Нина Пусенкова - Английский язык. Практический курс для решения бизнес-задач

In 1984, General Motors shrank the Cadillac two feet and sales declined, forcing the dismayed…….. to rethink the way it…… cars. Instead of interviewing car buyers only at the start of………….. met over three years with five groups, each composed of 500 owners of Cadillacs and other models, to discuss design ideas. General Motors literally placed these people behind the wheel of prototypes, letting them fiddle with switches and knobs on the instrument panel, door handles, and seat belts while…….. sat in back and took notes.

The result: The new De Ville and Fleetwood cruised into……. with subtle tail fins, nine extra inches, and fender skirts – all reminiscent of the opulent post-war automobiles. As a result…….. quickly increased. The troubles and the comeback taught the company a very tough lesson. GM says, «We learned to….. on the consumer.»

Many companies that once led in technology must now hang on to…….. by carefully tailoring their products to customer needs and……… quickly. Says Du Pont Chairman Richard Heckert: «As the world becomes more and more………., you have to sharpen all your tools. Knowing what’s on the customer’s mind is the most important thing we can do.» It is also cheaper than finding new buyers. Studies by Forum Corp., a Boston-based consulting firm, show that keeping a…….. typically costs only one-fifth as much as acquiring a new one.

Techsonic Industries in Alabama, which manufactures Hummingbird depth finders, keeps its customers…….. even though some 20 Japanese……. make technologically……… products. Depth finders are electronic devices that fishermen use to measure the water beneath the boat and track their prey. Techsonic had nine new-product failures in a row before 1985, when Chairman James Balckom…….. 25 groups of sportsmen across the U.S. and discovered that they wanted a gauge that could be read in bright sunlight.

«The customer literally developed a product for us,» Balkcom says. In the year after the $ 250 depth finder was……., Techsonic’s sales tripled. The company has 40% of the U.S. market for depth finders, and its motto – not surprisingly – is, «The……of any product or service is what the customer says it is».

Source: Fortune, 1990, June 25 (excerpts)

Terms:

interviewed, delivering, manufacturer, competitive, loyal, quality, engineers, development, customer, showrooms, designs, sales, market share, competitors, focus, innovative, launched, planners

Exercise 6. Translate into English.

Когда уволенный из «Форда» Ли Якокка пришел в «Крайслер» на должность президента, компания находилась на грани банкротства. «Крайслер» обладал завидным послужным списком в области исследований и разработок, хорошей дилерской сетью и первоклассными конструкторами. Однако Ли Якокка быстро выяснил, что компания не функционировала как целостный организм. Каждое подразделение работало в полной изоляции, не поддерживая никакого общения с коллегами. В концерне было 35 вице-президентов, которые ничего не слышали о делегировании ответственности. Корпоративная структура была совершенно не рациональна – сбыт и производство автомобилей находилось в ведении одного вице-президента. При этом производственники выпускали автомобили, не интересуясь мнением сбытовиков, просто надеясь, что их кто-нибудь купит.

В компании фактически отсутствовала целостная система финансового контроля. Никто в корпорации не имел представления о том, как составляются финансовые планы и проекты. Руководство было ориентировано на краткосрочные прибыли, а не на долгосрочное процветание компании. Вместо того чтобы пользоваться своим конкурентным преимуществом – сильными инженерными и дизайнерскими кадрами, – когда прибыли стали падать, «Крайслер» начал сокращать издержки за счет снижения инвестиций в исследования и разработки.

Качество автомобилей было неприемлемым, клиенты засыпали компанию жалобами и множество автомобилей возвращали дилерам для ремонта. Доля автомобильного рынка США, принадлежащая «Крайслер», постоянно уменьшалась, а уровень верности клиентов ее автомобилям был самым низким среди «Большой тройки». Потребители воспринимали ее бренд как «скучный и чопорный». Моральный дух сотрудников «Крайслер», которые не имели представления о командной работе, также оставлял желать лучшего. ( Продолжение см. в уроке 5. )

The History of Just in Time

Around 1980 we were all just getting used to the concepts of Material Requirements Planning (MRP) and Manufacturing Resource Planning (MRPII) with their dependence on complex computer packages when we began to hear of manufacturers in Japan carrying no stock and giving 100% customer service without any of this MRP sophistication.

