KEEPING YOUR EYE ON THE BALL

We sometimes read a newspaper or magazine or listen to a news report and hear about the downfall of U.S. manufacturing and how many people are losing their jobs in manufacturing plants. It sounds depressing but the question is, "Has the United States really fallen that far behind other countries in manufacturing capability?" The answer is no, and this video is meant to highlight just one example of a successful manufacturing company. There are thousands of others that could be discussed in a similar manner. There is no doubt that U.S. manufacturers are being challenged by companies in Mexico, China, India, Brazil, Indonesia, and all over the world-but that is nothing new.

The question is whether or not the United States can respond effectively to such challenges today as it has done in the past. Don't forget that much, if not most, of the machinery and equipment being used in foreign plants was produced in the United States. Note, too, that many companies-like Honda and Toyota-have built manufacturing plants in the United States. This video features Ball metal beverage containers. You've seen them everywhere. But have you given any thought to how those cans came to be? Have you wondered why Ball has been so successful in the United States that it expanded operations by buying four U.S. manufacturing plants from giant brewer Anheuser-Busch InBev?

The text mentions several things that U.S. manufacturers are doing to stay competitive in today's global markets. They include focusing on customers; maintaining close relationships with suppliers (e.g., using just-in-time inventory control); practicing continuous improvement; focusing on quality; saving on costs through site selection; utilizing the Internet; and adopting new production processes like computer-integrated manufacturing. Foreign businesses are busy copying what we do, so U.S. producers need to do things better and faster and cheaper, if they can. Speaking of cans, you can see and hear what Ball is doing to stay competitive in the video. Note that Ball is using a continuous process. What other processes might the company use? U.S. companies are using computer-aided design and computer-aided manufacturing, united in computer-integrated manufacturing. They also do flexible manufacturing, which means they can produce a variety of products using the same machinery. It should not surprise you to learn that Ball located its facilities close to its customers.

That makes distribution faster, easier, and cheaper. Of course, quality is a key consideration in any manufacturing plant. Can you imagine trying to open a can and having the opener break off in your fingers or having a can that leaks all over your car? Manufacturers try for zero defects, but often settle for some slightly lower standard such as Six Sigma (only 3.4 defects per million). Next time you take a cold drink from a can, think about Ball and the other companies that make the United States a major producer of consumer goods. Think, too, of the opportunities that will present themselves to tomorrow's college graduates. Students seem less attracted to manufacturing today, but that means more opportunities tomorrow for those students who see growth in some areas of manufacturing. That includes, of course, companies that produce solar panels, power plants, and more. You only have to look around your home or office to see the many products being made and the many products that will be made using biotechnology, nanotechnology, and so on.

1. Looking at the future of manufacturing in the United States, do you think U.S. companies like Ball are adapting to the challenges of foreign manufacturers? What is Ball doing to stay competitive?

2. The video mentions the loss of U.S. manufacturing jobs to overseas locations. What is this called? What is the opposite trend that has occurred in the United States with companies like Toyota and Honda?

3. What is meant by Six Sigma?