BBC "TWO" | Nippon | Episode 5 of 8 - "Taking on Detroit"
Summary
TLDRThe video chronicles the remarkable rise of Japan's automobile industry, detailing its journey from importing cars in the 1920s to becoming a global leader in the 1970s. It highlights the strategic moves by Japanese firms, the influence of foreign companies, and the pivotal role of the Japanese government. The narrative explores key innovations, labor relations, and the eventual international success of brands like Toyota and Nissan. Through resilience and ingenuity, Japan transformed its manufacturing capabilities, overcoming post-war challenges to revolutionize mass production and become a dominant force in the global car market.
Takeaways
- 🚗 Japan's car industry emerged as a dominant force in the global market, becoming a 'giant-killer' in automotive manufacturing.
- 🏭 Japan initially struggled with automobile production, relying heavily on imported cars and foreign expertise in the early 20th century.
- 🇺🇸 American companies like General Motors and Ford set up factories in Japan, significantly influencing the local automotive industry.
- ⚙️ The Japanese government pushed for domestic car production in the 1930s, leading to the establishment of companies like Nissan and Toyota.
- 🌐 World War II shifted Japanese automotive production towards military vehicles, which laid the groundwork for future industry growth.
- 🛠️ Post-war Japan faced significant challenges, including economic chaos and material shortages, but began rebuilding its automotive industry.
- 🚴 Mr. Honda adapted a small engine to a bicycle, creating the first motor-powered bicycle in Japan after the war.
- 🛣️ Despite early struggles, Japanese car manufacturers, with the support of the Ministry of International Trade and Industry (MITI), began developing better models and improving production techniques.
- 💼 The introduction of the 'just-in-time' production method by Toyota's Taiichi Ohno revolutionized the efficiency of Japanese car manufacturing.
- 🌍 By the 1970s and 1980s, Japanese cars had gained significant market share internationally, particularly in the United States, due to their fuel efficiency and reliability.
Q & A
How did Japan's automobile industry evolve during the 1920s?
-In the 1920s, Japan had only a few thousand cars, almost all of which were imported. Japanese manufacturers lacked the production know-how and engineering base to build cars economically.
What role did American companies play in the early development of Japan's car industry?
-American companies like General Motors and Ford set up large modern factories in Japan, producing 90% of Japan's vehicles. They brought parts from Detroit and taught Japanese workers American production methods.
Why did the Japanese government expel Ford and General Motors in the 1930s?
-The Japanese government was concerned about the economic drain and national defense implications of relying on imports. They wanted to build a domestic car industry, so they expelled Ford and General Motors and promoted Nissan and Toyota as principal suppliers for the Imperial Army.
How did World War II impact Japan's automobile industry?
-During World War II, car production stopped, and the focus shifted to military trucks. However, the trucks were unreliable and crude. Despite the war's devastation, the demand for military vehicles laid the foundation for Japan's motor industry.
What challenges did Japan face in rebuilding its automobile industry after World War II?
-Post-war Japan was in chaos, with the economy in ruins and a lack of raw materials. Companies struggled with too many workers and too few orders, and there was widespread unemployment and a thriving black market.
What was the significance of the Korean War for Japan's car industry?
-The Korean War provided a crucial order for 3,000 army trucks, which helped Toyota and other companies survive financially and led to a resurgence in production.
How did Japanese car companies like Nissan and Toyota improve their production methods in the 1950s?
-Japanese car companies formed technology tie-ups with foreign companies like Austin, Renault, and Hillman, learning advanced manufacturing techniques and aiming for 90% domestic production within five years.
What was the 'just-in-time' production method introduced by Toyota?
-The 'just-in-time' production method aimed to produce only what was needed when it was needed, reducing inventory costs and improving efficiency. Parts were made and delivered to the assembly line in the exact quantities required.
How did Japanese carmakers address labor relations and improve productivity?
-Japanese carmakers implemented new working practices and labor relations, focusing on cooperation and eliminating waste. Engineers like Taiichi Ohno at Toyota introduced innovations to maximize the use of human labor and machinery.
What impact did the oil crisis of 1973 have on Japanese car exports to the United States?
-The oil crisis highlighted the fuel efficiency of Japanese cars like the Datsun, which had the best fuel economy among models on sale in the U.S. This led to a surge in demand for Japanese cars, despite the overall economic downturn.
Outlines
🚗 The Rise of Japan's Automotive Industry
Japan's automotive industry emerged as a global leader, producing nine million cars annually by learning and innovating mass production techniques. Initially dependent on imports and lacking production know-how, American companies like General Motors and Ford established factories in Japan. However, the Japanese government pushed for domestic production, leading to the development of companies like Nissan and Toyota, which became principal suppliers to the Imperial Army.
🔄 Post-War Challenges and Innovations
After World War II, Japan's economy was in chaos, and raw materials were scarce. Entrepreneurs like Mr. Honda adapted by creating motor-powered bicycles. Toyota and Nissan, having survived the war, faced bankruptcy until the Korean War orders revitalized them. This period saw a struggle to maintain production and adapt to new economic realities, laying the groundwork for future automotive success.
🏭 Building a Domestic Car Industry
Despite skepticism from economic leaders, Japan's Ministry of International Trade and Industry (MITI) supported the development of a domestic car industry. Early post-war cars were crude, often built using parts from light trucks. To improve, companies like Nissan partnered with foreign manufacturers like Austin, importing technology and knowledge while striving for self-sufficiency and improved quality.