Japanese car manufacturers ensured that every steering column was assembled and fed onto a production line just as the car into which it was to be fitted rolled up at that particular stage. This was all managed by something called a kanban which meant «tag» and was the mechanism by which the assembly line told the feeder areas that they wanted another component. The first visitors to Japan came back to tell us that the kanban replaced MRP and was the key to Japanese success.

In time, we learned that the kanban was the last improvement step of many, not the first. The conceptual goals of minimised lead times and inventories rated above all else. The Japanese aim was having everything only when required and only in the quantity required – in other words, just-in-time (JIT).

We then learned that Toyota led the way in the development of the Japanese approach. We heard of something called the Toyota Production System which was the model for all that had happened in Japanese manufacturing. We heard of Taiichi Ohno, the production engineer responsible for this breakthrough.

The list below highlights what our Japanese counterparts had done.

Making something in large batches has several negative effects. The first thing which Westerners recognised was that stock levels are partly a function of order sizes. We had a formula for economic batch sizing in which the cost of set-up was offset against the cost of holding the stock. Our theoretical average stock level was half the order quantity + whatever element of safety stock we had built into our plans so reducing the order size would reduce our average stock.

There were, however, other considerations. A piece of plant cannot be immediately responsive to all demands upon it if it makes parts in greater quantities than are required at the time. Responsiveness, and hence service to our customers (whether they be external or the subsequent operations within our own plant) requires that we manufacture components in small batches.

We knew that smooth workloads make management of the manufacturing process far easier and had established smooth finished product plans with the adoption of Master Production Scheduling. However, no matter how smooth our final assembly plans, we still had lumpiness elsewhere.

The major contributor to parts being made in large batches is, of course, set-up times. Shigeo Shingo, a quality consultant hired by Toyota, had set about effectively eliminating set-ups. The accounting conventions that led Western businesses to make significant quantities of parts that may not be used were also shown to be ludicrous.

A major element of Western manufacturing’s inventory was that which we held in case of problems. We held safety stocks to allow us to continue manufacturing should some of the components or raw materials in our stores be found to be defective.

Ohno and his colleagues, ironically, had listened to the American quality gurus, W. Edwards Deming and Joseph Juran, who had advised Japanese industry as it recovered after World War II. Among the key concepts learned by the Japanese and neglected for many years in the West were:

Deming’s teaching that we cannot inspect quality in a product but must build it into the manufacturing process.

Juran’s definition of the internal customer. If we each give service to our internal customer then we will ultimately take care of the end customer.

By applying these teachings and aggressively eliminating all sources of non-compliance the Japanese moved quality onto a completely different plane. Where the West continued to measure percentage defect rates our competitors were working in parts per million.

As well as addressing the manufacturing processes, we learned that the JIT approach considered other contributors to improved quality. Is the component designed in such a way as to make it easy to produce or can we simplify it and reduce the chances of a defect? We began to think of «design for manufacture» and combining the previously separate functions of design engineering and production engineering.

We heard about things called «quality circles» where people in different areas of the business came together to investigate problems and work as a team to solve them – rather than follow our own approach of each area attempting to blame another. Perhaps most disturbingly we heard that inspectors were a thing of the past. All had now been trained as quality engineers and were in fact working as process improvement specialists so that their old function was no longer required.

Perhaps the most challenging concept for many companies was that of working with suppliers as partners. Buyers who spent their lives playing one supplier off against others and switching from one to another to save pennies heard that their Japanese counterparts single-sourced in nearly all cases. What is more, large corporations such as Toyota sent out their own specialists in manufacturing improvement to help their suppliers. Where savings were identified then benefits would be shared amicably.