REORGANISATION STRATEGIES AND
COMPETITIVENESS IN THE ITALIAN AUTOMOBILE
PRODUCTION SYSTEM
Sergio Conti
University of Turin,
Italy
1. THE ITALIAN AUTOMOBILE INDUSTRY: SOME STRUCTURAL
FEATURES
The Fiat group currently represents the largest Italian
industrial group. A few figures will give an idea of its significance to the
Italian economy: revenue represents 3.5% of GDP, employees are 4.2% of those in
employment, investment is 2.1% of the total, and research and development is
13.1%. Fiat Spa is a holding company with diversified activities (from cars and
industrial vehicles to agricultural machines, telecommunications, publishing and
civil engineering) but fully adopted this structure only at the end of the 1970s
(Mosconi and Rullani, 1978). Before this, it was organised on functional lines,
with a single profit centre and real decision-making concentrated in the person
of Vittorio Valletta. The passage to the holding company structure began in 1973
with the constitution of Fiat Engineering and ended in 1979 with the
constitution of Fiat Auto.
Despite the diversification, however, company resources and
skills are concentrated around the core business of the vehicle industry
(Enrietti, 1995), to which the following Fiat sectors belong: automobiles,
industrial vehicles, metallurgical products, vehicle components, industrial
components, accumulators, means and systems of production. In the mid
nineties these accounted for 82% of overall revenue. The automobile
sector alone generated 48%. This bias towards the automobile industry deepened
further during the 1980s through various acquisitions (Table 1).
Table 1 - Fiat Auto. Selected acquisitions in the
eighties.
SECTORS |
FIRMS ACQUIRED |
INCORPORATED INTO |
INDUSTRIAL VEHICLES |
Ford UK (1986) and Pegaso, Spain (1991) |
IVECO |
CARS |
Alfa Romeo (1986)
FSM (Poland, 1992) |
FIAT AUTO |
COMPONENTS |
Solex and Jaeger (1986) from Matra (France), electrical
parts and headlamps from Lucas (UK), Carello (ITALY, 1988) |
MAGNETI MARELLI |
|
CEAC (France, 1990) and Sonneneschein (Germany,
1991) |
MAGNETI MARELLI |
EARTH MOVING AND AGRICULTURAL MACHINES |
Ford New Holland (1990) |
FIAT GEOTECH |
Fiat Auto is the most important company in the group and
effectively holds a monopoly position in the production of vehicles in
Italy (excepting only a few bodywork specialists such as Pininfarina and
Bertone, and a few producers of sports cars, such as Lamborghini). This
dominance is the product of a history of continual takeovers and acquisitions.
Without going back to the period between the two world wars, it is enough to
note the acquisitions in the last twenty years: Lancia in 1968, Ferrari in 1974,
Alfa Romeo in 1986, Maserati and Innocenti in 1990.
This process has blocked all attempts by foreign manufacturers
to set up their own plant in Italy: the acquisition of Alfa Romeo shut out Ford
and that of Innocenti stopped potential Japanese competitors. The defence of its
own national territory has also meant that, despite the fact that Fiat possesses
subsidiary producers and licensed manufacturers in various continents, Italy
remains the production heart of Fiat's auto production system: in 1991, only 25%
of total production (i.e. 638,000 cars) was manufactured by sister or licensed
companies abroad.
There is a similar concentration of sales corresponding to that
of production: 60% of the cars sold in Europe were sold in Italy, keeping in
mind that Europe absorbs 94% of Fiat's exports. This dependence on the Italian
market is the fruit of a strategic decision taken at the beginning of the 1980s
when Fiat Auto was confronted with a series of critical problems: high debt and
low capitalisation, delays in updating its range of models, an over-extended
international presence, specialisation in low horsepower cars, rigidity in
industrial relations and significant losses of market share in Italy (Volpato,
1996). The strategy chosen was thus that of a drastic concentration of its
efforts in the European, and especially Italian, market. In effect, starting
from 1980, Italy has absorbed between 68% and 72% of sales in Europe (against
63% in 1979) giving Fiat the opportunity to set prices and achieve a greater
rate of profit than elsewhere in Europe. The dependence on the European market
has at the same time reinforced the company's specialisation in the lower
segments of the market, focused on smaller and cheaper cars, that is those most
in demand in the domestic market.
There is an important qualification to this leading position,
however, as Fiat models have high shares where there are barriers to Japanese
cars: Fiat holds 21.1% of their market, against Peugeot's 17.1% and Volkswagen's
10.1%. In contrast, its position is much lower in countries where no barriers
exist (only 4.8% against Fiat's European average of 14.8% (Mitsubishi Research
Institute, 1990; Camuffo and Volpato, 1997).
