| 2.1  | 
                        The automotive industry has played an important  role in the growth and development of modern industrial economies. It has supported  the growth of foundational industries, in steel, plastics and glass, and has  transformed societies and capital markets throughout the world.    | 
                      
                      
                        | 2.2 | 
                        After a century in this iconic role, the  automotive industry is now in transition. Where once the developed world  dominated automotive production, global trade is now being fuelled by emergent economies  such as China and Thailand. The competition for market share is fierce as production  exceeds demand and fluctuating oil prices have pushed mature automotive  manufacturers to review their forward production plans and investment strategies.                          | 
                      
                      
                        | 2.3 | 
                        Highly integrated with the fortunes of the  automotive industry, automotive component suppliers face mounting competitive  pressures to meet these new demands with increasing efficiency at an ever  decreasing price.   | 
                      
                      
                        | 2.4  | 
                        Australian component manufacturers face  additional challenges both ongoing and emergent such as: the geographical  challenges which increase costs and constrain access to markets; the limits of  the domestic market; the comparatively high price of labour, raw materials  (including oil); and the Australia dollar. All this is occurring in a shifting  and increasingly competitive global automotive market.    | 
                      
                      
                        | 2.5  | 
                        The global nature of the automotive market is a  key issue in consideration of the Australian automotive component manufacturing  industry. The domestic industry is responsive to the decisions of Australian  vehicle manufacturers, who are in turn responsive to the investment decisions  made by the global automotive industry. Consequently the Australian automotive component  industry is directed in part by decisions made by the upstream automotive  industry at a global level.   | 
                      
                                            
                      
                        | 2.6  | 
                        This is not to suggest that the future viability  of the Australian automotive component industry is beyond the control of the  local businesses that make up the industry. However, to forecast the future of the  Australian industry and understand domestic challenges it is necessary to  understand emergent trends in the global automotive industry.  | 
                      
                      
                        | 2.7 | 
                        This chapter provides an overview of the recent  history of the automotive industry and provides a context for the current and  future challenges facing the Australian automotive components industry.   | 
                      
                      
                        | 2.8  | 
                        It traces changes in trade patterns, devolution  of costs through the supply chain, and impacts of overproduction. It also  considers changing production models, off‑shoring and investment incentives which  are currently reshaping the global, hence the domestic, automotive industry.   | 
                      
                      
                        | 2.9  | 
                        Global automotive production strategies are also  undergoing significant change through developments such as industry  consolidation, joint ventures and alliances, global vehicle platforms and the  introduction of lean manufacturing models. These production changes have  significant implications for global competition between component manufacturers  who are pressured to achieve reduced costs and continuous improvement within  compressed timeframes.   | 
                      
                      
                         | 
                          | 
                      
                      
                        Profile of the global automotive industry  | 
                        
                      
                        Industry value and changing market dominance | 
                        
                      
                        | 2.10 | 
                        The automotive industry is a pivotal value-added  industry in the global economy directly providing almost nine million jobs  around the world.  Its value excluding  sales, spare parts dealerships and service, is estimated to be between 10 to 15  per cent of total world GDP.1                             | 
                      
                        
                      
                        | 2.11 | 
                        Automotive component suppliers make up the bulk  of value-added production in the automotive industry, accounting for more than  two thirds of added value. It is estimated that by 2015, this share will have  risen to almost 80 per cent.2                             | 
                      
                      
                        | 2.12 | 
                        The establishment of the European Union and the  progress of the international trade liberalisation agenda under the auspices of  the World Trade Organisation (WTO), Asia Pacific Economic Cooperation (APEC)  and various regional free trade agreements have seen traditional trade barriers  fall and opened new markets and opportunities for multinational growth.   | 
                      
                      
                        | 2.13  | 
                        Until 1960, motor vehicle manufacturing was  heavily concentrated in North America and Western Europe. The entry of Japanese manufacturers into  the market in the 1960s radically altered the competitive situation and, in  just 20 years, Japanese companies won control of 25 per cent of the global  market. Asia and Eastern   Europe have also entered the market as strong competitors—Asia now dominates 36 per cent of global production, Europe 33 per cent and North America  30 per cent.3                             | 
                      
                      
                        | 2.14 | 
                        Industry consolidation (discussed in more detail  later in the chapter) has led to 10 major automotive manufacturers producing 58  brands and accounting for ninety per cent of the global market. Producers in  China, India and Malaysia account for the remaining ten per cent. The Chinese  industry is rapidly growing—from 1997 to 2003 China’s automotive industry  accounted for three quarters of the Asia Pacific region’s total vehicle output,  and it continues to grow.4                             | 
                      
                      
                        | 2.15 | 
                        A significant threat to the automotive industry  in developed countries is the rise of manufacturing in developing economies.  Asian real exports in manufactures overall  (including automotive) have expanded by 15 per cent and now amount to around  thirty per cent of global trade. China’s manufacturing sector has grown on  average around 12 per cent a year since 1990, and now constitutes about 39 per cent  of its economy.5                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Foreign direct investment in developing nations | 
                        
                      
                        | 2.16 | 
                        An important indicator of the globalisation of  production in the automotive industry is the extent of foreign  direct investment (FDI) by major automotive producers in plants located in  external countries.6 Motor vehicle producers are among the  largest multinational companies in terms of investment in assets located  outside of their home markets—five of the world’s top eleven multinationals are  motor vehicle producers.7                             | 
                      
                      
                        | 2.17  | 
                        Automotive manufacturers are also consistently  ranked among the largest investors in developing economies. Within the last decade, this investment has contributed  substantially to the building of  automotive  production capacity in India, China and Eastern Europe: 
                      - The Indian automotive sector has received 7.81  per cent of the total foreign direct investment inflow, the highest share of  all manufacturing investment since economic liberalisation began in 1991.8 India increased output by 50 per cent over a six year period to 2003.9
 
                    - From 1996 to mid 2003, all 10 global motor  vehicle producers (MVPs) invested around $12 billion in Chinese automotive  operations.10 Chinese government joint ventures with major manufacturers contributed to the  tripling of the nation’s automotive industry output. The bulk of the increase  has been in the passenger car segment.11
 