🔧 Learning and Adapting Foreign Technology
Japanese carmakers like Nissan and Toyota learned from foreign partnerships, notably with Austin and Ford. Engineers visited foreign factories to understand advanced production methods, and local adaptations of foreign designs became common. Despite initial difficulties, these efforts led to significant improvements in manufacturing processes and vehicle quality.
🏎️ Entering Competitive Motorsports
Nissan entered its first home-designed car in the Round Australia Rally in 1958, testing its durability against international competition. Surprisingly, the Datsun won its class, boosting Japanese morale and marking a significant milestone in the country's automotive industry. This success symbolized Japan's recovery and growing confidence in its engineering capabilities.
💼 Labor Relations and Productivity Improvements
Post-war Japan faced significant labor disputes, notably at Nissan, where a major strike in 1953 led to the establishment of company unions and improved labor relations. Engineers like Taiichi Ohno at Toyota revolutionized production methods, introducing the 'just-in-time' system to minimize waste and improve efficiency, significantly boosting productivity.
🔄 Just-in-Time Production Revolution
The 'just-in-time' production system, championed by Taiichi Ohno at Toyota, transformed Japanese manufacturing. By producing only what was needed, when it was needed, factories reduced inventory costs and increased efficiency. This approach, coupled with rapid die change techniques, allowed for more flexible and efficient production, setting new standards in the industry.
🏭 Building Modern Factories
With government support and investment, Japanese car manufacturers modernized their factories, enhancing production capacity and efficiency. New plants like Toyota's Motomachi factory were built with advanced technology, helping Japan's automotive industry grow rapidly and meet increasing domestic and international demand.
🌏 Breaking into International Markets
In the late 1950s and early 1960s, Japanese car manufacturers began exporting to international markets, despite initial setbacks. Early exports to the U.S. faced challenges due to quality issues, but lessons learned from competitors like Volkswagen helped improve after-sales service and product reliability. Persistent efforts led to growing acceptance and success in foreign markets.
🌐 Overcoming Export Challenges
The 1973 oil crisis unexpectedly boosted Japanese car sales in the U.S. due to their fuel efficiency. Despite initial resistance and quality issues, Japanese manufacturers improved their cars and targeted markets like California, gaining significant market share. The crisis highlighted the advantages of Japanese cars and accelerated their acceptance in the American market.
🚗 Adapting to Global Competition
As Japanese cars gained popularity, American and European manufacturers sought to learn from Japan's production methods. The Japanese excelled in areas like flexible production, quality control, and labor relations, setting new industry standards. By the 1980s, Japanese cars captured a significant share of the U.S. market, prompting American companies to seek protectionist measures.
🌍 Establishing Global Manufacturing
To bypass import restrictions, Japanese car manufacturers began building factories abroad, including in the United States. This strategy allowed them to maintain market presence despite export limits. The establishment of foreign plants showcased Japan's ability to adapt and thrive in the global automotive industry.
Mindmap
Keywords
💡Japanese Car Industry
💡Mass Production
💡Nissan
💡Toyota
💡Just-in-Time Manufacturing
💡Post-War Reconstruction
💡Trade and Industry Ministry (MITI)
💡American Influence
💡Technological Innovation
💡Export Market
Highlights
Japan's car industry, despite being late to the automobile age, became the world's largest car producer by rewriting the basic lessons of mass production.
In the 1920s, almost all cars in Japan were imported. Japan lacked the production know-how and engineering base to build cars economically.
American companies like General Motors and Ford set up large modern factories in Japan, teaching Japanese workers the American way of production.
By the 1930s, Japan was experiencing a total foreign takeover of its automobile industry, producing 90% of its vehicles through American factories.
Japan's Ministry of Commerce urged industrialists to make cars domestically to address national defense and trade balance concerns.
During World War II, Japan's motor industry focused on truck production for the military, laying the foundation for its post-war car industry.
Post-war Japan faced chaos with no raw materials and halted military orders, but companies like Toyota quickly aimed to catch up with American productivity.
Toyota's post-war strategy involved trying to match American industrial productivity, despite initially being far behind.
The Korean War brought a surge in orders for Japanese trucks, which helped revive the industry and set the stage for its growth.
In the 1950s, Japan began focusing on developing its own car designs, starting with crude models derived from truck chassis.
Japanese firms, supported by the powerful Ministry of International Trade and Industry (MITI), aimed to make cars a strategic industry to boost the economy and technology.
The 'just-in-time' production method, pioneered by Toyota's Taiichi Ohno, minimized inventory and capital investment, significantly increasing productivity.
The 1960s saw rapid growth in Japan's car production, driven by new plants, improved technology, and the rise of the domestic market.
Despite initial quality issues, Japanese cars began making a significant impact on the American market by the late 1960s and early 1970s, especially after the oil crisis.
By 1980, Japanese cars held 20% of the American market, and Japanese firms had started producing cars in the United States to bypass import restrictions.
The Japanese car industry's transformation involved adopting and adapting American and European manufacturing techniques, leading to their dominance in the global market.
Innovations like flexible production, quality control, and the just-in-time system became hallmarks of the Japanese car industry's success.