Compared to its competitors, Fiat is distinctive in possessing
one specific feature, that of being able to depend on an important series of
supply companies belonging to the Group itself. The company took a strategic
decision over these activities in the late 1970s (Enrietti and Fornengo, 1989).
It transformed several of its own plants into independent companies. A first
phase of rationalisation was followed by a second in which greater importance
was given to innovation and diversification in the automobile market.
2. SPATIAL STRATEGIES AND REORGANISATIONAL STRATEGIES. THE
AUTOMOBILE INDUSTRY AS A COMPLEX INDUSTRIAL SYSTEM
We shall now look directly at aspects of the territorial
organisation of the company, going back to the fundamental bond that exists
between strategic behaviour, industrial policies and the spatial dimension of
development. The result that will emerge is a model of the production system
within which it will be possible to reorganise the wide variety of questions
which have been discussed in the previous section and to open up new discussion.
The territorial approach to the problems of transformation of an industrial
system is in fact a way of proceeding which is aimed, in other words, at
understanding how the system "works" as a whole through the relations which link
economic, social and institutional actors.
2.1 From expansion to crisis
The years immediately following the second World War were
crucial for the future development of Fiat. Working in a rapidly expanding
market like the Italian one, without any significant import penetration and with
few local competitors, Fiat focused its market strategy on small and
medium-sized models, It also organised production in a way which paid little
attention to R&D, planning or scientific activity. Fiat's entire strategy
war directed towards quantitative expansion, both in terms of employment
and productive capacity, paying little attention to its internal
organisation.
These technological and product decisions were accompanied by a
spatial strategy which deliberately enhanced the relative advantages of
concentration and mass production. This had two main features: the concentration
in the north-west of the country and in the city of Turin in particular; and
concentration of production in a few large, vertically integrated, factories. In
the Turin area, Fiat has in fact found, produced or has seen others produce (the
public administration) a large part of those "territorial conditions" which
marked the establishment of the system of mass production (Castronovo, 1971;
Gabetti, 1977).
Turin is rightly seen as representing the model of the factory
town, albeit with its own specific features and connotations. It comes as no
surprise that even in international literature Turin has been a favoured area of
study for the relationship between industry and the city in the era of the
second industrial revolution (Gabert, 1964; Jalabert and Gregoris, 1987; Sallez
and Schlegel, 1963).
This technical and location decision defined a company strategy
which was not to change right to the late sixties. With a few exceptions and
timid processes of internationalisation, Fiat's industrial investment was
identified with the boundaries of the Turin agglomeration: this area not only
contained the entire car production cycle (in 1968, about 1,300,000 out of
1,550,000 cars came from the Turin area), but Fiat also participated in the
whole range of production based on the internal combustion engine, involving a
close-knit network of small and very small supply companies, often completely
dependent upon Fiat.
While at the end of the 1960s, there were over 125,000
employees working in Fiat's Turin factories, at least an equal number worked in
production units which directly or indirectly were part of its network of
subcontractors. In reality, it has never been possible to delimit exactly the
boundaries of this network because of its composition is in a state of constant
flux, especially as regards the smaller suppliers. Fiat drew on around 1,200
direct contractors, about a third of the 3,500 units (often small and very
small) linked in some way to the automobile industry (Rossignolo, 1971). Under
these conditions, despite the high internal integration, during the 1960s, Fiat
acquired on average over 50% of its total turnover from external companies, of
which about half were located in the Turin agglomeration.
As a result of the automobile industry's strategy towards
indefinite output expansion and a consequent, and sometimes uncontrolled,
enlargement of the production capacity, the Turin area became one of the most
sectorally specialised regions in Europe, comparable to just a few other
international examples such as Detroit and the West Midlands. In Turin, in
contrast to these other areas, all these activities were concentrated within a
single corporation, while the company's control extended deeply into the labour
market and was at the centre of intense interlinking of political and economic
roles (Borlenghi and Dematteis, 1982; Conti, 1986).
2.2 The first turning point
The first great wave of reorganisation of the Italian
automobile industry - and of Fiat in particular - started in the 1970s and can
be largely explained by the environmental crisis produced by the location
and organisational "model" followed until that time. The rigidity of the
connections between the city and the company created conditions which challenged
the network of co-operation which had previously ensured successful
accumulation. It developed, in fact, an entropy of the social environment which
made the process of change triggered by the company increasingly difficult to
foresee and control.