                    - The opening of markets in Eastern Europe also  provides access to low- cost labour and has driven growth in intra-European  automotive trade. For example, German automakers Robert Bosch and VW have  invested heavily in Central and Eastern Europe. In addition, Korea’s Hyundai  Corporation has invested $1.3 billion in Zilina, Slovakia, to build a factory  for the manufacture of its Kia brand.12
   | 
                      
                      
                         | 
                          | 
                      
                      
                        Market forecasts and supply chain pressures  | 
                        
                      
                        | 2.18 | 
                        The changing profile of the automotive and  automotive component manufacturing sector is both driving change and being  driven by change. Market contraction and production shifts are a feature of  this changing profile.  | 
                      
                      
                        | 2.19 | 
                        The global automotive industry is currently  undergoing a profound structural transformation. This is reflected in the  extensive consolidations and alliances being formed between major existing  industry players and emerging companies in developing economies in Eastern  Europe and Asia.    | 
                      
                      
                        | 2.20 | 
                        There is increasing pressure on the motor  vehicle industry to become more competitive, more efficient, and more  innovative. At the same time, the race to build market share is being run on an  unfamiliar road, against a larger numbers of new competitors, and in a  changeable market conditioned by such factors as the high cost of fuel and  global warming.   | 
                      
                      
                        | 2.21  | 
                        It is the automotive component manufacturers who  have felt the brunt of these changes. The lean manufacturing revolution has  raised their exposure to market forces, increased their responsibility for  innovation and the associated staff training costs, and increased their  operating risks.    | 
                      
                      
                        | 2.22  | 
                        There are some suggestions that motor vehicle  manufacturers could work more collaboratively with supply chains to reduce some  of the cost downs13 pressure being exerted. This may mean adjusting approaches to supply management  and reconsidering operating models to address some endemic structural problems  in the industry and achieve a more integrated approach to component production,  supply and vehicle assembly.                              | 
                      
                      
                         | 
                          | 
                      
                      
                        Global overproduction | 
                        
                      
                        | 2.23 | 
                        The automotive industry in mature economies has  for some time now been showing strain, indicated by the round of industry  closures that have accompanied industry consolidations and off-shoring.  Restructuring in Europe in 2005 saw the loss  of hundreds of thousands of jobs and the closure of a significant number of  plants.14                              | 
                      
                      
                        | 2.24 | 
                        In August 2006, faced with higher petrol prices  and stiff competition from abroad, both General Motors (GM) and Ford are  struggling to restructure. Ford announced that it would slash fourth-quarter  production in North America to the lowest  level in 25 years.15                             | 
                      
                      
                        | 2.25 | 
                        Global overproduction appears to be driving the  aggressive demands for cost downs being passed on to automotive component  manufacturers. Automotive industry players in the short term place a great deal  of store on production of new models and innovative products to attract a  diminishing market share.  Global surveys  indicate, however, that the manufacturing sector overall expects that expanded  growth in demand will be the main generator of profits over and above product  or process innovation.16                             | 
                      
                      
                        | 2.26 | 
                        One of the most concerning features of the  contemporary global automotive market is therefore the combination of excess  production capacity and the diminishing demand for product. An estimated 86  million vehicles are built world wide and only 63 million sold. This coincides  with a slow down in population growth and saturation of developed markets in  Europe, United States and Japan.17                             | 
                      
                      
                        | 2.27 | 
                        Developing economies, especially in China and India,  potentially offer an expansion of the sales market as demand for cars in these  countries grows. However, studies indicate that development of these sales markets  is likely to be slow, due to limited disposable income of large sections of the  population.18 The situation is similar in Eastern Europe,  where the market is predominately for second hand vehicles.19                            | 
                      
                      
                        | 2.28 | 
                        In the meantime, it is expected that global  excess production will be fuelled by improved production capacity in these  countries. Consequently, while there may be growth in the global sales market  in the short to medium term, global oversupply is likely to remain.20                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Devolution of responsibilities in production tiers  | 
                        
                      
                        | 2.29 | 
                        The establishment of global vehicle platforms  (discussed below) offers opportunities for motor vehicle manufactures to  achieve significant economies in component purchasing, manufacturing and  design.21 This introduces a range of challenges and opportunities for automotive  component suppliers.                              | 
                      
                      
                        | 2.30 | 
                        Shared global platforms allow for the  development of interchangeable common components, enabling MVPs to let a single  global contract for supply of a particular automotive component or service.  The  purchase of components from one supplier under such a contract offers  significant economies of scale to the MVP, while subjecting suppliers to  greater global competition for the reduced number of contracts.22                             | 
                      
                      
                        | 2.31 | 
                        Automotive component suppliers fall into a  hierarchy of four production tiers. The tier a company falls into depends on  what stage of the production process they contribute to: 
                         - Tier 1 companies  hold a contract with a vehicle manufacturer to design and manufacture  production components for the vehicle manufacturer.
 
                         - Tier 2 manufacturers  make and supply a component which is incorporated by the Tier 1 supplier into  the production component delivered to the MVP. 
 
                        - Tier 3 comprises suppliers of materials or components  used by Tier 2 manufacturers.
 
                           - Tier 4 comprises suppliers of materials or  components used by Tier 3 manufacturers.23
   | 
                      
                      
                        | 2.32 | 
                        To service global platforms, tier one suppliers  of sub-assemblies are moving offshore. Second tier suppliers may follow to  establish regional production centres. Smaller or specialist component  suppliers must either follow, or become integrated into upper tier businesses  to survive.24                             | 
                      
                      
                        | 2.33 | 
                        Tier one suppliers are also consolidating and  forming partnerships and alliances with each other to achieve economies of  scale. These alliances are joint venture arrangements between component  manufacturers of products to assemble a product made of parts once sold  separately to the automotive vehicle manufacturer.   | 
                      
                      
                        | 2.34 | 
                        The outsourcing of intellectual property is one  consequence of these shifts in the organisation and operation of production  tiers. It has been suggested that progressive automotive manufacturers may in  the future limit their function to design specialists and marketers, giving  suppliers and retailers more independence and responsibility to develop and  trial innovations.25                              | 
                      
