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美國(guó)制造緣何撤離中國(guó)

美國(guó)制造緣何撤離中國(guó)

Sheridan Prasso 2011-07-04
與Sleek Audio數(shù)碼音響公司一樣,許多美國(guó)企業(yè)對(duì)中國(guó)代工產(chǎn)品的低劣質(zhì)量已經(jīng)忍無(wú)可忍,他們正在將產(chǎn)品生產(chǎn)撤回到美國(guó)本土。

????馬克?科萊克和兒子杰森當(dāng)年在佛羅里達(dá)州圣彼得堡市附近的一個(gè)小鎮(zhèn)成立了Sleek Audio數(shù)字音頻公司,生產(chǎn)iPod及其他音頻設(shè)備使用的入耳式耳機(jī)。公司成立之初,他們?cè)蛎绹?guó)的幾家生產(chǎn)商詢(xún)問(wèn)耳機(jī)的生產(chǎn)價(jià)格。當(dāng)然,中國(guó)生產(chǎn)商的報(bào)價(jià)更便宜,所以他們將生產(chǎn)外包給一家廣東的工廠(chǎng),并在2007年推出了首款產(chǎn)品。

????但是去年,該公司遭遇了一系列麻煩:產(chǎn)品質(zhì)量低劣、頻繁出差、溝通不暢、交貨延誤以及成本上升。最糟糕的情況是,整批1萬(wàn)只耳機(jī)在運(yùn)輸途中報(bào)廢,使公司損失了上百萬(wàn)美元,幾乎讓公司倒閉。于是,克萊克父子做出了一個(gè)重大決定:退出中國(guó),將產(chǎn)品生產(chǎn)撤回到美國(guó)。杰森說(shuō)道:“之前,我們的運(yùn)作非常困難和吃力。而現(xiàn)在,我們自己可以控制產(chǎn)品的質(zhì)量。此外,不會(huì)再出現(xiàn)交貨延誤的情況了。這真是太好了?!?/p>

????重新尋找代工工廠(chǎng)已經(jīng)成為一種趨勢(shì),Sleek Audio僅是其中一家。一些公司認(rèn)為在中國(guó)代工生產(chǎn)很麻煩,想把產(chǎn)品生產(chǎn)撤回到本國(guó),而這其中又以小公司為主。經(jīng)濟(jì)衰退使得美國(guó)的企業(yè)成本降低,而且許多工人急于找到工作;對(duì)于美國(guó)制造業(yè)來(lái)說(shuō),這些都是利好條件。加州、德州及美國(guó)各地的小企業(yè)——甚至是諸如通用電氣(GE)和卡特彼勒(Caterpillar)這樣的大公司——都充分利用當(dāng)?shù)氐募?lì)政策,至少將部分制造業(yè)務(wù)撤回到美國(guó)國(guó)內(nèi),生產(chǎn)在美國(guó)市場(chǎng)銷(xiāo)售的產(chǎn)品。

????代工業(yè)務(wù)撤回美國(guó)本土后,Sleek Audio的成本增加了15%至20%,但是用美國(guó)產(chǎn)的高檔鋁、鈦和特種碳纖維取代此前中國(guó)產(chǎn)的塑料配件使該公司重新設(shè)計(jì)的耳機(jī)在質(zhì)量上得以提升,價(jià)格自然也水漲船高。公司不僅獲得了“美國(guó)制造”的標(biāo)簽,而且重新設(shè)計(jì)的SA7耳機(jī)獲得了由美國(guó)消費(fèi)電子產(chǎn)品協(xié)會(huì)(Consumer Electronics Association)頒發(fā)的2011年最佳創(chuàng)新產(chǎn)品獎(jiǎng)。“雖然在中國(guó)生產(chǎn)可以節(jié)省大量的成本,但是最后算下來(lái),節(jié)約的費(fèi)用并沒(méi)有預(yù)期的那么多,”馬克表示?!敖?jīng)歷過(guò)了才會(huì)發(fā)現(xiàn),其實(shí)有很多隱性成本,比如交付延誤和運(yùn)輸產(chǎn)生的費(fèi)用?!?/p>

????2011年,Sleek Audio剛剛成立時(shí),美國(guó)制造商對(duì)某個(gè)特定配件的報(bào)價(jià)是19美元或20美元,而中國(guó)制造商的報(bào)價(jià)僅為2美元。但是當(dāng)克萊克去年決定退出中國(guó),詢(xún)問(wèn)美國(guó)制造商同一配件的報(bào)價(jià)時(shí),這一報(bào)價(jià)僅為8美元。此前報(bào)價(jià)為4至5美元的外殼現(xiàn)在價(jià)格僅為3美元。而且,克萊克父子還找到了一家從事工業(yè)設(shè)計(jì)的國(guó)防工業(yè)承包商,開(kāi)車(chē)僅需10至15分鐘便可抵達(dá)?!案鶕?jù)目前的經(jīng)濟(jì)形勢(shì),我們可以用較低的價(jià)格來(lái)外包我們的業(yè)務(wù)。我們清楚這一點(diǎn),我們也了解價(jià)格行情。因此,我們可以直接對(duì)制造商說(shuō)‘你不能向我們收這么高的費(fèi)用?!F(xiàn)在,很多美國(guó)本土公司開(kāi)始意識(shí)到,必須降低價(jià)格,從事規(guī)模化生產(chǎn),才會(huì)有競(jìng)爭(zhēng)力?!?/p>

