Why GM Matters: Inside the Race to Transform an American Icon [NOOK Book]

Overview


In November, GM CEO Rick Wagoner appeared before Congress to ask
for $25 billion to bail out the struggling Big Three automakers. To
critics like Thomas Freidman and Mitt Romney, it was a sign that the
American auto industry should be led out to pasture; if the ...
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Why GM Matters: Inside the Race to Transform an American Icon

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Overview


In November, GM CEO Rick Wagoner appeared before Congress to ask
for $25 billion to bail out the struggling Big Three automakers. To
critics like Thomas Freidman and Mitt Romney, it was a sign that the
American auto industry should be led out to pasture; if the Japanese are
better at making cars, they said, then we should let them do it. To
defenders, the loss of the country's largest manufacturing sector would
be an incomprehensible disaster. Nearly every day, the debate rages on
the op-ed pages. Billions of dollars and millions of jobs hang in the
balance.

In Why GM Matters, William Holstein goes deep inside GM to
show what's really happening at the country's most iconic corporation.
Where critics say that GM has sat on its hands while the market changed,
Holstein demonstrates that GM has already radically retooled its entire
operation, from manufacturing and cost structure to design. Where
pundits say we'd be better off without GM, he shows how inextricably
linked GM and the nation's economy still are: The country's largest
private buyer of IT, the world's largest buyer of steel, the holder of
pensions for 780,000 Americans, GM accounts for a full 1 percent of our
country's GDP. A dollar spent on GM has profoundly different
consequences from a dollar spent on Toyota.

Following a diverse cast of characters-from Rick Wagoner, the
controversial CEO, to design director Bob Boniface, to Linda Flowers, a
team leader on the line in Kansas City-Holstein examines the state of
GM's health and builds a persuasive argument that GM is essential to our
nation's well-being and, with the right economic climate, ready to
compete with Toyota as one of the biggest global automakers.
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Editorial Reviews

From the Publisher

“General Motors once dominated the auto industry, garnering more than 50 percent of the U.S. market share, but complacency, health-care costs, and competition from more efficient Japanese companies have all contributed to a dramatic decline. When GM CEO Rick Wagoner asked for a federal “bridge loan” of $25 billion for the big three automakers, the reception was anything but warm. Holstein, author of Manage the Media (2008), takes a look beyond the sound bites to reveal a car company struggling to meet high-tech standards while fighting for its very existence. Holstein argues that GM is worth saving because for every manufacturing job, there are 10 jobs throughout the whole chain of suppliers that also serve Ford and Chrysler; thus a GM failure could mean the collapse of the entire auto industry. Holstein’s defense of GM makes sense at a time when the company is about to begin production of a fuel-efficient, plug-in hybrid, a critical bridge to U.S. energy independence.”

— Booklist

“At a time when GM and the domestic auto industry are in acute crisis, this book makes sense of what has happened--and what should happen next. Bill Holstein is an extremely knowledgeable and perceptive journalist, and his book is a must-read for anyone who cares about the future of the American auto industry.”

— Alex Taylor, Fortune

“Holstein makes a compelling argument that the business model has changed dramatically - that Wagoner and other GM executives do get it - but by his own account the changes came far too late, and took far too long to implement.”

— Dan Calabrese, New York Post

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Product Details

  • ISBN-13: 9780802777737
  • Publisher: Bloomsbury USA
  • Publication date: 9/5/2010
  • Sold by: Barnes & Noble
  • Format: eBook
  • Edition number: 1
  • Pages: 288
  • Product dimensions: 6.12 (w) x 9.25 (h) x 1.00 (d)
  • File size: 376 KB

Meet the Author

William Holstein
William J. Holstein has written for BusinessWeek , the New York Times, and Fortune, among other publications, and is the author of the books Manage the Media and The Japanese Power Game.
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Read an Excerpt


Why GM Matters

Inside the Race to Transform an American Icon


By WILLIAM J. HOLSTEIN
WALKER & COMPANY
Copyright © 2009

William J. Holstein
All right reserved.