                      
                        | 2.35 | 
                        However, these shifts in production tier  responsibilities are not accompanied by opportunities for an increase in profit  share. A study conducted by the Centre of Automotive Research, University of  Michigan (USA), revealed that component suppliers are getting a smaller  percentage of the profits from the total value of assembled vehicle sales,  irrespective of year profitability.26                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Implications for Australian component manufacturers | 
                        
                      
                        | 2.36 | 
                        The rapidly changing market situation facing  component suppliers was a consistent concern raised throughout the inquiry. The  purchasing decisions of multinational companies are being centralised and so  are not taking into account local conditions and market impacts. This can place  significant and potentially unsustainable pressure on the domestic component  industry’s competitive pricing ability and capacity to supply.  | 
                      
                      
                        | 2.37 | 
                        The Australian Automotive Aftermarket  Association (AAAA) told the Committee: 
                          With the increased  globalisation and declining profit margins in the automotive industry, local  subsidiaries of international vehicle manufacturers are increasingly moving to  global sourcing of products to reduce costs and maintain profitability. This  change in purchasing strategy is being driven by head offices in Europe, Asia and the United States  and is based on current commercial realties rather than on the long term  sustainability of the local industry. Global sourcing policies are also  effectively “locking out” smaller suppliers with no international linkages  as there is often a requirement to have the capacity to supply the same (or  similar) products to other manufacturing locations around the world.27                          | 
                      
                      
                        | 2.38 | 
                        The Committee heard concerning reports about global  price matching practices of MVPs resulting in ruthless cost downs and contract  letting methods that seriously undermine the business confidence of component  manufacturers. While the Committee received little formal evidence on these  practices, the evidence received both formally and anecdotally is serious.
                                                     | 
                      
                      
                        | 2.39 | 
                        Global price matching has led to MVPs requiring  locally based suppliers to match developing economies ‘factory gate’ or  ‘ex-works’ prices (without including transportation and storage costs).28 This results in annual cost downs to local suppliers and is not the best  interests of a long term diversely competitive industry. These practices are  unsustainable in the long-term and lead to significant contract, and therefore  employment, uncertainty. 
                                                    | 
                      
                      
                        | 2.40 | 
                        There are a number of ‘industry culture’ issues  which are of concern to the Committee. While it is difficult for the Government  to directly influence these practices, greater discussion of the industry  culture, sustainability and a future vision is provided in the concluding  chapter.                          | 
                      
                      
                        | 2.41 | 
                        The Ai Group Survey of Victorian automotive  component manufacturers found that: 
90 per cent of local suppliers had lowered selling prices to  Original Equipment Manufacturers [MVPs] by an average of 5.5 per cent in the  previous year and further significant cuts were expected in the next two years.29                           | 
                      
                      
                        | 2.42 | 
                        This contract management process leads to an  insecure trading environment that is a significant disincentive to continued  multinational investment in Australia. Mr Bob Franklin, Managing Director of  Autoliv Australia, a first tier multinational supplier, told the Committee: 
What I am seeing when I have discussions with my head office  at the moment is a situation whereby they are saying that the risk profile in  Australia is too high, there are insufficient numbers of contracts available  for us to win in Australia, there is a lack of guarantees about contracts and  there is a lack of surety of holding those contracts for the long term which  suggests to them that, if they are going to make an investment in a productive  capacity, they would be better off making those investments in countries that  have a lower risk profile than what we have here today.30                           | 
                      
                      
                        | 2.43 | 
                        The Committee was told that MVP contract  management practices militate against long term planning and hence capacity to  invest in research and development (R&D),  putting the viability of local suppliers at  risk: 
there is great reluctance on the part of the local MVPs to  agree to long-term contracts, reserving the right to resource at any time for  any reason. This greatly limits the components suppliers’ willingness to invest  in R&D and to commit to new capital investment, thus undermining the  viability of the local parts sector in the long term. Naturally, this  contractual uncertainty is reflected in heightened caution towards the sector  from lending institutions. It would seem to us that there is scant regard for  any notion of mutual obligation in return for substantial assistance from the  public purse, certainly in respect of the previously mentioned issues.31                          | 
                      
                      
                        | 2.44 | 
                        The issue of accountability for public investment  is discussed later in the report. However, the lack of security in contracts  combined with consistent cost downs and the failure of MVPs to recognise the  increasing cost of raw materials is having a serious negative impact on the  overall security of the industry.                         | 
                      
                      
                        | 2.45 | 
                        The effects of these policies were seen in the  August 2006 crisis facing Ajax Engineered Fasteners. As the company struggled  to meet operational costs in an environment of increasing commodity prices,  there was no recognition of this in MVP contracts and the company was placed  into administration. The potential closure placed the automotive industry into  chaos, threatening stand down for thousands of employees across the industry.                         | 
                      
                      
                        | 2.46 | 
                        A rescue package was eventually sourced from  MVPs.32 The Committee considers this demonstrates a reasonable acknowledgment of the  responsibilities that the automotive industry holds across the component supply  chain.                             | 
                      
                      
                        | 2.47 | 
                        Increasingly it appears that MVP purchasing  decisions are based on price alone, although the Committee notes that GM Holden  rejects this notion. In response to the above issues GM Holden informed the  Committee: 
In sourcing new business to suppliers, GM Global Purchasing  and Supply Chain consistently base their decisions on an overall business case  considering a supplier's performance and competitiveness in the areas of  quality, service, technology and price. Any interpretation of this policy that  suggests a single focus on price is clearly incorrect. All four factors drive  our sourcing decisions and ongoing performance measurement. The way we look at  it, high performing suppliers who demonstrate excellence in quality, service,  technology and price contribute to GM Holden's strategic competitive advantage  within the market in which we operate.33                          | 
                      
                      
                        | 2.48 | 
                        Another consequence of global sourcing policies  is the necessity for local manufacturers to have the capacity to supply  globally. This is largely only possible if manufacturers are able to link into  global supply chains, which requires the commitment of MVPs to supporting the  local components industry and facilitating linkages into the global supply  chain. | 
                      
                      
                         | 
                          | 
                      
                      
                        Off-shoring and outsourced production   | 
                        
                      
                        | 2.49 | 
                        As discussed, diminishing sales markets and  resultant pressures on supply chains are severely impacting on local component  manufacturers. A further significant impact is felt from the moves to  off-shoring and out-sourced production. Off-shoring in manufactures has been  described as ‘the third wave of globalisation’. The effect on the automotive  industry has been profound. Off-shore activity may be realised through: 
                       - the use of imported components or material in  domestic-based production; or
 
