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"Why Are US Foundries Losing Market Share"
by Neil Chaudhry, COO/VP buyCASTINGS.com, Inc.
Our industry is going through one of the most challenging times. Some suppliers say they haven't seen it this bad in 40 years. Many foundries are closing up or consolidating. The ones with deep pockets are acquiring others while the majority are fighting for survival. There are several reasons, some obvious and some not so obvious...
First of all, the economy is in a recession-if you are a manufacturer, you knew that. Unfortunately, you knew that we were in a recession long before the economists. Technology is in a depression! Thanks to the bursting of the hyper-inflated-tech-bubble, over-hyped by the investment bankers and the Wall Street gurus. We have a war going on with no end in sight-the terrorist attacks of 9/11 caused many businesses to freeze spending and cut budgets.
Interestingly, the service sector is still growing while manufacturing is losing millions of jobs. The latest numbers show tremendous growth and hiring in construction, health care, financials and other "soft" sectors of the economy. While the technology and manufacturing sectors, the "hard", wealth-creating sectors of our economy are in a constant decline. The production of "hard" goods such as computer components and manufacturing components like castings are moving off-shore as the US corporations look for ways to cut costs.

One has to wonder, why do the prices that we pay for manufactured goods going down every year, including computers and cell phones going down every month. While prices we pay for health care, fees to our banks, closing costs, and costs to build new homes, new buildings are going up every year. This brings me to the original point, why are US foundries losing market share?

One detailed analysis shared with buyCASTINGS by one of our largest buyers of castings in the US was most enlightening...The US foundries, according to this Buyer, are losing to the off-shore foundries, NOT because of the material costs or even the direct labor costs. They are losing because of these "soft" OTHER COSTS-healthcare costs, OSHA issues, compliance requirements, administration costs, benefits costs, Worker's Comp, and legal costs. We can add to that the labor issues, training costs, EPA, ergonomics issues, energy shortages, freight costs...
What can we do? Two things: We can turn to our legislatures (directly and through our great trade associations like AFS, ICI, NADCA, and other cast metal chapters and associations.) Secondly, we can work smarter with better tools and technology.

Technology has always helped businesses cut costs (if you never bought a fax machine or a computer for your business then I guess you don't have to believe that.) If you are in the norm, you would agree that every decade, there is a major innovation which helps businesses improve productivity. In the 1990's, it was clearly the pervasive use of computers and the productivity software that helped us produce more and more with less and less time and resources. I believe, this decade will see a pervasive use of the Internet and the web-based tools by businesses to cut costs AND to get new orders. It's not about automating transactions or doing reverse auctions, it's about spending less time and doing less travel to get new business; it's about reducing soft costs and administration costs. One web-tool that allows businesses to cut costs and get new customers is an e-marketplace.

buyCASTINGS.com is the world's largest e-marketplace for the Metal Casting industry which allows it's members to cut costs by getting volume discounts and service discounts on freight, shipping, computers, software, natural gas, electricity, and NOW healthcare, payroll, benefits and OSHA compliance needs. The buying power of over 900 participating companies and the efficiencies of buyers and sellers meeting through an e-marketplace ALLOW us to do that. In addition, we match our foundries and suppliers' capabilities with our buyers' needs.

One of our Foundry Managers reports: "The dollars we save in cold calling, travel related expenses and in wasted time pursuing nonlegit RFQ's is 50-75%" by membership in buyCASTINGS vs. the traditional marketing and sales approach.
In the long run, the only advantage the US foundries will have is technology-how we use it, how quickly we deploy it, how smartly we adopt it and how aggressively we make it a job requirement-will determine our survival, profitability, and growth. At buyCASTINGS, we are doing our part. We welcome your participation and input...please email to nchaudhry@buyCASTINGS.com.
There is Hope!
According to AFS and Stratecasts, Inc., a mild recovery in 2002 will be followed by "...a series of boom years," through 2009 for the metal casing industry (For more information call Mike Lessiter, AFS, 847-824-0181).

Source: AFS & Stratecasts, Inc. 15 year trend in U.S. shipments of castings per year (in 1,000's short tons)
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