For Fiat, this form of production rapidly became impracticable
for reasons of a social and political nature. The reorganisation of the sector
thus implied a profound change in the economic and territorial development
model, expressed in:
a) a profound internal reorganisation of the conglomerate,
involving the transformation of Fiat from a traditionally integrated company,
with a very rigid and pyramid managerial structure, into a "divisional"
structure. Initially, in 1972, it was split into three operational sectors
(cars, industrial vehicles and tractors, miscellaneous activities) and then in
1976 into eleven sectors, each headed by a holding company, in turn controlled
by a single central holding company.
b) in constant attempts to regain control of the production
process through the introduction, in the "old" Turin factories, of electronic
technologies, accompanied initially by considerable falls in employment.
c) in a changed policy of industrial location, put into
practice in 1970 with a two-year investment plan for the construction of nine
factories in southern regions (for a total of about 17,000 employees, a figure
which was to double by 1981, mainly financed by regional policy legislation in
favour of the Mezzogiorno). The other element of the new locational policy
involved even more substantial projects on an international level. During this
period construction was completed of a car factory in the Soviet Union, and a
share of Citroen was purchased. In 1971 an agreement was signed to build a new
production plant in Poland, and a massive plan for investment in Latin America
(mainly Brazil and Argentina) got underway. In Western Europe, most production
remained in Italy and Spain (Seat) with significant exceptions in Ireland and
Portugal.
The overall goal of reorganisation was to seek maximum
flexibility in production methods and locations, which in turn implied
operational objectives: first, to move into a new market area and, later, to
structure the decentralised plants as a function of the whole system. The
new organisation of production was thus not limited to the mere duplication of
plant, but aimed at the decentralisation of specific stages of production to
dispersed medium-sized and specialised factories which were functionally and
strategically connected (Amin, 1986. The strategy was, in other words, to
"lighten" the Turin area - accompanied by the standardisation of some
manufacturing processes and some intermediate products without undermining the
continuing technological and organisational "centrality" of Turin. which does
not in itself deny the continuing technological and organisational "centrality"
of Turin.
3. THE EIGHTIES: THE GREAT RATIONALISATION
At the beginning of the 1980s Fiat Auto found itself in
difficult conditions in its national market. Domestic demand for cars was slower
than in other European countries (only in 1979 did Italy return to the
pre-crisis sales levels of 1973, while in the rest of Europe this happened in
1976). To this must be added low productivity and difficulty in managing labour,
inadequacy of the components supply industry, absence of an industrial policy
and high inflation.
In order to regain operating conditions comparable to its
competitors, a complex defensive strategy aimed at restructuring was designed
(Balliano, 1986). Apart from a decisive cost-cutting policy (the company
reduced its workforce by over 40% in seven years, from 134,621 in 1980 to 77,910
in 1986, and productivity doubled in the same period), the main elements of
which were: a) plant reorganisation, b) technological strategy, c) restructuring
of supply.
3.1 Plant reorganisation and the new geography of
production
The sudden introduction of technology necessarily had to be
accompanied by technical reorganisation: the almost immediate closure of three
engineering factories was followed by the decision to allocate highly innovative
investments to the South (automated and robotised manufacture and assembly in
Termoli and automated vehicle assembly in Cassino).
On the whole, this reorganisation of the production structure
led to a reduction in the number of active factories, to a growth in the degree
of saturation in the remaining ones and, above all, to the reduction in the
break-even point from the more than 1.5 million cars of the early eighties to
the 1.2 million at the end of the decade (Scott, 1991, 258). In addition, the
decision rather than in Piedmont has reinforced the move of the centre of
production towards the South, also taking into account the closure of two plants
in the North in 1992, those of Desio (Milan) and Chivasso (Turin). In any case,
the central company functions (top management, research, management training,
purchasing) have stayed concentrated in the North; it was only in the nineties
that some segments of research began to be moved to the South.
The overall rationalisation of the system would thus seem to be
going in the direction of a production structure based on new forms of
"polarisation" around a few highly integrated plants: Mirafiori and Rivalta in
the Turin area, Arese in Lombardy (formerly Alfa Romeo), which, with the
southern factories of Cassino, Termoli, Melfi, Pratola Serra and Pomigliano
d'Arco (again formerly Alfa Romeo), will constitute the key nodes in the
Italian automobile production system. The expected effect is therefore that of
creating a strategy of systemic integration between the various Italian regions
and within the Mezzogiorno itself by creating greater uniformity in the
distribution of the phases of work throughout the territory. In conclusion, more
detailed analysis of the production stages in each plant lends support to these
claims: as far as the stages of bodywork and sheet steel pressing are concerned,
there has, over time, been a process of replacement of the plants located in the
North with ones in the South. Engineering is the only activity in which the
number has actually increased with the new factories in the South. It follows
that in 1996 there was an equal number of engineering plants in the two parts of
the country, while there were more bodywork plants in the South.