Transcripts
[Music]
[Music]
Japan's car in the street has been the
giant-killer the cars they're testing
are what the rest of the world now has
to beat
[Music]
they come from behind to make nine
million cars a year more than any other
country as they overtook the world they
rewrote the basic lessons of mass
production this is the story of the
Japanese industry which made the
greatest dent in Western manufacturing
pride
[Music]
Japan had been late to enter the
automobile age in the 1920s there are
only a few thousand cars in the country
almost all were imported from abroad
for the Japanese driving cars with one
thing making them another they hadn't
the production know-how or the
engineering base to build them
economically
[Music]
with a huge potential market right for
the picking Japan now experienced a
total foreign takeover
American businessman moved in quickly
with their unmatched experience General
Motors and Ford set up large modern
factories parts were shipped over from
Detroit American managers taught their
Japanese workers the American Way soon
these transport factories were producing
90 percent of Japan's vehicles but the
Japanese government was alarmed they
didn't like the drain of cash out of the
country in 1930 the Ministry of Commerce
warned the fact that we depend on
imports is unbearable from the point of
view of national defense to say nothing
of the balance of trade Japanese
industrialists were urged to make cars
themselves
trader who made textile built their
first cars in 1934 for their first small
car Nissan bought secondhand machine
tools from the United States and hired
American engineers
because your knee there was a specialist
in casting in the fan so can I come so
cool he came from abroad called a newer
forging of nicosia yeah and in the forge
there was a foreign serie a bristle
cause yeah and it was the same in the
pressing shop this color so no cause you
were teachers then say that brothers by
now Japan was under military government
and pursuing a war in China the soldiers
wanted to bring the motor industry under
their own control they expelled Ford and
General Motors and built up Nissan and
Toyota
as principal suppliers for the Imperial
Army
[Music]
in the Second World War
trucks were all that mattered car
production stopped altogether as Japan
attacked the Western Allies despite the
propaganda the trucks were unreliable
and crude the demand for military
vehicles laid the foundation for Japan's
motor industry
but the great adventure ended in
surrender Japan was defeated and the
workers and managers had no idea what to
expect
Eiji Toyoda had joined his family's firm
in 1937 the world are there
senso up or what thought sceptile gonna
show they the law had just finished what
I got out doorman no God everyone was
wondering what would happen now I think
would happen to Japan what would happen
to our own daily lives and to our Karan
I know you can see honey no one on what
to expect we were all in a kind of limbo
so Titus surely you know chingkuo type
the economy was in chaos Japan was cut
off from its raw materials all the
military orders had stopped
the black market flourished
during the war mr. Honda small company
had made arrow engine parts a Virginie
grenade machine a hernia unless you went
out looking for them parts and materials
were impossible to get hold of so that
was my wife's job my job was to stay at
home using how modern unless he went a
long way you wouldn't find what you were
looking for and it was hard cycling all
that way in there anyway that was a
small 50 cc engine that the army had
used in the war so I got hold of one and
fixed it onto a bicycle and with that he
could bum a lot
Scipione through and that is the first
motor powered bicycle to be made after
the war no my biscuit fire engine that's
me three-wheeled bicycles and
motorcycles sturdy little vehicles which
carry unload all out of proportion to
their size today perform a very large
part of the freight hauling this is the
Nipponese version of the Stanley Steamer
when the operator starts the fire you
never know whether there's going to burn
up blow up or just behave itself
[Music]
gie drivers in jaffa and usually get
this number of wide berth when passing
on the screen the technical superiority
of the Americans who were now occupying
Japan had never seen clearer but the men
who built the Army's trucks wanted to
put the war behind them quickly and get
back to business
Toyota's factories had survived the
bombing mr. Ono was one of their
engineers Keitel or NATO thought it was
only two or three days after I defeat in
the war the company president Kiir trio
Toyota gathered us all together and he
made a speech that's nay he said you've
got three years to catch up with
American industry son in the motor
industry in Japan will be physically
fatal so the net thought you're on drugs
is also yeah - can I offer you
well I wondered if Kia true had realized
it American manufacturers productivity
was at least eight times better than
their own
then I thought to myself why not all
you've although catching up with the
Americans in three years question
son-in-law chat or at least we ought to
set about it in that sort of you only
did your auntie can Takata what the
decision was all worked out
to most catching up seemed a distant
dream machine or dachshund doing at that
time I was living in the single men's
dormitory and the chimneys of the
company's forge were just across from my
window so William you so when I looked
out and saw smoke coming out of them I'd
think oh great that means they've got
some coal so when there was nothing oh I
knew there'd be no vehicles made that
day even if I turned up for work well so
are those days we would go to the local
farmers and try to swap things that
we've made for food reward so we rode
through the course
companies struggled on but with too many
workers and too few orders they were
near to bankruptcy books in Nagpur
questa continuously Del Greco cetera one
day I heard a news flash on the radio
that war had broken out in Korea tonight
and when I went to the factory I
discovered that we'd got an order for
three thousand army trucks and suddenly
we were hard at work it was funny
because until that week we'd all been
laid off the president of Toyota wrote
the orders were Toyotas salvation I felt
a mingling of joy for my company and a
sense of guilt that I was rejoicing at
another country's war as Japan regained
independence in 1952 its motor factories
still concentrated on trunks it nearly
stayed that way when the companies
wanted to move into cars they were
opposed by the governor of the Bank of
Japan mr. Shimada
who said efforts to foster a car
industry in Japan are meaningless since
America can produce cheap high-quality
cars
shouldn't we depend on them for our cars
but the case for making them was put as
strongly by others Nick hewer at that
