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How the Airbus 380 project went astray and fell apart, and how it was put back on track. The story in some detail how the French and the German engineering groups in Toulouse and Hamburg failed to work together. How the German group was working with poor design software and simply fell behind, leading to the collapse of the program and the failure to put the wiring of the plane which extended for miles. 300 miles and 30,000 cables, something the Germans had never handled before. They had struggled with simpler versions of Airbus and now they were totally unprepared for this. A German engineer, Fuchs in Hamburg, worked closely with the French, transferring German engineering groups to Toulouse. French engineers in Toulouse were more advanced in the details of the work and in software design under French engineer Carcasses. The other problem that the Germans faced was that their individual engineering groups were poorly integrated and did not talk to each other, accelerating the collapse of the project. ...

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Delocalisation for Airbus as most of its production is in the euro area and its sales are in dollars. This policy is gradually taking hold to outsource manufacturing without making some of the errors that Boeing made with the Dreamliner.

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Forget Macron who is simply following French policy in the manner of De Gaulle, says Greg Ip in WSJ. The European Union has already set its policy to decouple its relationships in the supply chain from China, it just calls it something else -"de-risking." The EU he says is even tougher about this than the US. The EU's Leyen has stated: "The Chinese Communist Party's clear goal is a systemic change of the international order with China at its center... We need to ensure that our companies capital, expertise and knowledge are not used to enhance the military and intelligence capabilities of those who are also systemic rivals."  Mikko Huotari, the head of the Berlin based think tank Mercator Institute for Chinese Studies says that the US and the EU arrived at this through a process that went on in parallel. In fact the Scandinavian countries such as Sweden and Denmark, and the Baltic countries came across this much earlier before Biden became president because of acrimonious relations with China. This is also true of countries in Eastern Europe such as Czech Republic.  Germany's position is based on finding a transitional period for decoupling to reduce the impact on its economy. And even China is aware of this situation and looking for a transitional period for decoupling. More significant is the attitude of companies says Greg Ip- companies such as Tesla, Apple and even Airbus that have continued investments in China with little change. And it is this that president Biden is seeking to change with US policy positions. Another less observed aspect of this is the realization of both the US and EU, that the clear and obvious mistake of overconcentration of the supply chain in China was made under Merkel and the Bush-Obama adminstrations. China too realizes that it would have been better off - less recrimination from workers in the US,  and less costly damaging growth that led to climate change- if there was not this much overconcentration of the supply chain in China. In short it benefitted no one, and happened simply because companies sought to take advantage of attractive offers of building in China offered by local governments in China with subsidies from the Chinese government, and the manufacturing capabilities that kept expanding in a virtuous circle as better infrastructure and logistics were built over time. It goes to show that unless governments are vigilant and aware of these risks the unintended can happen with different consequences including destabilizing the social fabric and the political structure of western democracies.  ...

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Increasing demand and profitabilty of the newer fuel efficient twin engine planes seating 250-300 passengers for Airbus and Boeing- the Airbus 321, the Airbus 350, the 777X, 787-9, 787-10.

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The U.S. Defense Department awards Boeing a $30 billion contract for aerial refueling tankers. The first phase of this deal requires building 18 aircraft by 2017. EADS, the European supplier that lost out on its bid, had planned to build the planes in Mobile, Alabama, EADS had support of some southern states. Boeing sent a design based on its 767 commercial aircraft. This gives new life to Boeing's 767 program which was launched in 1982 and is seeing declining orders- down to 50 orders. Boeing says this supports 50,000 manufacturing jobs at Boeing plants in Washington and Kansas, and at suppliers around the country. EADS said it would have brought jobs to the Gulf region and keep 48,000 Americans employed.

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Efforts to achieve cost reduction on the Boeing Dreamliner and improve profitability. If Boeing used unit cost accounting or the difference between current sales and costs for each product delivered, the commercial jet division would show a loss of $69 million for the first 9 months of 2013.