                      - the production of finished goods overseas.34
                              | 
                      
                      
                        | 2.50 | 
                        While these activities may appear to be  discrete, off-shoring in the automotive sector supports a complex exchange of  products at various stages in the production chain between suppliers and  assemblers either co-located or at different points around the globe. In this  sense it is not simply a matter of investing in infrastructure in another  country.   | 
                      
                      
                        | 2.51 | 
                        In 2006 KPMG’s Economic Intelligence Unit  conducted a world-wide survey to ascertain the affects of globalisation on the  manufacturing sector. It found that three main considerations were taken into  account by manufacturers when making decisions about off-shoring: 
                       - increased market access and penetration;
 
                        - lower labour costs; and
 
                      - incentives offered by nations to attract  off-shore investment and innovation.35
                              | 
                      
                      
                        | 2.52 | 
                        Established brands are increasingly off-shoring  activities by investing in automotive plants as well as sourcing components in  developing countries to gain cost and other advantages. Emergent automotive  industries in Asia, but also in the Middle East and Eastern Europe, are feeding  into this global trade.   | 
                      
                      
                        | 2.53 | 
                        Following its accession to the WTO in 2003,  China has capitalised on FDI to become a major importer and exporter. China now  imports automotive components from other locations for assembly, and exports finished  vehicles and components back to supplier assembly plants in other countries.36                             | 
                      
                      
                        | 2.54 | 
                        The potential to outsource the manufacture or  assembly of vehicle components depends on the position of the component in the  production chain.  Some automotive  component products can easily be shipped across national frontiers and trade  areas whereas other functions, for example engine assembly, must be closely  integrated with the assembly process for inventory control purposes.37                             | 
                      
                      
                        | 2.55 | 
                        Centralised MVP purchasing policies are reported  to be driving the outsourcing trends for component supply. Ford and GM mandate  for price comparison with suppliers operating in low cost countries. Toyota has  a policy to develop local supply chains, nevertheless advises that competitive  pricing and quality in production is a significant factor in determining which  of the Toyota subsidiaries around the world will attract parent company  investment.38                             | 
                      
                      
                        | 2.56 | 
                        These global purchasing  approaches impact on the development decisions made by MVPs and suppliers.   | 
                      
                      
                         | 
                          | 
                      
                      
                        Increased market access  | 
                        
                      
                        | 2.57 | 
                        A fundamental driver of the off-shoring trend in  automotive manufacturing is the desire to increase global market share through  reduced costs and/or increased market penetration.   | 
                      
                      
                        | 2.58 | 
                        In the automotive industry, the success and  sustainability of any enterprise has traditionally been based on the strength  of local markets, and on the capacity of the domestic industry to retain market  share.39                             | 
                      
                      
                        | 2.59  | 
                        As discussed previously, the demand for cars has  ‘bottomed out’ in the developed world, where population growth is in stasis or decline  and market saturation has been reached. Meanwhile, projected population and  economic growth in China and India supports hopes that in time these countries  will become the world’s largest vehicle markets, with China soon replacing  Japan as the second largest market after the United States.40                              | 
                      
                      
                        | 2.60  | 
                        The KPMG survey found that, overall, thirty per  cent of companies world-wide are looking to Asian markets to drive growth.41 Asia is a future market for sales adding to its attractiveness as a location  for component manufacturing.  The KPMG  survey found that: ‘manufacturing has to be where the markets are. Countries  are saying, if you want to sell it in our country, you have to come and make it  here.’42                            | 
                      
                      
                        | 2.61  | 
                        Bilateral trade agreements may also indirectly  drive decisions to off‑shore developments to particular countries. Japanese  automotive companies have recently expanded operations into Thailand,  thereby gaining zero tariff entry into the Australian market through the  Australia–Thailand Free Trade Agreement.43                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Lower labour cost  | 
                        
                      
                        | 2.62  | 
                        Labour costs in the automotive industry are  affected by a range of factors, including international trade and investment  rules, domestic economic conditions, workplace relations, environmental and  other legislation or policies.  | 
                      
                      
                        | 2.63  | 
                        One of the principal, and most contentious,  motivations for off‑shoring has been to obtain cost advantages from lower wage  structures in developing countries. Labour costs in lower cost countries is the  issue most affecting the competitiveness of the automotive components industry  (see Figure 2.1).  | 
                      
                      
                        Figure 2.1: Issues most  affecting automotive component manufacturer competitiveness 
                           
                            
                          Source: Ai Group, FAPM and KPMG, The Victorian Automotive  Components Industry: Competitiveness, Profitability and Future Strategies, March 2005, p. 17. Percentage of respondents  listing as issue of concern, based on a survey of 70 component suppliers,  supplemented by 30 interviews of company executives.        | 
                        
                      
                        | 2.64  | 
                        Automotive manufacturers in mature markets have  sought to achieve cost efficiencies by relocating operations to the fastest  growing markets, which offer significantly cheaper labour in less regulated  working environments.44                             | 
                      
                      
                        | 2.65 | 
                        While cost saving on labour is a clear driver  for moving component manufacturing off-shore, there is some speculation that  this may only provide a short term gain. For example, China has faced two economic downturns over the  past 25 years, and another slowdown is considered inevitable at some point. Expectations  are that a major exchange rate realignment and revaluing the Chinese currency  is required to address underlying trade imbalances. Such a re‑evaluation would  dramatically increase the cost of doing business in China.45                             | 
                      
                      
                        | 2.66  | 
                        Lower labour costs in developing countries must  also be balanced with the lack of available skills in some off-shore locations.  A KPMG survey of automotive manufacturers found that around 45 per cent of  respondents considered acquiring employees with the right skills the most  pressing challenge after labour costs.46                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Investment and innovation | 
                        
                      
                        | 2.67  | 
                        Market shifts, over-production, cost downs,  off-shoring and outsourced production are placing mounting competitive  pressures within the global automotive industry.   | 
                      