time I was the official in the Ministry
of International Trade and Industry
responsible for the motor industry I
said that if we would have plan in the
post-war recovery of the economy so that
everyone in Japan could make a living we
needed major industries but we in
particular we needed to build up an
automobile industry because car
manufacture as many other industries
associated and we had to provide jobs
for a lot of people it's not clear make
a nice list Nick he thought then that it
would also help raise the general level
of technology for all those reasons we
had to bring on car making as a
strategic industry Accession meaty we
clung very firmly to this thinking today
I'm on target
[Music]
the powerful Ministry of Trade and
Industry methi was now backing them but
there was a long way to go
[Music]
[Music]
[Applause]
using the chasis from light trucks they
voted on bodies to make Japan's first
post-war passenger cars with their truck
origins they were sturdy but crude
as they started to develop better models
the firm's had to set up new car design
teams in the factories at Nissan one of
the car pioneers was mr. Tanner Bey
mani son the Hollen or cicada scalable I
was in this hands design department at
Cerrone it was in an old building made
of wood two stories high the floor was
pretty rotten are you gonna be doing
experiments and that sort of thing we
bring engine parts like cylinder blocks
upstairs and put him beside our desks
Shinda broke that go in more detail is
seconds away everybody do this law would
be away so after that who were forbidden
to bring heavy objects upstairs did we
had to keep them the other corners good
idea at the time half the cars were
imported so heavy tariffs up to 40% were
imposed to keep them out but for their
own industry they needed no harm and
Ford expelled before the war was still
the marvel
in Detroit Henry Ford with the biggest
car plant in the world his mass
production method set the standards
others had to follow
Detroit in the 50s was king of the
mountain the world couldn't do what they
did the world came to their door how to
make automobiles and I am and it was a
simple automobile highly refined for
simplicity sake
low cost of i buy and manufacture one of
the first Japanese to visit Ford's
Detroit Factory was AG Toyota Toyota
Thor Rock Arianna they told me that
because Ford was such a huge company
there were actually only a few people
who could answer all the questions in
the various areas we had raised and they
said why are you being so greedy why are
you making so many sort of moisture for
Dada - okay so I said I understand but
because Toyota is such a little company
we managers have to be involved in all
the manufacturing areas or the nation
must so please help me then why you
don't never though all sweaty much tail
Toyota was allowed to spend three months
inspecting the plants he wrote home to
his company newspaper throughout
assembly everything is tested again and
again I realized this is the way to
produce perfect cars there's much for
Toyota to learn here
and socially caneta was he mother's name
since our first measure was to encourage
the introduction of technology from the
developed countries Europe and America
done this we try to get all
manufacturers to form technology tie ups
with foreign companies new kagu north or
so you got on the understanding that
they move towards 90 percent domestic
manufacture within five years as a cue
to pass into array consists of Leona and
killed a the British taught the Japanese
how to make cars to when the son needed
help they signed an agreement with
Austin years of research experiment and
trials went into this car before the
Austin designers were satisfied now
manufactured with scrupulous skill from
the finest possible materials and tested
at every point the Cambridge will soon
be ready to leave the lines under its
own path at first
Austin shipped all the parts from
Britain but the government wanted Nissan
to make each component and finally the
whole car in Japan as soon as possible
before this could be done they had to
meet British Standards Nixtamal ma jim
boo and his sons it kills us much to the
kids at the time we made a new part for
ourselves as a result it would be flown
to Austin in England who thought there
it would be inspected and okay for
manufacture by us just it
Aric whole Beach was sent from
Birmingham to Yokohama to supervise
production of the Austin design that
equipment was very basic and it included
a lot of machines which were Japanese
copies of British and American and
German machines which they had produced
themselves know that because of the
difficulty of importing machine tools at
that time as they studied the blueprints
Hobe each found the Japanese engineers
eager to learn and persistent if you
couldn't give them a precise answer for
any reason then they would repeat the
question if they still didn't get an
answer then it would be left on one side
sure enough the following day or the day
after they would come up with the same
question again and we rather got the
feeling that they thought we were hiding
something from them and then they would
come out mr. hull Beach we must learn
from the West please can you answer this
question
with ho [ __ ] help the first Japanese
a40 came off the line in 1953 austin's
home factory was then one of the most
modern in Europe and Japanese engineers
like mr. Sasaki were sent to see it come
vehicle
Galip don't know what I saw how the
parts came from the founder and were
moved on to the machine shop by a very
rare it was all automatic with you
master eh it was the first time I had
seen anything like that and I thought it
was amazing
jujin not only deep down ladders me but
come tell o'clock they all had a tea
bringer and everyone had their own mug
which they'd go and fill from an urn and
then they'd rest for 10 minutes
I just wonder about the factory coupe
would you avoid our eyes you really
think embackment
production had to stop for 10 minutes as
well India
don't you remember - like your van other
firms made similar times with Renault
Hillman and other European companies but
the biggest Japanese firm Toyota was
determined to go it alone and develop a
modern all Japanese popular car their
first model was called the toyopet
even therefore the civil area we
collected together lots of thoughts from
Ford Austin Chevrolet and Hillman so on
and had a close look at them all
that's how we start to do cause I cut
scare coil what are the machine tools
the boring machines and so on were all
owned in common from before the war and
they look really worn out
I worked on them to get them or
something like automated to raise
productivity receive Malloy you're
imagining CEO Cynthia we had to do all
the designing ourselves and then do all
the work by hand
in the mid-1950s the protected Japanese
carmakers were learning fast but their