ISBN: 978-0-8027-1718-4



Chapter One What Went Wrong

It used to be that GM executives denied anything had gone wrong at their company. That denial was part and parcel of the problem. But today top executives from Wagoner on down are candid in acknowledging that GM ran off the rails. "Obviously, something went wrong because the company went, over about a fifteen-year period, from the midseventies until the early nineties, from being in a very strong position to being in a very different position and quite a bit weaker financially," Wagoner says in his office high in the Renaissance Center in downtown Detroit. "The model that had served the company unbelievably well for years no longer did."

That's an astonishing but true statement. An organization with many decades of experience and many hundreds of thousands of employees simply became outmoded. GM didn't stop working overnight, of course. A company that big is something more like an aircraft carrier. Even if it takes a torpedo hit below the waterline, it still has forward momentum. For a while. The reasons this happened are complex-a perfect storm of new competition, bad decisions, radical market shifts, and plain bad luck. But the answer to what went wrong begins in the history of how GM was created.

In the briefest possible fashion, the story goes like this: Billy Durant, a swashbuckling iconoclast who loved the art of the deal, created General Motors in 1908 by smashing together different auto companies headquartered in different cities-Cadillac in Detroit, Pontiac in Pontiac, and Oldsmobile in Lansing. It was at a time of enormous flux in the auto industry, much like today, and it wasn't at all clear which type of auto and which brand name would prevail. "I was getting every kind of car in sight, playing it safe along the way," Durant once said.

Altogether, Durant bought twenty-five companies, including parts makers, between 1908 and 1910 and put them under the General Motors umbrella. Between 1916 and 1920 he bought another fourteen, including Chevrolet and Fisher Body. He bought the companies with stock and never attempted to consolidate their operations into a single cohesive whole. Each vehicle and component division handled its own purchasing, set its own prices, and managed its own accounting. Although the field was fragmented at the time, and GM was by no means the dominant player, Durant's prospects seemed reasonably secure.

But an unexpected recession hit the U.S. economy in 1920, and GM's sales plunged. With the company on the verge of bankruptcy, Durant was forced out. (He died in 1947 managing an eighteen-lane bowling alley in Flint, having squandered a personal fortune of $120 million, an incredible sum for that era. Wagoner wisecracked in a 2003 speech that the prospect of ending one's career that way "has haunted GM chairmen ever since.")

In 1923, the company was taken over by Alfred P. Sloan Jr., whose roller and ball bearing company had been acquired and eventually assimilated into General Motors. Out of the chaotic assembly of companies Durant had put together, Sloan created a system with greater controls, particularly financial controls. It was Sloan, for instance, who figured out a price ladder for GM cars; whereas Durant had allowed his various companies to compete against one another with similarly priced cars, Sloan sought to differentiate their products, so that a buyer in a given price bracket would have only one GM option. He positioned Cadillac at the top, a car for the wealthy or the aspiring, followed in descending order by Buick, Oldsmobile, Pontiac, and Chevrolet. He also introduced the concept of annual style changes, replacing the haphazard introduction of new models with a schedule that buyers could predict-and anticipate.

But even as Sloan brought a measure of order to GM, it was still not really a unified company with a centralized management. Within divisions there were separate fiefdoms, which managers guarded against meddling from headquarters. And the company kept adding pieces, reaching out into the world. Between 1923 and 1928, it opened nineteen assembly plants in fifteen countries in Europe, South America, Asia, Australia, New Zealand, and South Africa. It made outright purchases of other automotive manufacturers, such as Britain's Vauxhall in 1925, Germany's Opel in 1929 (at the start of the Great Depression), and Australia's Holden in 1931. The new companies added to the group kept operating largely independently.

This fragmented model worked well for many decades. It worked so well that between 1948 and 1950, management started agreeing to a compact with the United Auto Workers that over coming years would pour unprecedented wealth into the hands of workers. In 1948 it agreed to the concept of annual cost of living pay increases. Then in 1950 it agreed to provide its workers full pensions and free health care coverage for life. These were the origins of how the UAW became so powerful that GM's cost structure was essentially uncontrollable.