                      
                        | 2.68 | 
                        With global trade liberalisation, free trade  agreements, national advantages are diminished and international competition  becomes more intense. As a result, incentives may be needed to attract MVPs and  tier one suppliers to set up, or remain onshore.  | 
                      
                      
                        | 2.69 | 
                        Many nations offer a mix of tax concessions,  including R&D concessions and other industry incentives. While these  incentives apply generally to manufacturing, in some instances they have had a  profound impact on investment decisions and locations in the automotive  industry.   | 
                      
                      
                        | 2.70 | 
                        Figure 2.2 provides a summary of the global  investment incentives for the manufacturing sector. However, there ‘is a need  to better understand the diversity of tax incentives offered by other countries  (particularly among developing economies) as these can have a major effect on  the effective tax rate.’47 The Australian Automotive Competitiveness and Investment Scheme (ACIS) forms a  significant part of the other incentives offered to attract global automotive  manufacturing investment in Australia. ACIS is discussed further in Chapter 5.
                                                     | 
                      
                      
                        Figure 2.2 Global manufacturing investment incentives 
                           
                            
                          Source Ai  Group, Manufacturing  Futures—Achieving Global Fitness, April 2006, Appendix A | 
                        
                      
                         | 
                          | 
                      
                      
                        Value of innovation | 
                        
                      
                        | 2.71  | 
                        Investment in R&D for product innovation is  regarded as the best means by which automotive manufacturers can gain a  competitive edge in the current trading environment—not only to hedge against  pressures from low cost countries but also to expand opportunities into new  markets.   | 
                      
                      
                        | 2.72 | 
                        Developments in Europe  have been underpinned by the outsourcing of high value design and engineering  functions. This has led to the growth of an industry segment providing design  and engineering services, which has the capacity to develop and build the small  volume niche vehicles that are popular with European consumers.48                             | 
                      
                      
                        | 2.73 | 
                        A strong  R&D and innovation profile is powerful attraction for foreign investment  and this is being recognised in European countries facing similar outsourcing  pressures to Australia.  For example, Sweden’s automotive industry has a strong R&D profile,  developed with substantial government and industry support.  High government and industry investment in  research has resulted in Sweden being viewed by the global automotive industry  as a leading location for R&D and new product testing.49                            | 
                      
                      
                        | 2.74  | 
                        Changes in international safety and environmental  standards are driving future automotive innovation. It has been estimated that  the automotive industry will have to increase R&D spending on technology by  20 per cent to meet new legislative requirements and competing demands.50                             | 
                      
                      
                        | 2.75 | 
                        Escalating high fuel costs have also prompted  greater awareness of the greenhouse impact of cars and the development of  hybrid technologies.51                             | 
                      
                      
                         | 
                          | 
                      
                      
                        The emergence of new production strategies   | 
                        
                      
                        | 2.76 | 
                        A further challenge facing the automotive  component sector is the emergence of new production strategies in the  automotive industry. Automotive producers continue to evolve and refine production  strategies to remain competitive as the automotive market diversifies. These  strategies are interrelated and comprise: 
                      - industry consolidation and the formation of  alliances;
 
                      - the development of global vehicle platforms; and
 
                      - the adoption of lean manufacturing production  processes.
   | 
                      
                      
                         | 
                          | 
                      
                      
                        Industry consolidation and alliances | 
                        
                      
                        | 2.77 | 
                        As the global market becomes more dynamic,  gaining an economy of scale is critical. Over the previous two decades the  industry has seen an acceleration in large automotive business consolidations.  Well known brands have been ‘bundled’ and a relatively new trend towards  partnerships and joint ventures, particularly with partners in Eastern Europe and Asia,  has evolved.52                             | 
                      
                      
                        | 2.78 | 
                        Historically, consolidation and merger has been  a major strategy used by MVPs to improve competitiveness and offset the costs  of developing new technologies.   | 
                      
                      
                        | 2.79 | 
                        In recent years the trend towards the formation  of alliances and partnerships has evolved as a useful tool to aid market  penetration, and to avoid tariffs and other trade barriers when entering new  markets. The European passenger car industry now consists of just nine  companies while Japan’s penetration of international markets has been based on  successful joint ventures.53                             | 
                      
                      
                        | 2.80  | 
                        Alliances are also a key feature of the capacity-building  of China’s  fast growing automotive industry. Under the ‘Trading the Market for Technology’  policy, the Chinese government requires that foreign companies form 50:50 joint  ventures to produce vehicles locally. Foreign investors routinely face competition  from their own joint venture partners which produce similar products under  their own brands.54                             | 
                      
                      
                        | 2.81 | 
                        Chinese industry participants have now achieved  the scale necessary to enter the global mergers and acquisitions market,  entering Korea in 2004 and Europe in 2005.55                             | 
                      
                      
                        | 2.82 | 
                        While there are indications that economy of  scale may not secure success in 21st century automotive markets, it is  nevertheless expected that amalgamations will continue to feature in the  industry. According to one forecast the number of independent vehicle  manufacturers worldwide will fall from 13 in 2002 to 10 or less in 2015, based  on the projected rate of the formation of alliances.56                            | 
                      
                      
                         | 
                          | 
                      
                      
                        Global vehicle platforms  | 
                        
                      
                        | 2.83 | 
                        Mergers and alliances among automotive producers  have enabled the establishment of ‘global’ vehicle platforms.   | 
                      
                      
                        | 2.84 | 
                        Traditionally, the passenger vehicle market was  segmented according to vehicle size, with luxury lines falling in a wedge at  the top of the size and price ratio.57                             | 
                      
                      
                        | 2.85 | 
                        Following the oil shock in the 1970s, the market  transformed. Car products were no longer differentiated on size and vertical  product class structures. MVPs built market share and badge loyalty by the  production of many and different models. Based on only two or three basic  engine blocks, each model variant required supply of individual components.58                             | 
                      
                      
                        | 2.86  | 
                        The development of common production platforms  allowed for the use of interchangeable common components for a range of brands  and the letting of single global contracts for their supply.59                             | 
                      
                      
                        | 2.87 | 
                        From 2002 to 2008 the number of global platforms  with capacity exceeding one million units per year is expected to increase from  five to fifteen.60 This  production strategy allows for significant economies of scale in production and  supply. It also requires component producers to increase capacity for  large-scale production to supply worldwide markets.61                            | 
                      