technology was way behind the rest of
the world went missing produced their
first home design Datsun model they
wanted to test it against the foreign
competition so in 1958 they entered it
in the round Australia Rally
human never see I thought we might get a
bit of publicity but even if we didn't
we've been on the worse for it
because having the chance to test the
car and those conditions would be very
useful you might open this early
[Music]
dr. Sangha drunken offensive scheme
ashtanga yoga nagato-san no podía so the
author rocky does money matter
Oh Veronica of anonymous investor
porkiness am NOT an optimal Vista
machine I see a doctor's antibodies she
meant Akira however we have that big
crystal inertia
ji-woon Okinawa Okinawa captain ah
look we went to find out how our car was
stabbed but also to take notes on the
performance of other countries cars that
was our purpose in going so the whole
team were engineers to Australian and
even Japanese surprised Datsun won its
class
Kuala new home nor couldn't lie there
nuan Ginga so you see we'd been defeated
in the war kiln and everything of the
fleet so when a Japanese car with
Japanese drivers did well in an
international competitions it gave
everyone a tremendous lift
the Japanese had now recovered from the
war they were still poor by Western
standards most people could afford only
motorbikes but 11 companies were already
making cars Toyota trained women
graduates for its sales force we went on
training course after training course we
even learned about servicing when we
took the demonstration cars out we'd
sometimes see our competitors from
another color Anya parked outside a
house and we'd know a Salesman was in
there and when they in turn saw our cars
parked they knew that Toyota was in
there trying to clinch a deal high up
we'd see why you had to be very careful
with these demonstration cars I'd either
have to get up very early in the morning
or go in the evening when it was dawn to
throw our riders off the scent I park in
alleyways the cars they sold were
expensive and to make more sales the
companies had to get the prices down the
key to that was not just technology but
working practices and labor relations in
the factories
[Music]
undeniably I know I don't I protected my
Japanese labor relations weren't always
the envy of the world after the war
there was constant strife as new
industry-wide unions battled with
managers after wartime service in the
Air Force mr. Meyer key went to work in
a car plant you know what you cut it to
the grassland his sankhara dukkhata were
loud yoni Nissan was the company that
went 12 months on ten months work
because it was on strike at least two
months a year
Chingy induction didn't go smooth edges
were paid late it was a very unsettled
race doing normal so who's your tightest
cutter donkey what labor relations were
so bad I thought well I've joined a
company that looks as though it's about
to go broke my doctor she was obscure
too much they were odd I was general
secretary of the you and I held frequent
meetings with the shop stewards in order
to pass on information it was very hard
to get enough to eat just on our wages
everybody thought that we had to do
something about it you who knew I mean
know what that alone is the crucial
showdown for the car industry came in
1953 the national car workers union the
Zenji took on the companies in a claim
for wages and more shop floor control
Nissan refused to negotiate and locked
out the strikers Musto so I say oka
behind the barricades Nissan's managers
stayed in the factory case we camped out
in the offices on the second floor of
the administration block I done blocked
the staircases with wood so that nobody
could come up so got out there were lots
of offices
nicaya and we spread blankets which was
the desks so they're square we were in
there for 45 days you do they know what
the Nissan dispute became a symbolic
fight watched closely by other employers
at the Lord you give out 31 you're my
you don't maybe there funiculus the
Japanese Employers Association gave us
great support they were there no ma say
held meetings with us and advised us on
anti-union tactics ok no Cushi she
Sakura
since this was the sort of strike that
the management couldn't really cope with
the only course of action was to
eliminate to the Union our CEO is your
new destiny that was the only way we
were going to get anywhere these days if
there was no alternative know this
matter so you could are you
the management plan was to outmaneuver
the strike leaders by encouraging a new
more compliant company Union which would
settle quickly
Masaru Miyake became the leader of the
breakaway union its slogan was only
those who love the company love the
union they put pressure on the strikers
there's empathy Nick stare so he did
know but they called on us at our homes
and they said to us if you hold out like
this there may be no job for you to come
back to that was the sort of
intimidation there was Dino
communicative but they said if you come
over to the new young you won't have to
repay the money that you've borrowed
from the old Union not the one that's
not so they were caisson octamer ended
after 14 weeks the tactic succeeded
Meraki led the workers who changed their
allegiance back to work still puzzled
insulin Yahoo this day we marched in a
narrow column to make it look as if
there were a lot of us as we marched in
people from the first unit started to
come over instead of the increasing
numbers it was an extremely effective
nicole got a doctor toe so they got cuz
I'm not a high table you got anymore
at the moment we entered the works that
was the end of the first Union you
couldn't not that was me
the company had its victory it was a
turning point the disputes stopped the
first union was disbanded from then on
managers had cooperation and a new
freedom to change working practices at
Toyota the engineer who did most to push
the pace was taiichi ohno patella
protego ji though the kid still
Sushil machines actually work by
themselves meter so someone's standing
over one watching it intently might
think he's working think so the machines
doing fine on its own so I'd say that's
a waste of Manu Hyundai out the corner
mom without MIT's kitty my journey was
only midscale Naga told you all you must
in a syringe if I found a job that was
being done efficiently one day I would
say try doing it with half the number of
men mr. hofstadt skied in it and after a
time when they had come back he said
that they've done that I'd say okay half
the number again yeah Oh hum when they
intersect oh you're not gonna knit did
you mail me on this you at night I'd
have dreams
my job was the last one on the lion I
dream that I wasn't keeping up just as
the engine was about to fall off the end
I'd wake after the shout you're not
gonna talk your things got to that stage
