16. Back | 
                        
                        
                          | 24 | 
                          Mr P Conroy, Australian Manufacturing  Workers’ Union (AMWU), Transcript, 29   August 2006, p. 71–3. QMI Solutions also emphasised the importance  of adopting new technology: ‘Recognising that some 98% of the world’s  innovation occurs outside Australia, an important aspect of QMI’s technology  diffusion activities is the identification of technologies that are  particularly relevant to Australia’s diverse manufacturing sector’; Submission no. 10, p.1. Back | 
                        
                        
                          | 25 | 
                          Dr C Emerson MP, Transcript, 28   August 2006, p. 23. Back | 
                        
                        
                          | 26 | 
                          Dr J Wells, RMIT, Transcript, 28   August 2006, p. 23. Back | 
                        
                        
                          | 27 | 
                          CSIRO  media release 07/73, 1 May   2007. Back | 
                        
                        
                          | 28 | 
                          Increased  exports of manufactures is therefore desired as a sign of a more productive manufacturing  sector rather than being desired in its own right for some ‘mercantilist’  reason. It is consistent with the view expressed in the Industry Statement 2007  that ‘exports are not inherently more meritorious than goods sold on the  domestic market’; Department of Industry, Tourism and  Resources (DITR), Global Integration:  Changing Markets. New Opportunities, Background papers, no. 1, p. 21. Back | 
                        
                        
                          | 29 | 
                           J Edwards, ‘Export weakness, investment  strength’, CEDA Competing from Australia  Project Paper, no. 2, p. 3. Back | 
                        
                        
                          | 30 | 
                          A variety of costs may be eligible—certain  expenses incurred for an overseas representative; a marketing consultant; a  marketing visit; communications; free samples; trade fairs, seminars and  in-store promotions; promotional literature and advertising; and overseas  buyers visits. Back | 
                        
                        
                          | 31 | 
                          Austrade, Submission no. 18, p. 7. Back | 
                        
                        
                          | 32 | 
                          ACCI, Submission  no. 33, p. 25. Back | 
                        
                        
                          | 33 | 
                          For example, the Council of Textile and  Fashion Industries of Australia  advocated ‘raising of the EMDG cap to $60  million to better capture medium sized businesses’, Submission no. 17, p. 19. Back | 
                        
                        
                          | 34 | 
                          ACCI, Submission  no. 33, p. 25. Back | 
                        
                        
                          | 35 | 
                          Austrade, Review of the Export Market Development Grants Scheme, Looking at the EMDG Scheme, June 2005,  p. 26, known as the ‘Jollie Review’  after its facilitator,Mr Peter   Jollie. Back | 
                        
                        
                          | 36 | 
                          ACCI, Submission no. 33, p. 5. Back | 
                        
                        
                          | 37 | 
                          Ms Johnson from the Australian Electrical  and Electronic Manufacturers’ Association (AEEMA) explained: ‘I am sorry, I  haven’t got four months to spend on trying to convince Austrade that we should  get approved body status, so now we are spending money on a consultant to do  it. Really, it should be that I could sit down with Austrade and say: “We did  all this. I can’t tell you how the exports are going to increase but could you  take it on faith, as we’ve taken 20 companies to Taiwan and about 10 of them  have got contracts”.’ Transcript, 7 December 2006, p. 16. The EMDG Legislation Amendment Act 2006,  which comes into effect for new applicants on 1 July 2007, removes export earnings criteria  from the calculation of grant entitlements. Back | 
                        
                        
                          | 38 | 
                          DITR, Global  integration: Changing markets, new opportunities, 2007, p. 7. The Industry  Capability Network has an even higher estimate; that about two-thirds of world  trade is accounted for by the global supply chains of multinational corporations; Submission no. 6, p.3. Professor  J Houghton claims that ‘across OECD countries, intra-industry trade  accounted for almost 70 per cent of total manufacturing trade between 1996 and  2003’, but the share of Australia’s manufactures trade which is intra-industry  is much lower; ‘Global chains: Australia’s challenge in the evolving world  economy’, CEDA Competing from Australia Project  Paper, no. 1, pp. 9-10. The Industry Statement 2007also notes that foreign-owned firms account for about a third of  manufacturing output in Australia and a large proportion of exports; p. 17. Back | 
                        
                        
                          | 39 | 
                          DITR, 2007, pp. 17–8; and its Background Paper no. 4, p. 6. Back | 
                        