                      
                         | 
                          | 
                      
                      
                        Changing manufacturing models  | 
                        
                      
                        | 2.88  | 
                        The automotive industry has always been at the  forefront of new industrialisation processes, including management and  organisational techniques. The transforming production models of the late  twentieth century have beencontinuous  improvement strategies (kaizen), ‘lean  manufacturing’ organisational techniques and ‘pull’ or just-in-time production  (kanban).62                             | 
                      
                      
                        | 2.89 | 
                        Traditional volume production, as devised by Henry  Ford, was achieved by top down management, discrete task allocation and high  levels of vertical integration (ownership of the entire product chain).  By contrast, the theory of lean manufacturing  values quality and customisation over volume through networked supply chains.63                             | 
                      
                      
                        | 2.90 | 
                        Lean manufacturing can reduce risk and provides  time management and efficiency gains while retaining the flexibility to respond  to changing customer values and tastes.64                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Supply chain implications of lean manufacturing    | 
                        
                      
                        | 2.91  | 
                        For component suppliers, a significant  by-product of the adoption of lean manufacturing for the automotive industry has  been the devolution of former in-house production tasks down the supply chain.65                             | 
                      
                      
                        | 2.92  | 
                        Only 25 per cent of value in a vehicle is now controlled  by automotive assemblers. Accordingly, suppliers are carrying more  responsibility and risk in the production process than previously. Tier one  suppliers may design, manufacture and supply sub-assemblies, carrying a  significant management role in the supply chain coordination.66                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Take-up of lean manufacturing   | 
                        
                      
                        | 2.93 | 
                        While lean manufacturing philosophies have  clearly been a revolutionising force in the automotive industry the model has  not been adopted wholesale.67                              | 
                      
                      
                        | 2.94 | 
                        Germany and Japan, for example, have fostered  extremely productive systems based on collaborative work practices, whereas  other countries with different or more adversarial workplace relations systems  encounter problems. Fiat found obstacles, for example, in setting up their  automotive venture in India because of labour market regulations.68                             | 
                      
                      
                        | 2.95  | 
                        Lean manufacturing models demand increased  flexibility and the adjustment of orders and provision of product within short  time frames. The process results in a low tolerance of error, minimal inventory  stock and tight operating margins.69                             | 
                      
                      
                        | 2.96 | 
                        Most suppliers regard adopting ‘just in  time’ lean manufacturing methods as essential to meet the demands of the  globally competitive automotive industry: 
                          Any company that is not practicing lean  manufacturing right now will fold. It is absolutely essential. Reliance on old  manufacturing techniques is not an option.70                             | 
                      
                      
                         | 
                          | 
                      
                      
                        Finding a position in the global marketplace | 
                        
                      
                        | 2.97  | 
                        Clearly, the Australian automotive components  industry is facing challenges beyond domestic market forces. The global  automotive industry provides more competition than every before, largely due to  the changing market dominance of new manufacturing countries.  | 
                      
                      
                        | 2.98 | 
                        Automotive component manufacturers have borne  the brunt of the changes produced as a result of global over-production and the  devolution of responsibilities along supply chains. This changing marketplace  coupled with the move to global purchasing by motor vehicle manufacturers has  placed significant pressure on the local industry.  | 
                      
                      
                        | 2.99  | 
                        To compete, Australian component manufacturers  are seeking export markets and, increasingly, are off-shoring and outsourcing  their manufacturing to take advantage of low labour costs and so have the  capacity to supply global vehicle production lines.  | 
                      
                      
                        | 2.100 | 
                        Notwithstanding these export consideration,  component manufacturers are still dependent on the viability of the local  vehicle manufacturers. Consequently, any downturn in production and employment  at the major manufacturers can have serious negative effects on the component  industry.  | 
                      
                      
                        | 2.101 | 
                        The next chapter addresses the component  sector’s relationship with MVPs, employment profile and training practices.  | 
                      
       
      
       
                        
                          | 1  | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re–engineering the  Global Automotive Industry, Cambridge University, 2004,  p. 91, and ‘The Global Picture’, The Automotive Industry—an Integral Part of  Innovative Sweden, The Ministry of Industry, Employment and Communications,  Sweden, October 2005, p. 23. Back  | 
                        
                        
                          | 2  | 
                            ‘The Global Picture’, The Automotive Industry—an Integral Part of Innovative Sweden, The  Ministry of Industry, Employment and Communications, Sweden, October 2005, p.  24. Back  | 
                        
                        
                          | 3  | 
                          ‘The Global Picture’, The Automotive Industry—an Integral Part of Innovative Sweden, The  Ministry of Industry, Employment and Communications, Sweden, October 2005, p.  23. Back | 
                        
                        
                          | 4  | 
                          ‘Extinction of the Predator, Special  Report: the Global Car Industry’, The  Economist, 10 September 2005, p. 61, and International Metalworker Federation, IMF Auto Report 2004, Geneva  Switzerland, 2004, pp. 43–44. Back | 
                        
                        
                          | 5  | 
                          World Trade Organisation, World Trade Developments in 2004 and  Prospects for 2005, p. 2 and Australian Industry Group, Manufacturing Futures—Achieving Global  Fitness, April 2006, p. 29. Back | 
                        
                        
                          | 6  | 
                          OECD Foreign direct investment  statistics guidelines require that a foreign investor must have at least ten  per cent ownership in an enterprise and can have an effective voice in the  management of the enterprise. OECD, Recent  Trends in Foreign Direct Investment in OECD Countries,  2000, p. 26,   accessed 28 June 2006,  <www.oecd.org> . Back | 
                        
                        
                          | 7  | 
                          United  Nations Conference on Trade and Development (UNCTAD), 2000, data cited  in A.  Goldstein, ‘Local Entrepreneurship  in the Era of E-Business: Early Evidence from the Indian Automobile Industry’, International  Conference on ‘E-commerce for Development: Reviewing Early Experiences, Comparing  New Ideas’, co-organised by the OECD Development Centre, Paris, France and the  School of Development, Innovation and Change, University of Bologna, 4-5 May  2001, p. 2. Back | 
                        