sure not your cure say I'm a rocker this
new tether yeah ultimately and without
way I'm gonna say
if I just called the former and said
stop the waste people wouldn't
understand what I meant no
constitutional because Crocker theatre
thundered they'd say but we've always
done things that way or this man's a
hard worker but I'd say you can't see
straight
that's not real work
you go Tomo again today so unless I
spoke to the worker right on the shop
floor it was difficult to get things to
change have cameras in it immediately I
worked in a particular field isn't it
come the rain will soon as we know with
the introduction of the production line
as a former nurse job changed and you
more they know his role now is to see
that the line ran smoothly
did you before that it felt that wasn't
enough that they weren't getting their
hands dirty they were getting work
you're not you know I get that mr. Ono
would come along and say your job is to
stand here and make absolutely sure that
the line is Olivia properly cutter young
I remember him drawing a chalk circle on
a floor and saying you stand-in here oh
no was the most creative engineer in the
post-war car industry he made the
maximum use of human labour and he
changed the whole system which fed the
assembly line itself
in the traditional method the many
different parts doors or engines had
been pushed out in big numbers and piled
up beside the lion until they were
needed this was Henry Ford's method
single or new-home no talking it is also
super super itself we done that in
post-war Japan especially in the motor
industry we would have gone straight
away there are more those two more
dishes ok goods needed to be turned into
money as quickly as possible
Timothy so we really had to keep our
stocks to the bare minimum you can
imagine a
owners saw that by carrying one or two
months stock tire to a tying up immense
amounts of capital so they reorganized
the factories until the assembly line
and the making of the parks ran at the
same rate parts are only made and pulled
to the assembly line in the quantity
that was needed
the Japanese called it the just-in-time
method more just in time nor its
foundation of auto with the just-in-time
system the most important thing was to
produce only what was needed when
workers needed more parts they
themselves would go and get them talking
you don't worry but if they took
thoughts away without leaving anything
jobs change you would have a problem so
just as in a supermarket where customers
take goods from the shelves in exchange
the most money we used what we call a
Kanban instead of money or a Kanban at
each workstation the Kanban acted as a
sort of order for
Kanban said in the settlement this
number of these parts has been used so
please make this number of the same
parts and place them here now my uncle
or mr. Ono found a stack of doors on
bumpers kennel close that they're made
and left on one side he took it as he
walked past its crash he'd kick it on
say don't make noise stragglers just use
stick to making only what's needed when
it's needed
the Americans use their huge presses to
stamp out the same parts for weeks at
the time the Japanese made fewer
vehicles but a range of models so they
had to use the same presses to make
parts for different cars
we help subbu Shinobu
I wanted the machines to produce sets of
a hundred of one shape and then changed
to another turret little more me
something to slow the production may
have only taken minutes miss hum
changing the machines take hours and
everyone will be standing around doing
nothing wasting time then their CEO Tony
Nara
oh no got the time for changing that
dies in the presses which took up to
three hours in America down to a few
minutes then the same machine that had
just been pressing mudguards could get
on with other parts
[Music]
the oh no revolution to get the best use
of labor and machines was extended to
all the suppliers productivity increased
fourfold in ten years but the factories
were old what was needed was investment
so help came again from me tea yeah I
had to be in court though to show you
can you call Courtney he didn't talk to
me we talked to the Japan develops
impact small and medium enterprise bank
use in order to arrange chief loans for
companies there that was the system we
set up fortunately a lot of people came
forward who were very positive about
wanting to reinvest and we used our good
offices to help them as soon which they
can afford it or say so gonna in
Karnataka don't know sir on the finance
scheme was originally set up to run for
five years it was extended to run to ten
years you put in that time the ministry
was able to arrange about sixty four
billion yen in loans for investment
purposes Ricardo Italy which was an
enormous sum in those days Antigua good
know you can zealously men's the car
firms plan new plants that would be as
modern as any in the world
tow to built the first Motomachi in 1959
takagi new coordinates name we got a
loan from the World Bank I think it was
about a billion yen and I was told okay
you get half get up for the I wasn't
even a section so I said how do I go
about it and they said well that's for
you to work out
yeah so now coach thinking outdoors
Jesus yummy it was a fairly spectacular
Leslie and if everything worked out
successfully it could prove very good
for Roy else's future but if it were to
fall on stony ground then we'd be faced
with a real disaster they chose you
[Music]
so nobody is showing a territory contact
money up until they're among the people
I worked with if a new workman joined
within a few days or so and I found out
his name of course but also where he was
from whether his parents were alive
whether or not he had brothers and
sisters when the new production
facilities came in all that disappeared
economic so cambiar died in that case he
was away to a snotty tyranny so you know
so people are not like them destiny as
the new factories were opened the output
of cars grew by up to 80 percent a year
Japan's economy was roaring into high
growth and the car makers were leading
the way
[Music]
do not test anymore time ha
[Music]
Casino suits are you there without
putting a dick Nakata though they were
secure companies needed more workers
they were recruited from all over Japan
[Music]
due to miscarriage in Tokyo tu y yo no
doing a soda
Chiana etre she shall not have any
hobbies needsto met
[Music]
companies provided housing for their new
workforce and offered security and
lifetime employment
school leavers were trained in company
schools as an investment for the future
[Music]
as sales grew more and more families
became the proud owners of their first
car there was still 103 people for each
car in Japan compared with 3 in America
the stage in a nation's development
known as motorisation was now underway
in 1960 alone 3 million Japanese took to
the road for the first time at driving