????在中國(guó)代工生產(chǎn)的一個(gè)大問(wèn)題是,公司需要委派全職員工監(jiān)督生產(chǎn),而這對(duì)于小公司來(lái)說(shuō)是無(wú)法承擔(dān)的。馬克說(shuō),這意味著他們不得不經(jīng)常出差、或熬夜到凌晨2點(diǎn),通過(guò)電話(huà)與中國(guó)員工進(jìn)行溝通,即使只是一些非?,嵥榈膯?wèn)題。小公司的訂單通常受到大規(guī)模訂單的擠壓,意味著他們經(jīng)常會(huì)受到怠慢。馬克表示:“我們?cè)趫?chǎng)時(shí),他們會(huì)給予特殊照顧,讓我們滿(mǎn)意。”杰森補(bǔ)充道:“我們?cè)趫?chǎng)時(shí),他們的生產(chǎn)質(zhì)量很好,但是一旦我們告訴他們?cè)偕a(chǎn)10,000到20,000件,他們就會(huì)出現(xiàn)問(wèn)題?!?/p>

????現(xiàn)在,公司的產(chǎn)品生產(chǎn)完全依照規(guī)范進(jìn)行,克萊克父子能更有效地進(jìn)行控制。他們估計(jì),現(xiàn)在,不同公司提交的訂單可以創(chuàng)造100個(gè)就業(yè)崗位。鑒于美國(guó)缺少一種特殊的紅木原料,他們目前還不能在美國(guó)生產(chǎn)全部所有的產(chǎn)品,其中35%的配件仍在中國(guó)生產(chǎn),他們計(jì)劃在今年年底之前將80%的配件生產(chǎn)撤回美國(guó)國(guó)內(nèi)?!拔覀兊拈L(zhǎng)期目標(biāo)是,90%至95%的配件將來(lái)都在美國(guó)本土生產(chǎn),”杰森表示?!拔覀儗⑸a(chǎn)撤回到美國(guó)后,不斷收到表達(dá)感謝的郵件。這種感覺(jué)真好。”

????譯者:?jiǎn)虡?shù)靜

????When Mark Krywko and his son, Jason, launched Sleek Audio, a small business making in-ear headphones for iPods and other audio devices from a Florida town near St. Petersburg, they asked several U.S. manufacturers for quotes on how much it would cost to make their product. It was, of course, oh so much cheaper in China, so they contracted with a factory in Guangdong province and launched their first product in 2007.

????But last year, fed up with low quality, too much travel, communications problems, shipping delays, rising costs, and -- worst of all -- a ruined shipment of 10,000 sets of earphones that cost millions and nearly brought the company to its knees, the father-and-son team made a big business decision: quit China and move their manufacturing back to the U.S. "It became very difficult and taxing on us," says Jason. "Now we control the quality of the product. No more waiting for production has been a wonderful thing."

????Sleek Audio is part of a trend called reshoring, in which primarily small businesses decide that China is a hassle and that they want to bring their operations closer to home, where the recession has lowered costs, created workers eager for jobs, and made it easier to justify U.S. manufacturing. Reports have emerged from California, Texas and all across the country as small businesses -- and even large ones like GE (GE) and Caterpillar (CAT) -- take advantage of local incentives and move back at least some of their manufacturing operations for products sold in the U.S. market.

????Sleek Audio's costs are about 15% to 20% higher because of the move back, but the company's redesign of earphones that replaced a formerly Chinese-made plastic component with U.S.-made high-end aluminum, titanium and special carbon fiber, resulted in a higher quality product that justifies the price. It not only gets a "Made in USA" label, but Sleek Audio's redesign of the SA7 earphone won a 2011 Best of Innovation award from the 2011 Consumer Electronics Association. "Even though there's a tremendous cost savings when you go to China, in the end it really isn't that much," says Mark. "It's the hidden costs -- the delays, the shipping costs, you pick all that up on a learning curve.

????When Sleek Audio got off the ground in 2005, they first found that U.S. manufacturers were quoting prices of $19 or $20 for one particular component that the Chinese were offering to make for $2. But when the Krywkos decided to quit China last year and asked around again about making the part the U.S., this time the answer was $8. A box that used to be quoted for $4 to $5 in the U.S. before was quoted at $3 now. And the Krywkos found a defense contractor doing industrial design that they hadn't known existed before, just a 10- to 15-minute drive down the road. "The economy has allowed us to get better deals. Now that we're aware and we know the pricing, we can say, 'You can't charge us this much.' But companies now realize that if they want to be competitive, they have to lower their prices here and work on quantity."

????A big part of the problem in China is that small companies cannot afford to have someone there full-time to oversee their operations. That means they have to travel, or stay up until 2 a.m. to talk to people on the phone in China over even minor problems, says Mark. Small companies often get their production runs squeezed in between larger orders, meaning that they can get short shrift. "Great care would be used to satisfy us when we were there," says Mark. Adds Jason: "We'd go there and they would do it perfectly, but when we'd say go ahead and make 10,000 to 20,000 pieces, that's when the differences would happen."

????Now, with manufacturing to their specifications done just down the road, the Krywkos have much more control. And they estimate that their orders from various U.S. companies now support 100 jobs. They haven't been able to make everything here -- in fact, a particular type of Rosewood can't be found in the U.S. But while 35% of their components are still made in China, they plan to have 80% back here by the end of this year. "Our long-term goal is 90% to 95% of everything we make made here in the U.S.," says Jason. "We've been getting thank you emails for bringing it back to the U.S. It feels very good."

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