                        
                          | 8  | 
                          A. Goldstein, ‘Local Entrepreneurship in  the Era of E-Business: Early Evidence from the Indian Automobile Industry’,  International Conference on ‘E-commerce for Development…’, OECD Development  Centre, Paris, France and University of Bologna,  4‑5 May 2001, p. 2. Back | 
                        
                        
                          | 9  | 
                          International  Metalworker Federation, IMF Auto Report  2004, Geneva, Switzerland, 2004, p. 43. Back | 
                        
                        
                          | 10  | 
                          International  Metalworker Federation, IMF Auto Report  2004, Geneva, Switzerland,  2004, p. 25. Back | 
                        
                        
                          | 11  | 
                          International Metalworker Federation, IMF Auto Report 2004, Geneva,  Switzerland, 2004,  p. 43. Back | 
                        
                        
                          | 12  | 
                          ‘Europe  Circles the Flat Tax’, Business Week,  26 Sept 2005, p.  29. Back | 
                        
                        
                          | 13  | 
                          ‘Cost downs’ refers to the now standard  pricing practice whereby the price a manufacturer pays for a component falls by  up to eight per cent for every year of the potentially five year contract. Back | 
                        
                        
                          | 14  | 
                          Details cited in European Foundation for  the Improvement of Living and Working Conditions, Trends and  Drivers of Change in  the European Automotive  Industry: Four  Scenarios, European Monitoring Centre   on Change, Dublin, Ireland, 2004, p. 11. Back | 
                        
                        
                          | 15  | 
                          J.  Vail, ‘America  Gets its Wheels’, Knowledge News, 26 August 2006. Back | 
                        
                        
                          | 16  | 
                          KPMG, Industrial  and Automotive Products, Globalisation  and Manufacturing, 2005, p. 20. Back | 
                        
                        
                          | 17  | 
                          Excess capacity in Europe has been  estimated at 30 per cent. Trends and Drivers  of Change in the European Automotive Industry: Four Scenarios, European  Foundation for the Improvement of Living and Working Conditions, European  Monitoring Centre  on Change, Dublin,  Ireland, 2004, p. 6; G. P. Maxton and J. Wormald, Time for a Model Change: Re-engineering the Global Automotive Industry, Cambridge University Press, 2004, pp. 5–7. Back | 
                        
                        
                          | 18  | 
                          ‘Extinction of the Predator, Special  Report: the Global Car Industry’, The  Economist, 10 September   2005, p. 61 and see Balancing  the Risks: Building Australia’s Economic Resilience, Australian Industry  Group, December 2005, p. 1. Back | 
                        
                        
                          | 19  | 
                          Data from Polish research in May 2004  found that roughly 50 per cent of all cars in Poland are more than 11 years old,  and used car imports into Poland,  principally from Germany,  increased for the first half of 2004, as prices fell to levels of  affordability. International Labour Office, Automotive  Industry Trends Affecting Component Suppliers, Geneva, 2005, p. 49. Back | 
                        
                        
                          | 20  | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re-Engineering the  Global Automotive Industry, Cambridge   University Press, 2004,  pp. 16, 128, 132. Back | 
                        
                        
                          | 21 | 
                          International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, p. 47. Back | 
                        
                        
                          | 22 | 
                          Department of Employment and Workplace  Relations (DEWR), Submission No. 11,  p. 8. Back | 
                        
                        
                          | 23 | 
                          Victorian Government, Submission No. 24, p. 4. Back | 
                        
                        
                          | 24 | 
                          Australian Industry Group, Manufacturing Futures—Achieving Global  Fitness, April 2006, p. 29. Back | 
                        
                        
                          | 25 | 
                          ‘Extinction of the Predator, Special  Report: the Global Car Industry’, The  Economist , 10 September   2005, p. 64. Back | 
                        
                        
                          | 26 | 
                          ‘Estimating the New Automotive Value  Chain’, The Centre of Automotive Research (CAR), Alatarum Institute, University  of Michigan, November 2002, quoted G. P. Maxton and J. Wormald, Time for a Model Change: Re-Engineering the  Global Automotive Industry, Cambridge University Press, 2004, p. 161. Back | 
                        
                        
                          | 27 | 
                          Australian Automotive Aftermarket  Association (AAAA), Submission No. 18, pp. 4–5. Back | 
                        
                        
                          | 28 | 
                          DEWR, Submission  No. 11, p. 6. Back | 
                        
                        
                          | 29 | 
                          Cited by DEWR, Submission No. 11, p. 6. Back | 
                        
                        
                          | 30 | 
                          Mr R. Franklin, Autoliv Australia, Transcript of Evidence, 26 June 2006, p. 54. Back | 
                        
                        
                          | 31 | 
                          Mr D. Hugo, Flexdrive Cables Australia Pty  Ltd, Transcript of Evidence, 26 June 2006, p. 11.  Back | 
                        
                        
                          | 32 | 
                           A. Trounson, ‘Holden Flies in Parts to  Save Jobs’, in The Australian, p. 1. Back | 
                        
                        
                          | 33 | 
                          Mr K. Acquilina, National Manager,  Government Relations and Public Policy, GM Holden. Correspondence dated 12 July  2006. Back | 
                        
                        
                          | 34 | 
                          Australian Industry Group, Manufacturing Futures—Achieving Global  Fitness, April 2006, p. 29. Back | 
                        
                        
                          | 35 | 
                          KPMG, Industrial  and Automotive Products, Globalization and Manufacturing, January 2006, p.  17. Back | 
                        
                        
                          | 36 | 
                          Data in ‘FDI into OECD Countries Jumps 27%  in 2005’, OECD: Building Partnerships for  Progress, accessed 28 June 2006, <www.oecd.org>. Back | 
                        
                        
                          | 37 | 
                          International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, p. 78. Back | 
                        
                        
                          | 38 | 
                          Victorian Government, Submission No. 24, p. 8; Toyota  Australia, Submission No. 9, pp. 4‑5. Back | 
                        
                        
                          | 39 | 
                          The  Automotive Industry—an Integral Part of Innovative Sweden, The Ministry of  Industry, Employment and Communications, Sweden, October 2005, p. 15. Back | 
                        