schools
but the Japanese car market growing so
fast was closed to the rest of the
world's manufacturers and was a Private
Reserve
Western cars were still ahead
technically but were out of reach they
could be admired at motor shows but
tariffs and other restrictions made sure
they remain exotic and inaccessible the
crew are no guy bukhara could mute to
listen a scene from abroad it may have
looked as if we were being excessively
defensive for all I know but it was
caused by the feeling that we still had
a very long way to go out that you kinda
thought there was a plus and the minus
side to such heavy government
involvement not all firms like the
guidance they were being given by the
bureaucrats
mr. Honda who'd become the leading
motorcycle manufacturer wanted to start
making cars as well
but media tried to stop him
[Music]
at all very money the bureaucrat still
had their heads for the build notions of
central control they were absolutely no
help he wouldn't believe what a hard
time I had with me t anything when I
wanted to make cars they said keep out
Toyota and listen are doing it already
so here are you visit I'm free to do
what I want
the war's over you know combien Amana
Pandava zombunny Cyrano very ID
Dido sonnets Critias radio taniwha says
and I saw me Hockney juuhachi Monday say
que dicen idea Joshua sorry Sakana nani
ga goo percent ozone OG omaha molly
sweeney me she do it so late day
Americanism cicada II know you do
cessation in the 1960s as their
efficiency improved and manufacturing
costs came down to world levels for
Japanese firms looked overseas for new
markets but the export story had started
inauspiciously back in 1957 when tire to
ship their first cars to California
[Music]
Jihan no come here son I said the car
wasn't ready for a mess over and I
didn't want them to sell it there
tonight there but mr. cameo who was head
of Toyota sales said one day we'll have
to do business in America because the
market there is so enormous you give me
a fancy composite magn ago he said you
may not agree with me but we need to
sell some cars there just to establish a
bridgehead
I know it's good run I thought it was a
piece of junk
it was didn't start and call weather
very well we didn't do a lot with it we
just had it around the test fleet and I
could never go home look at it and
thinking it was a joke
was badly made under power terribly
underpowered for American Express ways
Nissan sent a group of engineers to
California and see how their small
dancin cars would stand up to the
American climate and tougher driving
conditions
mr. Tanner Bey was one of the testers
carry on or soak in the hot speeds were
much faster where in Japan it was usual
to travel at 50 to 60 kilometres per
hour
they were driving at 50 to 60 miles per
hour so they were doing nearly twice as
fast don't matter
the first Toyota's were a sales disaster
salud Gallery luckily it had trouble
getting onto the freeways in Los Angeles
because the acceleration wasn't poured
it couldn't get into the flow of traffic
there were a number of problems of this
sort
anyway we couldn't sell the cars we'd
sent over there which in a way isn't
surprising because you can't sell a kind
that can't be driven in Miami technical
skill
the Japanese kept on trying the target
was not so much American cars themselves
as European imports like Volkswagen
Nissan sent mr. Katayama to study their
success Hioki meet a routine
orthogonal humidity Renoir Naropa door
service Nathan after much observation I
discovered the Volkswagens secret was
there after sale service they supplied a
lot of spare parts and train people in
after sales service I mean couldn't
monument in this respect they were much
better than any of the American
companies Katayama
and his team struggled to sell the cars
and provide proper service part cigar
Adriano Caron or Audrey I think ara
since we didn't have a supply of spares
I was forced to remove parts from other
cars we had service the ones that had
broken down tomorrow as this went on our
company cars are gradually being
stripped of more and more of their parts
wanted in some cases we were left with
just an empty shell symbol
they actually not to drop them he hired
a local advertising agency to win over
the American public
what a man discovers his stolen
summoning he does the obvious he gets
out of town
this getaway car is the new Datsun for
tensive and standard equipment includes
white sidewall tires and the interior
how's this for steel up front a soft
padded dash heater defroster seatbelts
and contour seats in the back all vinyl
upholstery wall-to-wall carpeting and
yes even a mesh tray a standard low
price by the late 1960s American car
companies at last began to take notice
this is an easy story to tell all you
have to do is count it starts back in
the 50s on the road count the fun cars
in this picture
go ahead we'll wait
now I had 20 years things have changed
this is the 1970s some people call them
the Japanese beetles their real names
Toyota and Datsun by now the Japanese
had overcome the early quality problems
and were making their mark especially in
California we saw one went out there for
sales being always little nippers cars
running up and down the streets and they
had 15% of the market place or somesuch
number said wait a minute what's going
on here
[Music]
in 1973 the world economy was hit by the
oil crisis petrol prices rose four times
over all car firms suffered including
the Japanese when one company faced
bankruptcy the Japanese response was to
take workers off the assembly line and
send them out to sell the cars
door-to-door when I went to the houses I
found it very hard to deal with
housewives face to face I'd give up very
easily went on like that for quite a
while didn't have much courage you see
when you sing up for UT and I in the sky
my model la única ha ha ha but really
there was nothing for it but to go out
and try to sell the cars because the
company was facing a crisis and we had
no work to do here we were worried about
the situation and well we had to make a
living but in America the all shock gave
the Japanese an unexpected bonus the
United States government without figures
which showed the Japanese dancing had
the best fuel economy of any model on
sale this is one of our most valuable
resources a gallon of gasoline
not be wasted
I don't put it in the aperture my
cooking area well the advertising
manager came up with the slogan Dadson
saves he got the idea from Jesus Saves I
said well that puts me in a bit of a
spot I'm not too sure about using that
in an advertising campaign for money in
a typo you will squeeze every mile out
of every precious truck
say so no local it's a mob thought I
should all know stoke the moola don't
they in fact they sell a six months
backlog of stocks in two months and the
oldest continues to flood in the North
Sea color to market a good other week