                        
                          | 40 | 
                          DITR, 2007, p. 3. Another term for  making use of a global supply chain is ‘off-shoring’, but this has a more pejorative  connotation. It is generally used about relatively unskilled activities being  transferred away from the domestic economy (but the expression ‘on-shoring’ is  not often used when activities are moving to the domestic economy). It is often  associated with another disparaging term ‘hollowing out’, referring to a  reduction in the scope of manufacturing operations within an economy. The Industry  Statement 2007 also noted that ‘feedback from industry through submissions and  consultations indicated that access to global supply chains was necessary to  capitalise on emerging opportunities and to access current knowledge and  technologies’; p. 18. Back | 
                        
                        
                          | 41 | 
                          Department of Foreign Affairs and Trade, Submission no. 38, p. 17. Back | 
                        
                        
                          | 42 | 
                          Ms C Hawkins, Cinnabar  Designs, Transcript, 8 February 2007, p. 3. Back | 
                        
                        
                          | 43 | 
                          Mr B McManus, NEC, Transcript, 15   March 2007, p. 19. Back | 
                        
                        
                          | 44 | 
                           Ms S Grierson MP, Transcript, 2   March 2007, p. 16. An example of an Australian company which has  long adopted this approach is Borg-Warner (now Dana) which in 1963 started manufacturing  two generic rear axle assemblies which would suit a wide range of Australian  made cars, and went on to export them around the world. Back | 
                        
                        
                          | 45 | 
                           Australian Industry Group (Ai Group), Submission no. 31, p. 12. Back  | 
                        
                        
                          | 46 | 
                          AMWU, Submission  no. 34, p. 61. Back | 
                        
                        
                          | 47 | 
                          Mr J Hawkins, the Treasury, Transcript, 1 December 2006. Back | 
                        
                        
                          | 48 | 
                          Ford Australia, Submission no. 4, p. 2. Back | 
                        
                        
                          | 49 | 
                          Austrade, Submission no. 18, p. 4. Back | 
                        
                        
                          | 50 | 
                          ICN, Submission  no. 6, p. 5. Similarly, the Industry Statement 2007 notes that an  international business survey ranks Australia only 99th of 125  economies for its presence in global supply chains; Global integration: Changing markets, new opportunities Background paper no 4, p. 8. Back | 
                        
                        
                          | 51 | 
                          Prof M Dodgson, private capacity, Transcript, 19 October 2006, p. 16. Back | 
                        
                        
                          | 52 | 
                          Mr D Cameron, AMWU, Transcript, 29   August 2006, p. 72. Similar concerns were expressed in a study by Cambridge University’s Institute for  Manufacturing, which warned ‘the common assumption that the intellectual high  ground of design and development can be retained locally, in the absence of a  local production capability, may not be valid’. Professor M Gregory et al, University of Cambridge  Institute of Manufacturing, ‘Making the Most of Production,’ Exhibit no. 20, p. 9. Back | 
                        
                        
                          | 53 | 
                          AMWU, Submission  no. 34, p. iii. Back | 
                        
                        
                          | 54 | 
                          Mr P Conroy, AMWU, Transcript, 29   August 2006, p. 81. Back | 
                        
                        
                          | 55 | 
                          Mr D Cameron, AMWU, Transcript, 29   August 2006, p. 81. Back | 
                        
                        
                          | 56 | 
                          Dr P Burn, Ai Group, Transcript, 29 August 2006, p. 8. Back | 
                        
                        
                          | 57 | 
                          Mr Conroy, AMWU, Transcript, 29 August 2006, p. 79. Back | 
                        
                        
                          | 58 | 
                          Austrade have forged Australian links into  international projects including the rebuilding of New Orleans post Hurricane Katrina. Back | 
                        
                        
                          | 59 | 
                          DITR, Global  integration: Changing markets, new opportunities, 2007, p. 25. Back | 
                        
                        
                          | 60 | 
                          DITR, Global  integration: Changing markets, new opportunities, 2007, p. 25. Back | 
                        
                        
                          | 61 | 
                          ICN, Submission  no. 6, p. 2. Back | 
                        
                        
                          | 62 | 
                          The ICN holds a nation-wide database of  Australian industry capability, volunteered by firms. Back | 
                        
                        
                          | 63 | 
                          SAMP Global. Back | 
                        
                        
                          | 64 | 
                          ICN, Submission  no. 6, p. 7. Back | 
                        
                        
                          | 65 | 
                          Refers to a new manufacturing  installation; not a purchase of share or of an existing facility. Back | 
                        
                        
                          | 66 | 
                          This argument was put, for example, by the  AMWU, who argued that Invest Australia should have a sharper focus on  greenfield investment; Submission no. 34,  p. 12. Such a focus was an important element in the Irish success; Professor R   Green, private capacity, Transcript, 14 November 2006, p. 19. Back | 
                        
                        
                          | 67 | 
                          Mr B Jones, Invest Australia, Transcript (Services inquiry), 1 December 2006, p. 34. Back |