(grunting)
- Sweet, okay, we're recording.
(claps)
So, I'm in New York right now
and The Verge offices
are basically shut down.
We're all working from home,
because of the coronavirus outbreak.
And while we can still publish remotely,
a lot of stuff is just shutting down.
- Indoor shopping malls across the state
closed last night, until further notice.
- 98.8% of our schools have closed down.
- 100% of the workforce must stay home.
- Right now, the urgent problem
is the public health crisis.
We need to slow the spread of infections,
and filled out hospital capacity.
That's what's most important.
But behind the public health crisis,
there's also a manufacturing gridlock
that's gonna cause huge problems
for basically every hardware company.
It turns out mass producing
hardware is really complex,
with thousands of moving parts,
and almost no stockpile to fall back on,
when a disaster like the coronavirus hits.
When China went on lockdown in February,
it basically stopped
electronics manufacturing cold.
An analyst group called TrendForce
estimates that 5.7
million laptop computers
shipped in February, which
might sound like a lot,
but it's a 48% drop from last year.
We're already seeing some
of the impact from that.
If you need to replace a
broken MacBook right now,
you could be waiting for awhile.
And some analysts are predicting
the next round of iPhones
could also be delayed.
Manufacturing is just a
much more brittle system
than people realize,
the result of a hundred years
of cutthroat competition.
But to see how it got that way,
you have to look at the big picture.
Making a computer or a smart phone
is really complex.
But, the process itself is
really just an assembly line.
This system was pioneered by Henry Ford
in the early 20th century.
- [Narrator] Everyday, as
many as 80 boxcars of parts
arrive at each plant.
- Everything has to happen
in the exact right order.
So, running out of a specific part
can stop the whole assembly
line in its tracks.
To make sure that didn't happen,
Ford arranged his system in batches.
Executives would decide at
the beginning of the process
how many cars to make.
But, batch production
created other problems.
It was really hard to
guess the right batch size
so far in advance.
And even if the executives
hit the right number,
they had to manage huge
stock piles of inventory.
Whether it was parts
waiting to be assembled,
or cars waiting to be sold.
(metal banging)
After the second world war,
Toyota pioneered a new approach
that would fix the inventory problem.
It was called the Toyota
Production System,
or just-in-time production.
It looks decades to perfect,
but by the 80's, they were making cars
more cheaply than anyone in Detroit.
He became the first manufacturer
to make 10 million cars a year,
all thanks to efficiency
of the new system.
Under the Toyota System,
production's continuous
and inventory is kept
to an absolute minimum.
Components arrive just
in time to be assembled,
and the finished product
arrives just in time to be sold.
It takes a lot of coordination
to make that work.
But, if you can do it,
you don't need those
huge warehouses anymore.
Which saves a lot of
money in the long term.
Keeping excess inventory down
is particularly important
for electronics companies.
Nobody wants last years camera,
or last years processor
in this years phone.
So, excess components
are usually just wasted.
And the components that change the fastest
are often the most
expensive ones in the phone.
When Tim Cook first came to Apple in 1998,
his main job was moving the company over
to lean, just-in-time manufacturing,
keeping inventory costs
as low as possible.
Fast forward 20 years,
and the entire hardware
industry works that way.
But, we know from previous disruptions,
that system can be really fragile.
- Okay, so remember the March
2011 earthquake and tsunami
that knocked out the Fukushima
Daiichi Nuclear Power Plant?
Right, I promise I have a point.
As a result of the tsunami,
it suddenly became a lot harder
to buy cars in certain colors.
Here's how that happened.
There was a plant nearby
that made a pigment
that makes car paint sparkle.
It was used by pretty
much every car maker.
At the time of the tsunami,
it was the only place in the
world that made this pigment.
Also, the site of the pigment stockpile.
Suddenly, it was really hard to buy cars
in certain shades of red and black.
In fact, about 20% of Toyota's inventory
was affected by this.
- Under the just-in-time system,
inventories are kept so
low that manufacturers
don't have anything to fall
back on if something goes wrong.
If any one of your
suppliers stops shipping,
you have to halt manufacturing
until you would find a replacement.
That's hard enough for a car,
but for something as
complex as a smartphone,
there are thousands of parts
and dozens of different suppliers.
The supply chain is bigger
than any one company
or any one country.
Just look at this tear down
iFixit did of the Galaxy S20 Ultra.
Samsung is a South Korean company,
and they make a lot of their own parts.
But, you also have a ton of Qualcomm chips
designed in the US and
probably fabbed in China.
The Bluetooth module is from Murata,
which is based in Japan.
The wifi modules built by Qoryo,
another US company that's
most likely building in China.
That's a really big supply chain,
which is a dangerous thing to have
if you're in a global pandemic.
Any one of those companies
might have to shut down
because of the coronavirus.
Either because the factory closes,
or the home offices are so messed up
that they can't respond to orders.
If that happens, Samsung's gonna have
a really hard time making this phone.
While you might think they
have a lot of those chips
stashed away, just in case,
the logic of lean manufacturing
and just-in-time production means
they probably have less than you think.
(light music)
At this point, Chinese factories
are starting to open up again.
But, they're running at half capacity,
and it's gonna be a slow process
getting them back to full strength.
There's also a natural delay
built into the product cycle.
Apple's new iPad Pro
seems to be unaffected
since those devices
went through production
two months ago.
But, anything that was planned for release
two months from now is
probably running into trouble.
Which is why analysts are so nervous
about the next round of iPhones.
So, we don't know what will happen.
There's still a chance manufacturers
will get up to speed in time,
but don't be surprised if a lot of
the big hardware releases of 2020
end up getting pushed back.
- You remember the paint
pigment I was telling you about?
So, the factory reopened in May,
but it took them until September
to catch up on their back orders.
But the good news is,
by 2013, the company
that made the pigment,
Merck KGaA, had opened a second factory.
So, now there were two.
One in Germany and one in Japan.
It's not as easy to move the
iPhone out of China though.
I mean, the iPhone
relies on skilled labor.
In 2017, Tim Cook pointed out
that there are way more
tooling engineers in China
than there are in the US.
The plain fact of the matter is that
there aren't a lot of
places that Apple can go.
Just-in-time manufacturing
is very efficient.
But, it's also very fragile.
Resilience doesn't show up as clearly
on a balance sheet.
But in times of crisis, it
might be exactly what we need.
- Hey, thanks for watching.
Sorry for the shaky
camera and the bad sound.
We're doing our best.
I know it's a little scary
in the world right now,
but yeah, take care of yourself.
Wash your hands, and try
not to go outside too much
and we'll get through this.
