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The plant in Tychy, Poland where Fiat turns out 500,000 small cars a year, one every 55 seconds. Chrysler engineers are now visiting this plant to see what can be done with small car production. The Fiat 500 is turned out here. Its Fiat's best effort in terms of quality. Zdzislaw Arlet, is director of the Tychy (pronounced TICK-ee) plant. He says the right combination of robots to individual workers was critical to achieve efficiencies and to have the flexibility to switch to different Fiat small car models depending on which is selling more. This enables the Tichy plant to operate round the clock six days a week. About three years ago workers were assigned an individual ID that is stamped on the sections of the car that they assemble so any problems at the end of the line can be traced to the source. As a result of these efforts defects have fallen from 20% in 1996 to just 4% now, and the time to have a car roll out of the assembly line has been halved.

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The problems for Chrysler may not be as much the culture gap between nationalities, as Daniel Howe of the Detroit News points out, as in other areas. It is not going to be in the union area as the President's auto task force has studied the other risks facing Chrysler, and is aware of the failed effort of United airlines unions to run that airline. In the agreements by which 55% ownership of Chrysler is given to the UAW union, the government leaves the union entirely out of the management of the company, which is left to Fiat. And the UAW seeks to sell off its ownership share at the earliest favorable opportunity. The risk lies in the fact that the new models such as the 40 miles per gallon car Fiat is required to build as one of 3 milestones, each worth an additional 5% stake above the inital 20% stake, will not be built till 2012. Meantime as the President said, Chrysler will have to find ways of staying afloat in a market where it is seeing a 40-50% drop in sales each month this year over 2008, with cars that are "less reliable, less popular, and less fuel efficient than foreign competitors." ...

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A former WSJ Detroit Bureau chief says that if GM is to receive help it should go into government receivership, old management and the board have to go, shareholders would lose value as shares become worthless, and old union contracts have to go, and only then would the industry get back on its feet. The same should happen for Ford and Cerberus, and the shares becoming worthless would take away the control that the Ford family has of the company, giving it a fresh start with new management. He is saying what many have thought true for a long time, management of these companies have failed Detroit and the midwestern states for a long time, for decades in which management has simply protected its own interests and avoided taking the steps needed for renewal of the companies. The few changes have simply come so late and are inadequate in this crisis.

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The view of a Prof. of Finance at New York University's Stern School of Business on the auto industry and the destruction of capital. About $110 billion of destruction of capital between 1980 and 1990 for GM and Ford, and the destruction of $182 billion in capital that was invested in GM between 1998 and 2007. From a Finance point of view this is society's capital that can be better invested. The total $465 billion invested in GM and Ford between 1998 to 2007 says Yermack could have purchased all the shares of Toyota, Honda, Nissan and VW. The job losses overstate the situation he says, as jobs would be created in other auto factories which expand as Detroit contracts, which is already happening as sales decline is less steep at other automakers such as the Japanese. Regarding the proposals to ask the automakers to build environmentally friendly cars with serious fuel efficiency, he says its like asking the cigarette companies finance cancer research, considering their lobbying efforts to gut serious conservation or environment friendly legislation....

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Fiat announced that it will buy all the U.S. government's shares in Chrysler. This comes a few days after Fiat payed back $1.3 billion to buy an additional 16% of Chrysler, increasing ownership to 46%. Fiat will have a 52% ownership stake in Chrysler after the purchase. By the end of the year Fiat says it expects to own 57% of Chrysler. Under the loan agreement Fiat automatically gets 5% of Chrysler if it begins producing a car rated at 40 miles per gallon. Chrysler earned $116 million in the first quarter of 2011.