                        
                          | 40 | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re-engineering the  Global Automotive Industry, Cambridge   University Press, 2004, pp.  6–7; ‘Extinction of the Predator, Special Report: the Global Car Industry’, The Economist, 10 September 2005, p. 61 Back | 
                        
                        
                          | 41 | 
                          KPMG, Industrial  and Automotive Products Globalisation  and Manufacturing, October 2005, p. 6. Back | 
                        
                        
                          | 42 | 
                          KPMG, Industrial  and Automotive Products, Globalisation  and Manufacturing, October 2005, p. 9. Back | 
                        
                        
                          | 43 | 
                          Victorian Government, Submission No. 24, p. 8. Back | 
                        
                        
                          | 44 | 
                           International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, p. 51 and Australian Industry Group, Manufacturing  Futures—Achieving Global Fitness, April 2006, p. 29. Back | 
                        
                        
                          | 45 | 
                          The Hon. Alexander Downer, Minster for Foreign  Affairs, ‘Australia, Asia and Global Drivers for Change’, Speech: Future  Summit 2006, Brisbane, 12 May 2006;  KPMG, Industrial and Automotive  Products Globalisation and  Manufacturing, October 2005, p. 11. Back | 
                        
                        
                          | 46 | 
                          KPMG, Industrial  and Automotive Products Globalisation and Manufacturing, October 2005,  pp. 10–11. Back | 
                        
                        
                          | 47 | 
                          Australian Industry Group, Manufacturing Futures—Achieving Global  Fitness, April 2006, p. 60. Back | 
                        
                        
                          | 48 | 
                          European Foundation for the Improvement of  Living and Working Conditions, Trends and  Drivers of Change in the European Automotive Industry: Four Scenarios,  European Monitoring Centre on Change, Dublin,   Ireland, 2004,  p. 3. Back | 
                        
                        
                          | 49 | 
                          The Automotive  Industry: an Integral part of Innovative Sweden, The Ministry of Industry,  Employment and Communications, Sweden, October 2005, p. 9. Back | 
                        
                        
                          | 50 | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re-engineering the  Global Automotive Industry, Cambridge   University Press, 2004, p.  255. Back  | 
                        
                        
                          | 51 | 
                          Mr David   Lamb, CSIRO, Submission No. 28,  p. 3. Back | 
                        
                        
                          | 52 | 
                          International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, p. 67. Back | 
                        
                        
                          | 53 | 
                          ‘The Global Picture’, The Automotive Industry – an Integral Part of Innovative Sweden,  The Ministry of Industry, Employment and Communications, Sweden, October 2005,  pp. 24‑25. Back | 
                        
                        
                          | 54 | 
                           J.   Sun, ’China:  the Next Global Auto Power?’, Far Eastern  Economic Review, March 2006, pp. 37–39. Back  | 
                        
                        
                          | 55 | 
                          ‘Detroit’s  Loss is China’s  Gain in Great Drive Forward’, Australian  Financial Review, 22 June   2006, p. 68 and J.  Sun, ’China: the Next  Global Auto Power?’, Far Eastern Economic  Review, March 2006, p. 40. Back | 
                        
                        
                          | 56 | 
                          ‘Extinction of the Predator, Special  Report: the Global Car Industry’, The  Economist, 10 September   2005, p. 62 and  International  Labour Office, Automotive Industry Trends  Affecting Component Suppliers, Geneva, 2005, p. 64. Back | 
                        
                        
                          | 57 | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re-Engineering the  Global Automotive Industry, Cambridge   University Press, 2004,  p. 23. Back | 
                        
                        
                          | 58 | 
                          G. P Maxton and J. Wormald, Time for a Model Change: Re-Engineering the  Global Automotive Industry, Cambridge   University Press, 2004, pp. 22‑23. Back | 
                        
                        
                          | 59 | 
                          DEWR Submission  No. 11, p. 8. Back | 
                        
                        
                          | 60 | 
                           International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, pp. 46–47. Back | 
                        
                        
                          | 61 | 
                          International Labour Office, Automotive Industry Trends Affecting  Component Suppliers, Geneva,  2005, p. 48. Back | 
                        
                        
                          | 62 | 
                          Centre for TPM (Australasia), Submission No. 12. Back | 
                        
                        
                          | 63 | 
                          G. P. Maxton and J. Wormald, Time for a Model Change: Re-Engineering the  Global Automotive Industry, Cambridge   University Press, 2004,  pp. 108–11. Back | 
                        
                        
                          | 64 | 
                          B. Hatch, ‘Kaizen Culture, Organisation, Reinventing  Leadership’, Australian Financial Review  Boss, vol. 7, July 2006, p. 45. Back | 
                        
                        
                          | 65 | 
                          International Metalworker Federation, IMF Auto Report 2004, Geneva Switzerland, 2004, p. 17. Back | 
                        
                        
                          | 66 | 
                          See discussion G. P. Maxton and J.  Wormald, Time for a Model Change: Re-Engineering  the Global Automotive Industry, Cambridge University Press, 2004, pp.  146–47. Back | 
                        
                        
                          | 67 | 
                          R. Gough, M. MacIntosh and B. Park, ‘The  Influence of Decentralised Bargaining Systems on the Introduction of Continuos  Improvement Practices in Australian Automotive   Components Companies’, Asia  Pacific Business Review,vol. 12,  no. 2, April 2006, p. 211. Back | 
                        
                        
                          | 68 | 
                          A. Goldstein, ‘Local Entrepreneurship in  the Era of E-Business: Early Evidence from the Indian Automobile Industry’,  International Conference on ‘E-commerce for Development…’, OECD Development  Centre, Paris, France and University of Bologna,  4‑5 May 2001, p. 14. Back | 
                        
                        
                          | 69 | 
                          The IPA Work Reform Unit ,‘The Capacity to Manage Index Report 3:  The Australian Automotive Industry’, IPA (Institute  of Public Affairs) Review, vol. 55,  no. 2, June 2003, p. 19. Back | 
                        
                        
                          | 70 | 
                          Mr Steven Leece, Managing Director, Moog,  United States headquartered precision component manufacturing, quoted in KPMG, Industrial and Automotive Products,  Globalisation and Manufacturing, 2005, p. 21. Back |