But none of that mattered because GM kept gaining ground through the 1950s and 1960s. In 1962, at the high-water mark, it controlled 50.7 percent of the U.S. automotive market. "Back in 1963 when I joined, GM was without question and by a wide margin the dominant automotive producer in the world," recalls Robert Lutz, who is now vice chairman of global product development and the oldest member of Wagoner's management team. "We actually had a concern in the U.S., as our market share was heading over fifty percent. There was noise from the Justice Department that GM would be split up. So it was almost a disincentive to achieve greater growth and efficiency. We had a structure that worked very well for us back then, which was a great deal of divisional autonomy." By that model, once a division had its budget approved, it could design and develop and manufacture its own cars without oversight from the top.

That model helped the company make each of its brands distinct, which the market wanted. But it also made the process of making decisions at GM enormously complex and convoluted. "GM organization charts out of the sixties were published in these huge light-green foldout things," Lutz says. "It looked like a gigantic inverted oak tree. There were so many little boxes and so many divisions-and we still had all the nonautomotive."

By "nonautomotive," he means all sorts of businesses that were not even remotely related to the making of vehicles-like, for instance, the Inland Ice Cube Tray Division, which sold parts to Frigidaire for use in refrigerators. Indeed, when Lutz first arrived at GM in 1963, very little had changed in decades in the way the company was run. "It was very much into the dictates of Alfred P. Sloan-there was a degree of central coordination but decision making was decentralized," Lutz adds. "It was unbelievably slow, complex, and bureaucratic." But in an era with precious little competition from outside the United States, inefficiency could run unchecked, and the company was still "totally competitive, because we had such enormous power that we could always steamroller everybody else," Lutz says. "Even if we were late coming out with something, once GM geared up to do it, whoever started it would get crowded to the sidelines."

Nor had much changed by the time Rick Wagoner joined the company in 1977. GM was still divided and subdivided. "Our tradition was separate brands," he says. "Chevy was a pretty integrated auto company itself. Pontiac was, and so was Buick. To their credit, I think the leaders in the late seventies and early eighties saw that that needed to change. But that was hard to do, changing fifty years of history."

At about this time, in 1973 and 1974, the first major oil shock hit the United States, and the game started to change. Toyota had entered the U.S. market in 1957, but by the early seventies had gained only a very small toehold. Their first model, the Toyopet, had been derided by consumers and the automotive press, and the company's image hadn't entirely recovered. But with the new thirst for fuel-efficient cars, Toyota became a much more significant player.

Part of Toyota's advantage was in its totally different management model and manufacturing system. Toyota and other Japanese manufacturers had learned a great deal from W. Edwards Deming and Joseph M. Juran, two early pioneers of quality and efficient manufacturing who had been involved in helping the American war machine improve the quality and output of ordnance and armaments. But American manufacturers, confident in their superiority following World War II and basking in postwar prosperity, largely ignored these statistics gurus. The Japanese, however, had been stung by the manufacturing power of the United States during the war. They were open to learning. Their goal after the war was to "catch up and surpass the West."

So Deming and Juran lectured, consulted, and urged Japanese manufacturers to embrace concepts such as quality assurance and total quality control. If war-torn Japan committed to continuously improving its industrial processes, it could lead the world within a single generation, Deming suggested in 1951.

The Japanese, partly as a result of the war's devastation, also were prepared to do more with less. They had a fundamental understanding of the need for efficiency; in their model, it made a difference that each worker on the line took fewer steps to get a part and made fewer turns of the screw to attach a part. And as countless books have revealed, Toyota had a different philosophy about labor-management relations. There was very little of the hostility that characterized relations between American managements and labor forces, including GM's. In Japan, management and labor were in the battle against the enemy together; they had little or no time to fight each other. And unlike GM, Toyota had a clearly centralized management system, with the Toyoda family at its heart. (The product name had been altered slightly to Toyota to make it more appealing to American customers.)

All this gave birth to what was called the lean manufacturing system, built on several signal principles: there was kanban, in which parts were delivered to the assembly line just as they were needed, rather than being stockpiled; kaizen, a philosophy of constant improvement; and a team-based approach to manufacturing, in which a small group of workers would be responsible for each phase of building an entire car, unlike the Henry Ford system of long, depersonalized assembly lines, where few workers could be held accountable for the quality of their performance.