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The U.S. market looks like it is becoming the kind of maturing market that Japan and Germany have become for automobiles. Germany and Japan saw sales peak at high levels and then decline. And they have been declining steadily for several years. The US has a growing population and demographics because of immigration compared to Japan so there wil be continued demand for new cars. However since 2000 carmakers have introduced so many price incentives, interest free loans, and other ways of pushing sales that sales have continued to climb to unsustainable levels. All through the 1990's sales were in the 15 million range, then after 2000 sales climbed, except for the short period of uncertainty after 9/11/2001 Trade Center bombings. Sales climbed up to 17 million and stayed at these higher levels till the recent crises in 2007 saw a drop in sales and a shift to smaller fuel efficient cars. GM was offering 0% financing for 5 years through its Keep America Rolling campaign in the aftermath of 9/11. By 2005 automakers were offering as much as $8000 in discounts on pickup trucks. Employee pricing enabled regular customers to buy at employee prices. The Big Three sold to rental fleets unsold cars, so much so that by 2005 25% of all vehicles made by GM and Ford went to rental fleets, to rental companies in which these companies had large ownership stakes. For GM this became part of strategy. Fixed costs were high and the UAW contracts made it difficult to layoff workers, a jobs bank in which layed off workers could remain till rehired was itself quite costly as money had to be paid to the workers in the job bank. With this kind of inflexibility in the labor market GM could only spread all the fixed costs for its aging workforce which required pension payouts to retirees and health payments to retirees, by selling more automobiles. During this period of inflexibility in labor, and the legacy costs of previous boom years since the 1950's with generous UAW contracts, GM and Ford pushed sales to unsustainable levels; without considering the furture implications of this short term strategy. Another way this could hurt is by pulling sales in future years into current years because of interest free financing or huge discounting which probably happened in 2004-2005 and is seeing a payback today in 2008. At the peak in 2005 carmakers were planning further expansion of SUV capacity or expansion of other carmaking facilities. Gas was still not at the high levels of today. In 1999 gas cost $1.15 cents a gallon, and it was a little higher than that, but nowhere near what we are seeeing today. These new plants are coming up just as the sales are dropping dramatically, the half million SUV's sold in 2008 is about half the sales in 2003, enough to fill 2 plants when many more plants are being built or opening. The new capacity of 4 plants capable of producing 1 million vehicles is looking like a big mistake, like the new Toyota Tundra plant in Texas. Some of the new carmaking capacity is a Toyota plant in Tupelo, Mississippi, a Honda plant in Indiana, and a Kia Motors plant in Georgia. All this means a big drop in factory utilization rates. GM has 2 plants making full size SUV's. Later this year GM will cut production at these plants and at 2 plants making pickup trucks to utilize them only for 1 eight hour shift a day. Toyota has 1 full plant of excess capacity, not including the plant opening in Tupelo, Missisippi, making it likely to be down in utilization very significantly as well. Nissan is only using 65% of capacity at plants in Canton, Mississippi and Smyrna , Tennessee. And these utilization rates reflect the impact at the early stage of the housing crisis, consumption spending is only now beginning to bite, and unemployment is still to take a hit, so th economic recession immpact is still not reflected in auto sales. Even now GM and Chrysler cling to the hope of a sales pickup in late 2008 and in 2009, which is looking less likely by the day. J.D. Powers survey show the North American auto making capacity at 18.7 million cars and production this year at 14.1 million. This means the automakers have disastrously misjudged the auto market, and the role their own actions in pushing sales have affected the market in inflating the sales numbers beyond what is a sustainable sale increase. When credit tightening and lower consumption spending, housing crisis, and higher unemployment all hit the US in full impact by 2009 the situation is likely to worsen significantly and could become a disaster. ...