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Boeing makes the decision to make the next version of the Dreamliner, the 787-10, exclusively at its plant in the North Charleston area of S. Carolina. This is a non-union facility. Larry Loftis, Boeing's vice president and general manager of the 787 program, says the decision was made because it is not practical to ship by air the midbody section of the new plane which is 114 feet long, 10 feet longer than the 787-9. It would not fit into the modified 747 aircraft used to ship jet parts from one manufacturing facility to another. Currently this midbodysection is assembled in S. Carolina from pieces shipped by air from Italian and Japanese plants. Then flown to Everett, Washington or a S. Carolina assembly line for the final steps in the manufacturing process. Reliability and quality issues for the Dreamliner, and cost, are also better addressed by reducing shipment from one manufacturing facility to another. The decision to build this non-union plant in 2009 created strains with the labor unions. The 787-10 is 224 feet long, carries 320 passengers, one third more than the 787-8 and 15% more than the 787-9. It has a list price of 289 million. Boeing has 132 orders from airlines and lessors for this new version....

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The work of innovation teams that help reduce lost production time and make production more efficient on Boeing's 737 production lines in Renton, Washington. There are 1300 improvement teams at Boeing for commerical jet production. Examples range from conventional improvements such as remapping production arrangements to unconventional ones like the use of hay loaders to put seats on passenger planes. The work requires highly motivated production engineers and Boeing has a long tradition of this. Boeing has increased 737 jet production to 35 a month from 31.5 with the help of such improvements. The goal is to make 42 planes a month by 2014, and 60 by 2017 when the 737 MAX goes into production. Boeing has a large backlog of orders- 3,700 jets of which 2,300 are 737s.

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Ostrower and Cameron point out that Dennis Muilenburg, the new CEO of Boeing, is first and foremost a engineer. He comes from a different background than former CEO Jim McNerney. McNerney graduated from Yale University, and followed a path of consulting with McKinsey, work at P&G, moved to General Electric where he worked under Jack Welch for many years, before the position at Boeing. This was a path for many CEO's at the time. As the U.S. returns back to its manufacturing and technological roots and with the manufacturing and technical problems at Boeing and Airbus, Muilenburg brings the right focus to meet future challenges. Muilenburg graduated from Iowa State University with a bachelor's degree in aerospace engineering, a master's degree in aeronautics and astronautics from the University of Washington He joined Boeing as an engineering intern in 1985, and is at Boeing since 1985. Since Dec. 2013 Muilenburg was president and COO, leading Boeing's effort to use automation to cut costs of developing and building commercial jets. Before that job he headed Boeing Defense, Space and Security, where he is credited with improving the operating margin from 9% in 2009 to 10.8% in 2013. He cut costs and closed facilities as the division share of Boeing revenue declined from about 50% in 2009 to about 34% in 2014 following defense spending cuts, but did this while maintaining higher research spending to drive efficiency improvements, say analysts. At Boeing Muilenburg's first 14 years were spent designing jets and military systems, some for contracts such as the advanced fighter jet program which Boeing lost to Lockheed, before moving to Washington D.C. for a new unit selling air traffic management services. He says the move was a period of personal growth for him more than any other period in his career. Muilenburg enjoys cycling, and puts in about 120 miles per week around Chicago...

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Changing perceptions of European companies about the viability of U.S. manufacturing in 2012-2014. The views of Atlas Copco AB, and Skanska, two Swedish companies, on why it makes sense to make products in the U.S.

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Reporting for this highly informative article on wind energy development in Brazil was done with a grant from the Pulitzer Center for Crisis Reporting. Forero gives a detailed account of the setup of about 400 huge wind turbines larger than the size of a Airbus 380 in a windy area of Bahia state by a Brazilian company Renova Energia. It is an area that experts say is nearly perfect for the steady wind needed. Brazil has increased its wind generation capacity to 3% of its energy generation in 3 years since the first auction for companies seeking to build wind farms. By 2021 energy planners in Brazil see this going up to 10% of its energy generating capacity. New limits on the generation of hydropower is shifting the focus to speeding up the development of wind energy by the government of Dilma Roussef. State owned banks provide loans to companies like Renova Energia. New technology from French, Dutch, and Spanish companies with advanced sensors that shift the position of blades to adapt to wind conditions, the size of windmills of over 400 feet, and 1.6 megawatt turbines, make wind energy a realistic option for Brazil's expanding energy needs growing at 5% a year. French energy company Alsthom has a plant outside Salvador, the capital of Bahia state, to manufacture windmill components. This helps meet Brazilian government requirements for a certain percentage of local manufacuring of components....