they were saying that centers cars
however much they cost and we were
really kept on our toes Geordi by heart
the fella that is Michael Mayer suddenly
what they sold was hot and suddenly what
Detroit's all was not and that was a big
big break if you will for the Japanese
they just happened to be at the right
place at the right time where fuel was
concerned while American gas guzzlers
stood unsold and the workers who built
them were laid off imports rose fast it
was a foreign car but some unemployed
Detroit area residents changed all that
this afternoon frustration bitterness
and most of all anger that's the mood in
Detroit these days and it's chronicled
every night on the local news a lot
better how long have you been off work
well I got a lead up on uh not even a
month ago you feel this had a lot to do
with that the foreign car sir
[Music]
the Japanese tailored their cars for
every export market but actually when
you children are going to start a Karim
Allah yawns ooh cute the kite Animus
americano California shoo-in I know
Jung Joo you know soon you may get the
assassin solitaire clematis it's a lot
Salina reticle to go with him I saw
Oprah Europe Authority look at us
they'd been the first to introduce
robots
they'd make breakthroughs in cleaner
engines to meet anti-pollution
requirements they'd improve quality now
it was the Americans in the Europeans
who came to Japan to see how it had all
been done
I will go back to Nagoya and I'd walk in
those places and I can remember and I'm
sure you can't use this on a tape I say
holy [ __ ] look what's happening here
no7 effective monk rajappan option out
to new Odeon de resulta travel Makar on
amateur a new some venue I'm
particularly a poor 8ug Lemonnier don't
want Paul said to the travail pass
pretty group and you can see that this
is a different world the word pace was
dramatically more rapid than it was in
the United States people were just
working like dogs and there was an
eagerness and an effort that I had never
seen in my entire experience anata no
koe kanga hajiman can you automatically
sign show me Aneesa Reutimann came in a
document zoo can adapt it much much data
cannot an Old South oh it's for its
canisteo Nana do demos the rest of the
world began to learn about flexible
production but just-in-time system
quality control and Japanese labor
relations late fifties if Toyota made
200,000 units of anything it was
surprising now it was 2 million big
difference by 1980 Japanese cars had 20%
of the American market the American
companies faced huge losses and asked
for protection
and so to prevent the once proud
American car industry from going
completely down the drain they actually
asked our government if we would in some
way limit our exports to the United
States Ronnie nothing else I got a tip
Denis I said to them that if you impose
limits and competition you won't help
your industry to get strong again that
way thing is that there and silver now
if your intention is to make your
industry competitive again limits of the
last thing they gave me this job because
he thought Kunal
in the end though because of the
political situation between the two
countries our government set up the
voluntary restraint system in fact it's
a compulsory in voluntary restraint
system sorry that
the Japanese agreed not to ship more
than 1.8 million cars a year to the
United States Europe set limits as well
so to get round the import restrictions
they started making Japanese cars abroad
Toyota began at an old General Motors
plant they sent Japanese managers to
retrain the American workers Yun Jie on
site my yard son Macarena QC assist at
Sandia scientists
Sanjana aguma Gintama morality Elton
John okay I know gigantic are even in
foreign language acoustic
[Music]
scotchy star cochamo Cara Shido
sidonians in tow America didn't do those
on either a some other mono mundial
instead of c4 here to make himself clear
he didn't understand if like you'd
understand I didn't understand what I
mean
Teddy Montoto
you thought of another juvenile
the Japanese transplants grew fast
within a few years they'd open 10 new
factories in the United States super
while she thought ah she deshita
[Applause]
back in Japan the firm's kept up the
pressure for higher productivity
sanguine a UFO phenomenon Pocahontas
don't know McKinney quantity Omega 2
very much
[Music]
[Music]
Viviane [ __ ] what people up everybody
[Music]
you'll get yours it's called
oh you can about them right though it's
means oh cool - returning with a
racially homogeneous worker yes it's
much easier to discuss things in fact
it's perfectly natural for us to have a
unanimous agreement in whatever we
undertake don't go to Corvette's
colonists they've done a lot to share
with their people and to build
participation with their people but
they've also driven their people
literally almost unmercifully now know
primarily in Japan but even in this
country they're driving the people to
levels of worker pace that one wonders
if you can sustain over the long term
nearly 60 years after Ford's first show
the Japanese of the American Way of mass
production Ford badge cars are being
made in Japan again but now it's a
Japanese firm that designs and builds
small models on Detroit's behalf
with Bakkerud on every continent the
Japanese now make 30% of the world's
cars they started late
they kept out imports but with fierce
competition at home they transform the
old Detroit methods their efficiency
became almost unstoppable so we had to
start from scratch again after the war
that's what accounts for the strength of
Japan's industry today that's what I
think because that's what I'm like I'm
not afraid of anything
hmm oh honey who are you except the wife
he thought you know save your pity what
about in Japan we have an old saying the
last parts of the ferret
great thinking ye when a ferret is
cornered and about to document it it
will let out a terrible smell to repeal
its enemy an escape say he losta that's
real now same with human being when
they're under so much pressure that they
feed it's a matter of life or death they
will come up with all kinds of ingenuity
Nong Khai each year a barrel has
abandoned
[Music]
this gonna say the same about the mascot
exceed Escalade
it may be an overstatement to say we
went from being pupils to be in teachers
girl kaga the-- them are but we've been
running for all we're worth after our
competitor your saw recently we've drawn
neck-and-neck and we may win or lose by
a nose Miguel Herrera comes back at them
or is there a store go anyway there are
naturally things that we can still learn
from others he mother mockery dog around
our avocado and it is turned out that
there are some things that others can
learn from us and Collier or Sheriff no
Yuka I'm gonna roll you are addicted
[Music]
[Music]
[Music]
you
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