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Whats the breakdown of costs for Detroit's Three Auto Companies. The following infomation is from documents submitted by Ford Motor Company to Congress. Detroit Auto Companies Foreign Makes like Toyota Hourly cost Hourly cost Hourly wage for workers $29 $26 (Toyota Kentucky plant) Holidays and Vacation pay & pay for Detroit laid off workers $14 $9 Cost of Health Care and Pensions for $16 Toyota has only 300 retired retired workers workers Overall cost $71 $49 The biggest difference is in the cost of paying laid off workers, jobs banks, and in the cost of paying the health care and retirement pensions of retired workers. And for GM there are about 1 million of them, (96,000 active workers, 497,000 retired workers and also the dependents of retired workers) costing GM $4.8 billion on health care. At $1500 per car for GM costs on health care vs. $200 per car for health care costs at Toyota. The difference is $1300. If this is factored in to the profitability of small cars then the field is skewed one way. On a $23,000 car that is a 5% margin right there for adiffernce of $1100 in health care costs. If this is the way profit is calculated on small cars with this health care differential factored in then there is always a muddleheaded tendency to product he bigger cars and trucks because they can absorb this differential better. But it doesn't make sense that this should dictate how the business is run. And it could lead to serious mistakes which appears to be the situation at the Detroit companies, the way they went into the downturn right into 2008 with a product mix that was going to be hit hardest by a change in customer preferences. ...

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The automakers are still stuck with dependence on pickups like the Dodge Ram which provides 17% of domestic vehicle sales and the F-150 pickup truck for Ford which provides 26% of domestic vehicle sales. Even though they earn estimated $5000 to $10,000 per pickup this dependence has hurt the automakers, as they are losing money due to the neglect of the rest of their lineup. In 2008 the domestic pickup sales will decline 10% to 2 million units from 2.2 million according to Global Insight. Sales to customers now will almost entirley be to construction industry users in a bad construction market, as other customers who used pickups for general use are shifting to other vehicles.

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New models introduced by Chrysler, Ford and GM, and the revitalization of the U.S. auto industry in 2011-2013.

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USA car sales drop 37% in January 2009 over same period in 2008. Sales at GM dropped 49%, at Ford 40% and Chrysler 55%, at Toyota 32%, at Honda 28%, at Nissan 30%. Subaru and Hyundai saw sales increases. Analysts at IHS Global Insight say the stimulus package may help prevent things from getting much worse, but it would be wrong to count on the stimulus package for a pickup in sales in the second half of this year. This is ominous for the Detroit car companies as they seek government help to avert bankruptcy. Chrysler is hoping to make tieup with Fiat, but it will be a year before Fiat cars make it to the US and longer for its cars to be made in the US, so it is not clear what will happen in 2010. Ford's economists think the market is nearing bottom, but if that is not the case it may prove risky for Ford.

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The global auto industry has capacity for producing 92 million vehicles in 2009, but only 60 million cars will be sold next year, according to CSM Worldwide. And CSM forecasts capacity utilizations will not return to the 2007 rate of 80% till 2014. And because of their better product mix, more new models, and better fuel efficiency, the Japanese, Korean and European carmakers have a better capacity utilization than the Detroit Big Three, even though they are also hurting badly as credit collapses and and an overextended American buyer is wary of new purchases. Robinet, the head of global vehicle forecasting at CSM Worldwide, estimates that the Big Three Detroit automakers will only need half their current production capacity in 2009, something he says is not sustainable for any industry. If these estimates hold true then there is a major earth shaking experience ahead for Detroit automakers that is not reflected in the attitudes and the bargaining about who benefits and who concedes what from unions, management, workers, bondholders, dealers and suppliers, even after the near miss for the bridge loans. It is a situation in which even globally and among the strongest automakers like Toyota and Honda there is going to be a lot of misery in 2009 and beyond. Only some automakers around the world will survive this shakeout. ...

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This piece in the oped pages of the WPost reminds readers about one conspicuous failure at General Motors, the failure in good labor relations. It quotes columnist Marquis Childs during the booming business years of the war, July 10, 1944. Childs wrote about a visit to Detroit where he saw a broad gulf between business leaders and labor leaders, between management and workers, where he said they could not hear each other except when they raised their voices. By 1958 when the auto sales had dropped and strikes loomed, the union demands during negotiations were described by the WPost in an editorial as extravagant proposals. Elsewhere in the coverage on Alfred Sloan's contribution, one writer describes Sloan's success as a manager but also points to his failure to setup good labor relations. This failure played an important part in GM's eventual failure and filing for bankruptcy on June 1, 2009.