Whereas GM and the Americans in general had "mass," Toyota and the Japanese in general had "lean"-and lean, in the new era, was clearly better. Their vehicles were cheaper and more efficient, and did not break down nearly as often. The lean model also allowed for quicker decision making and much more efficient use of materials and energy, not to mention manpower. GM and other American manufacturers, in contrast, had not changed their fundamental approach since the days of Henry Ford's Model T.

Jack Smith, who became CEO in 1992, is the GM executive who is given credit for recognizing that there was a serious competitive imbalance. "The first indication that something was different in the auto industry was in the midseventies, when we had an overseas team that happened to be in Japan," he recalls. "They witnessed a fast die change by Nissan."

It was an unusual place for an epiphany. A die is one of the massive steel forms that shape the large metal panels of a car; massive, earthshaking stamping presses hold these dies and pound out thousands of identical parts a day. American companies would use a single die set to stamp a warehouse full of parts, then laboriously change dies before starting on another part. At the Nissan plant, the Americans saw a die that would take GM hours to change get swapped in fifteen minutes flat. They were astonished.

Such are the things that manufacturing advantages are built on. With a shorter changeover time, the Japanese company could use each press more efficiently, doing a short run of each part before switching dies and stamping another part. This required less downtime, fewer presses, and less warehouse space, all of which offered potentially huge cost savings. It was clearly a better model.

The GM team brought their observation back to headquarters, where committees reigned supreme. "At that time, we had policy groups. One was the overseas policy group, and I was working with that group," Smith explains. "If this is really true what they're doing, changing dies in fifteen minutes, it had huge implications. You have the capability to really reduce the investment [needed to manufacture cars]."

Smith was impressed, and he took the team's findings to his bosses. But his message, Wagoner recalls, went over "like a lead balloon," Top GM management wouldn't hear it and continued to deny that the Japanese had any advantage. Many executives suspected the Japanese had production technology secrets, like a specialized piece of equipment, that GM would eventually learn about. They could not accept that the Japanese had devised a superior manufacturing or management method.

Smith, however, persisted in trying to learn more about the Japanese system. In the early 1980s, he traveled to Japan and met senior members of the Toyoda family. He wanted to learn more about how they did what they did. The Toyodas, in turn, wanted to have political cover to expand their operations in the United States. What better way to protect themselves from political backlash than to have a joint venture with America's largest car manufacturer? "They weren't real comfortable with the culture and a joint venture would be a great place to start," Smith recalls.

In 1982, Toyota and GM began discussions about creating just such a joint venture: New United Motor Manufacturing Incorporated (NUMMI), which would be housed in a shuttered GM plant in Fremont, California. It was to be a collaborative effort that would manufacture cars that GM and Toyota could each sell under its own brand name. In the two years it took to negotiate the deal, Smith, then head of product planning, learned even more that alarmed him. "We had an opportunity to review our manpower versus Toyota's at a Toyota assembly plant that was making a relatively small car," he explains. "Toyota said it had two thousand people" at work on the project. "We had fifty-five hundred people doing comparable work in the United States. I lugged that information back to Detroit and it was very unwelcome news. The people responsible for manufacturing were in denial."

To be sure, Toyota was learning a lot about GM as well. "We took them to a couple of our plants and they were scared by the way we operated. They were really leery" Smith says. "They couldn't believe that not everyone came to work every day and that there were alcohol and drug problems."

The bad news continued as the two archrivals geared up to start manufacturing together in 1984. At NUMMI, the two companies had created a unified management team empowered to make its own purchasing decisions. But the members of the team-even the GM personnel-weren't impressed with GM's quality. In quality and in cost, the vast majority of GM's parts just weren't competitive. "We only won three or four parts" in the competition at NUMMI, Smith says. "We won seats," he says, and "wiring harnesses, but that came from Mexico. We won front drive axles, but that was because Toyota was out of capacity. The message coming back was that our components were out of line. This was a tough recognition for the organization. We were grossly uncompetitive in everything."

This was a very dark period in GM's modern history. The company was completely adrift without any clear and coherent strategy. Its cars weren't nearly as good or as reliable as those of a new set of competitors. Its manufacturing processes were antiquated. A new CEO, Roger B. Smith (no relation to Jack Smith), had started in 1981, and he was clearly not up to the job. He could not articulate a strategy for GM to respond to Toyota and others. Thus, when Toyota came along, GM had a ripe underbelly-a corporate structure that put it at risk to a much more centralized, focused organization like Toyota-yet its arrogance prevented it from responding.