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The transfer of high speed rail technology by Kawasaki to China, starting with deals made in 2004. Kawasaki did this fearing that other competitors would win the business. It transferred the technology believing that it would be years or decades before China would develop its own capabilities and compete with high speed rail manufacturers in Japan and Europe. Kawasaki says the understanding was that the transferred technology would be used inside China, and not for export. China insists it has improved on the technology that was transferred with its own innovations, and it has the right to compete in the world high speed rail market. A high speed rail line between Shanghai and Beijing is being built using Chinese technology by China South Locomotive and Rolling Stock Industry Corporation (CSR), to cut the time from 10 hours to 4 hours. This is part of a network that will be extended to 9700 miles by 2020 according to the government's plan. As part of its export of high speed rail China Railway Construction Corporation is developing a high speed rail line connecting Istanbul and Ankara. China is bidding for contracts in Brazil and in the USA. The issue of transferring technology is becoming a sensitive one for Germany, Japan and the USA. It means transferring the technology as the price of getting a share of the Chinese market, but paying the price later on with competition from Chinese competitors in the same industry. China is developing its own civilian aircraft that would compete with the Boeing 737 and the Airbus 320. Min Zhu, special advisor for the IMF and former deputy governor of the People's Bank of China, told the Wall Street Journal CEO Council, that China's share of advanced machinery manufacturing could reach 30% of global exports by 2020, from 8% today. ...

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Matthew Slaughter of the Tuck School, Dartmouth, says that the principle of comparitive advantage should determine what America exports and imports. Under comparitive advantage each country concentrates its energies on the particular goods and services that it does better than other countries. Free trade operates under the idea of comparitive advantage, but in practice it is quite different than its textbook economic counterpart. It is constantly changing as new countries or industries in different countries try to upset the existing pattern. Under a textbook example Airbus should not exist because Boeing was the most efficient manufacturer upto that time, and new entrants in a industry are nurtured for years with support from the governments of their countries. And in some situations the governments may exclude certain companies or industries from support such as Komatsu and construction equipment in postwar Japan, and Infosys and software outsourcing in India, and still survive and grow. Under comparitive advantage Japan should still be importing construction equipment from Caterpillar in the US, and there would be no serious competition in that industry. This would work to the detriment of the principle of competition in free trade which is just as important to free trade as the idea of comparitive advantage, with new entrants in an industry upsetting the old way of doing things and creating price/quality improvements. Slaughter simply pulls back off the shelf the old idea of comparitive advantage without seriously considering its real life aspects. Without dealing with trade distortion from currency manipulation, from the impact on jobs, without considering the continuing critical role of manufacturing in developed economies to provide the standards of living for a large middle class, and creating the kind of society that people of developed countries aspire to. He mentions GE's Immelt and the President's Council on Jobs, but makes no effort to engage Immelt 's statement in his recent op-ed article in the Washington Post, that the concept of transitioning from a export-oriented economic powerhouse to a services led consumption based economy could be done without loss of jobs, prosperity and prestige, was fundamentally wrong. He has only one line for manufacturing's role in America's economy. This line says knowledge intensive industries such as education and software are just as important as manufacturing, but fails to mention that manufacturing has received less attention in recent decades. In so doing he is discounting his own profession of concern for the high rate of joblessness in the U.S., and the need for a new focus on manufacturing in the U.S. to reverse that trend. By saying that imports are not a sign of failure but can raise standards of living, and leaving it at that, Slaughter does not acknowledge that consumer debt that US consumers have taken on in the process certainly affects future prospects for the US economy. And he makes no mention of the need for rebalancing the world economy, which is exactly how free trade should work ideally. Countries that have high imports export more to rebalance the world trading system, as currency valuations are allowed to adjust makig their exports more attractive. By not taking into account the realities of free trade, and the need for practical measures to rebalance without policy induced distortions by state run economies, Slaughter ignores the idea of free trade that works as it should and for all countries. The irony is that Immelt's own committment to jobs and competitiveness has been questioned in online blogs and most recently by an editorial in the Wall Street Journal on January 26, 2011, titled "The Misallocators." That editorial refers to the outsize role of GE Capital in GE's earnings during the past decade, and the lack of credibility of a focus on competitiveness and jobs that this creates for GE. It mentions the loss of 34,000 GE jobs in the US during the last decade. ...

