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Focus: Global Supply Chain and Logistics

Our Weekly Feature Article on Topics Related to Global Supply Chain & Logistics
 

From SCDigest's On-Target e-Magazine

- Nov. 30, 2015 -

 

Supply Chain News: Now, Labor Shortage is Issue in China, as Global Manufacturing Trends Likely to See Major Shifts in Coming Years


Wage Inflation, Demographics a Key Issue for China, as Trend is to Move Production Closer to Demand

SCDigest Editorial Staff

 

China rose to become the world's second largest economy and top manufacturer on the back of tens of millions of workers willing to work for very low wages.

That model is changing - rapidly.

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Moody's Analytics predicts that these and related changes in market dynamics will cause the US trade deficit with China to start to diminish and turn positive by 2042.

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"Over the coming decades, a labor shortage will force Western brands to remake their China operations or pack up and leave," the Wall Street Journal recently wrote in a major article on this changing dynamic. "The changes will mark a new chapter in the history of globalization, where automation is king, nearness to market is crucial and the lives of workers and consumers around the world are once again scrambled."

The change is driven by a number of factors. While Chinese factory wages remain low by Western standards, they have been rising rapidly in recent years, eroding China's competitive advantage against not only developed countries but also versus nations such as Vietnam, Cambodia, Bangladesh and Ethiopia, especially in the apparel sector, where moving operations is relatively easy, given its labor intensity.

According to recent data from The Boston Consulting Group, productivity-adjusted manufacturing wages in China are about $14.60 this year, or about two-thirds of the US average of $22.68. But that gap has been rapidly shrinking.

That is in large measure automation is coming even to the apparel sector. A supplier making jeans for Levi's in the Zhongshan area of China started using automated lasers are replacing dozens of workers who once rubbed Levi's blue jeans with sandpaper to create the worn look that has become popular with many consumers. Automated sewing machines have significantly reduced the number of seamstresses needed to stitch designs into back pockets. Digital printers make intricate patterns on jeans that workers used to create with a mesh screen.

Demographics as usual play a key role in the Chinese labor economics. The country's working age population (15-59 years old) peaked in about 2010, at an incredible 900 million people or so, and has since started to fall, with the United Nations estimating the working age population in China will decline to about 700,000 million by 2050, as it faces a rapidly aging population.

As others have said, China in fact may be the first country to grow old before it becomes rich. The share of the Chinese population older than 60 is forecast to double by 2050 from 2015, to 36.5%.

Although wage growth in China may ease this year because of an economic slowdown there, the upward pressure is almost certain to increase in coming decades as the number of workers plunges.

Indeed, just recently China largely reversed its decades-old "one child" policy that limited family size, now allowing parents to raise two offspring. But perhaps surprisingly, experts expect the new policy will have little impact on Chinese demographics, as the years of a one-child culture has led most couples to prefer just a single son or daughter.


(Global Supply Chain Article Continued Below)

 
CATEGORY SPONSOR: SOFTEON

 
 

Seeing these demographic changes, Chinese Communist Party Chief Xi Jinping last year called for "an industrial robot revolution" in China despite still having nearly a billion workers needing jobs. One Chinese province actually has launched a program called "replacing humans with robots."

 

Source: New York Times


According to the International Federation of Robotics, China will have more installed manufacturing robots than any other country by 2017, and is expected to deploy some 150,000 annually by 2018, more than three times the 44,000 robots projected in the North American market that year.

There are lots of anecdotal stories to support that view that China is transitioning to robots.

Chinese appliance maker Midea, for example, plans to replace 6,000 workers in its residential air-conditioning division - nearly 20% of its work force - with automation by the end of the year.

In May, Shenzhen Evenwin Precision Technology Company started work on a new factory that will be run almost entirely with use of about 1000 robots. Those robots will replace 90% of the 1800 workers currently at a nearby factory, reducing employment there to just 200 needed to operate the new automated plant.

Market Changes will Also Impact China's Status as Factory to the World

"Consumer demand is growing for customized goods, whether they are pharmaceuticals tailored to individual genes or craft beers tailored to individual palates. That makes distance from market an increasing disadvantage, especially ordering huge quantities of goods from China and waiting a month for delivery by ship," the Wall Street Journal recently noted. "Factories are likely to get smaller and more dispersed, so they are closer to customers, wherever they live."

That in fact is exactly the strategy that sports apparel giant Under Armour is pursuing, as we reported last week. Using what it calls a "local for local" manufacturing approach, the company is already bringing back some production to the US, with plans for more.

Key elements of that strategy: much great use of automation and the ability to cost-effectively customize goods to meet specific consumer or market needs. (See Under Armour Making Bold Move for Made in USA, Thinks it Can Help Reshape American Economy.)

So called "mass customization" - a term that gained traction during the dot com boom more than 15 years ago but which never really took hold as a practice - may in fact now become a reality, driven by the interest fro, on-line shoppers in ordering precisely what they want.

For China and the companies that source from China, "These changes threaten to remake the traditional manufacturing model where goods are produced in huge runs in China's coastal cities and shipped thousands of miles by sea," the Wall Street Journal reports. "Instead, technologists expect a profusion of smaller factories over the coming years, designed to meet local preferences."

In fact, Wall Street research firm Moody's Analytics predicts that these and related changes in market dynamics will cause the US trade deficit with China to start to diminish and turn positive by 2042. That would be a huge change from recent years, where the US trade deficit in goods with China continues to grow, certain to set another record again this year at somewhere around $350 billion.

One winner in all this may be Mexico, where proximity to the US can enable companies producing there to run a short supply chain similar to that of domestic production, with the benefits of the NAFTA free trade agreement and - for now at least - low upward pressure on wages. Factory pay has lately been rising only 2-3% annually, much lower than Chinese wage inflation.

Mexico's productivity-adjusted manufacturing wages will be just $9.33 in 2015, Boston Consulting Group estimates.

Do you think there really is an increasingly labor shortage in China? How do you see it playing out? Let us know your thoughts at the Feedback button (email) or section (web form) below.


 

Recent Feedback

We see many companies moving toward localization. Companies are recognizing that with the use of the refined metrics of total cost of ownership (TCO) to uncover the hidden costs and risks of offshoring and reducing costs with sustainable strategies such as robotics, improved product design, automation etc., they can increase competitiveness and manufacture in the U.S. profitably.


In order to help companies decide objectively to reshore or offshore, the Reshoring Initiative can help with free TCO which can be found on the ReshoreNow.org website.

 


Sandy Montalbano
Consultant to Reshoring Intiative
Reshoring Initiative
Dec, 04 2015
 
 
   

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