(Continues...)




Excerpted from Why GM Matters by WILLIAM J. HOLSTEIN Copyright © 2009 by William J. Holstein. Excerpted by permission.
All rights reserved. No part of this excerpt may be reproduced or reprinted without permission in writing from the publisher.
Excerpts are provided by Dial-A-Book Inc. solely for the personal use of visitors to this web site.

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Table of Contents

Pt. I The Stakes

1 What Went Wrong 3

2 People on the Front Line 18

3 Does GM Matter? 31

4 Who Is Rick Wagoner? 43

5 2005: The Crisis Begins 57

Pt. II The GM Transformation Effort

6 Mastering the Toyota Way 69

7 Going to Kansas City: Making GMs Work 79

8 Design Rides Again 102

9 Battling for the New Camaro's Soul 118

10 The Chevy Volt 130

11 OnStar: "Pretty Good for an Ex-Locomotive Salesman" 155

12 China: Where Buick Is King 171

13 The Global GM 191

Pt. III The Future

14 The Battle of Perception 209

15 Toyota: "Human After All" 231

Conclusion: The Economic Crisis and GM's Future 240

Acknowledgments 255

Index 257

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Customer Reviews

Average Rating 4.5
( 8 )
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Sort by: Showing all of 8 Customer Reviews
  • Posted September 24, 2010

    more from this reviewer

    Why GM's impact goes beyond cars

    Everything reported in this book is just right - you only need to adapt to its time frame: The book ends with the 2008 national recession. It explains how General Motors hit a financial crisis in 2005, and how former CEO Rick Wagoner and his team tried to fix things before the federal bailout. Business journalist William J. Holstein's cast of characters includes not only Wagoner and fabled former CEO Bob Lutz, but also a whole constellation of designers, engineers and marketing specialists in Asia, Europe, Australia and Detroit. Holstein tells GM's story complete with behind-the-scenes sagas about the Camaro, the Volt, OnStar and the rise of Buick in China. All this is intriguing information, and the author's insights remain valid even though the book ends with Wagoner testifying twice before Congress in 2008 before his ouster by the feds. Holstein fills you in on the situation before Wagoner's departure, the government takeover of GM and Toyota's recall crisis. If the events leading up to GM's fall and rebirth still intrigue you, getAbstract believes this book delivers fresh reporting about the auto giant and its biggest drama.

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  • Posted May 9, 2009

    more from this reviewer

    If you thought poorly of GM, this book will change your opinion!

    Having been a GM product development engineer and manager before retiring in 2004, I can verify that the changes at GM since 1992 that are reported here significantly improved its operations, and largely corrected the mistakes of the previous 40 years. Jack Smith and Rick Wagoner's leadership of GM's turn-around would have been heralded as one of the greatest ever if the Congressionally sanctioned banking mistakes hadn't led to the economic downturn of our economy in 2008 that also undercut every automaker.

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  • Anonymous

    Posted May 8, 2009

    I Also Recommend:

    GM Does Matter

    This is an eye-opening book. It provides a great explanation of how Rick Wagoner and his team were transforming GM into a truly global company. Anyone who believes GM's leaders are out-of-touch may be convinced otherwise. Holstein also makes very clear the huge impact of General Motors on the U.S. economy. This isn't just about Detroit, it's about America.

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  • Posted April 28, 2009

    Good overall study of a very timely topic

    Overall the book is well researched and written . I wish Mr. Holstein had been more probing and critical of Mr. Wagoner's tenure as CEO . But the book gives insight to the inner workings of GM at a time when more people need to understand the importance of this "former" industrial giant . I don't believe the American public really understands the importance of a manufacturing base in our country . If Chrysler and GM go bankrupt , the harsh reality will affect everyone in this country , like it or not . The book tries to dispell the 25 year old negative perceptions most Americans have of GM that persit to this day .

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    Posted February 27, 2009

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    Posted July 8, 2010

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    Posted January 20, 2009

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    Posted February 14, 2009

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