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Manufacturing in the US is adding jobs for the first time since 1997, according to government data. Job growth in 2010 was 1.2%, or 136,000 jobs. IHS Global Insight expects total manufacturing jobs in the US to increase in 2011 to 12 million. Manufacturing will be a modest contributor to job growth according to economists. Economists projections show a gain of 2.5% or 330,000 manufacturing jobs in 2011. Moody's Analytics estimates job growth of 2% a year through 2015. Government incentives, need to replace aging equipment and rehiring in the automobile industry will help manufacturing. At the same time manufacturers are cautious about hiring and increases in automation reduce the need for workers compared to earlier periods. Overall the loss of about 6 million manufacturing jobs since 1997 will not be made up. Yet the improvement is a positive sign as the US faces high unemployment and companies make investment in new factories overseas to meet growth in emerging markets.

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Mike McNamara, CEO of Flextronics, on the increasing competitiveness of U.S. manufacturing and the return of manufacturing jobs to the U.S.

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Boeing's improvements in quality and production processes for the Dreamliner, as the first Dreamliner which will not need major additional work before delivery comes off the production line. Costs of production have reached the point to where Boeing is losing $100 million on each plane sold. Ony 300 small assembly tasks remained, closer to the 200 that is the company's goal, and improvement over the 6000 additional small assembly tasks remaining in the early versions. The Everett, Washington plant now can make a 787 Dreamliner plane every 6-7 days. It costs Boeing $242 million to make each plane, and it sells them for $113 million according to UBS analysts. Boeing will have invested about $20 billion in the Dreamliner by 2014, when analysts say it should turn a profit.

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Workers ended a 3 month strike at Caterpillar's Joliet, Illinois plant, essentially giving in to reduced healthcare and pension benefits and wage freezes for older workers. Under the deal workers hired before May 2005 receive no hourly pay increase, workers hired after that date get a one time 3% pay increase with future pay increases decided by Caterpillar management. Hourly pay at the plant ranges from $13 to $28. About 25% of the older workers are eligible to retire. A $7.8 million fund to supplement incomes of laid off workers will now be used for retirement bonuses. Caterpillar persuaded workers to ratify the contract by increasing the bonus for ratifying to $3100 per worker from $1000. During the strike Caterpillar continued operations by using managers and temporary workers and using 100 workers who crossed picket lines.

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Boeing reaches a tentative agreement with the International Association of Machinists & Aerospace Workers in Nov. 2011. Under the agreement Boeing will build the 737 MAX, a retooled version, at a union plant in Renton, Washington. In exchange the union will not oppose Boeing's use of a new nonunion plant in South Carolina for assembling some 787 Dreamliners. The agreement when approved by union vote would extend the contract for 4 years till 2016. Advantages to Boeing lie in labor peace during a period when Boeing plans to increase production by about one third, over 2012-2014, to meet aircraft orders of $332 billion. Existing 737 production has been moved up to 35 a month, going up to 42 a month, accelerating the pace significantly, making it important for both sides to avoid labor discord. The Max first delivery is planned for 2017. In the current unemployment crisis there was considerable incentive on both sides to resolve the issue quickly, after the union had raised the issue with the National Labor Relations Board. It provides Boeing with flexibility in assembling some of the 787's in S. Carolina along with assurance for union commitment to productivity, and gives the union assurances that Boeing will continue to maintain significant maufacturing presence in the Washington area, a win-win for both sides. The NLRB appeal will be dropped by the union....