In conclusion, the progressive location of factories in the
South, with the consequence that from 1994 more than 60% of Italian production
come from this area, expresses "discontinuity" in Fiat's strategy. The position
may be summarised as follows.
First, the policy of relocation towards the South represents a
break with the past compared to Fiat's classic location policy, an
organisational structure centralised and concentrated in Piedmont. Production is
now scattered in factories distributed throughout many regions.
Secondly, starting in the 1980s, the southern factories, both
old and new, have been the places where Fiat Auto has experimented and
introduced not only process innovations, but also new models of production
organisation and of industrial relations.
Thirdly, until the 1970s, Fiat's production location was
polarised, with the North which constituted as an integrated system and the
South specialised in only a few functions. In the 1990s, there is a single
integrated model nationwide, with "sub-integration" in North and South.
Fourthly, in the context of the changes just described,
continuity is represented by the company's central functions (top-level
management, research, management training, purchasing) remaining concentrated in
the North. In the "historical" region of Turin, there is a strengthening of the
strategic metropolitan role (management functions, R&D, marketing) and the
trend towards specialisation in production with a highly innovative content.
This can be deduced from analysis of investment plans made public by the company
for 1992-1996: investment aimed at process innovation and for maintenance of
production efficiency were concentrated in Piedmont with, respectively, 36% and
52%, of the company’s total investments. A much higher investment share (about
80%) went to Piedmont for new products (Figure 1).
3.2 The technological strategy
Technological transition was ensured by an intense process of
fixed investment. The number of robots in use rose from 225 in 1980 to 2,500 in
1992; in some factories and some production segments automation was almost
total.
With the gradual rise in the number of production plants in the
South, this area has become increasingly important in the dynamics of the
technological and organisational development of Fiat Auto. During the 1980s,
with the factories in Termoli and Cassino, the Highly Automated Factory
(HAF) was introduced. This marked the passage from the traditionally rigid
automation to a flexible form.
The reorganisation of these plants was in fact in the direction
of obtaining high flexibility, i.e. the possibility of producing more models and
versions in the same factory at the same time, increasing the degree of
differentiation of the various models, adapting them to the needs of specific
market segments. Thus, at Cassino, flexibility, in terms of the possibility of
alternating production of different models during the same day, at the end of
the 1980s was almost double compared to the "old" plants in the Turin
metropolitan area, where the same car models were produced. Unsurprisingly, the
productivity analysis carried out in 1988 on a sample of 38 world car production
plants (Krafcik, 1988) showed that Fiat had the best performance in Europe, even
though there was still a gap between it and Japanese manufacturers.
With the end of the 1980s, however, the HAF model began to be
questioned, as it was realised that Total Quality, Fiat Auto's strategic
objective for the nineties, "cannot be the result simply of high technology, but
also [must be] the fruit of intelligent and responsible human work" (Bonazzi,
1993, 77). A new technological and organisational strategy was thus devised.
This was the Integrated Factory (Cerutti and Reiser, 1991; Bonazzi,
1993), in which the adjective integrated underlines the project's main
feature and aim: to integrate the functions present in the factory by process.
In effect, in the traditional production structure, each Fiat
plant is divided into three parts: manufacturing, which controls
production and maintenance; technical services, including the planning of
maintenance and technology link-ups; production services, including
logistics.
With the Integrated Factory, the plants are re-organised around
just two operating units: the "common services and plants" units for
activities which cannot be decentralised, such as energy production, and the
operational production units, which are independent from the technical
and management points of view. Production units are, in turn, divided into
"Production", responsible for manufacturing itself and for materials management
and planning, and "Production Engineering", which ensures the effectiveness of
the technical system through maintenance men and specialists and also manages
the evolution of products and processes.
The basic operating structure of the production unit is the
Elementary Technical Unit (ETU), which is entrusted with the government
of elementary technological sub-systems, characterised by a homogeneous process
and/or product (for example, in the case of engine production, the ETU manage,
in addition to assembly, the production of the engine block, the driving shaft,
the distributing shaft, the piston rod and the cylinder head), with the aim of
optimising production processes, to improve results in terms of competitiveness,
quality, costs, mix and quantity. From the organisational point of view, within
the ETU the number of hierarchical levels is reduced, non-hierarchical forms of
organisation of work are present, such as the "technological team" (made up of
the elementary technical unit manager, the line technologist, the
maintenance man and operators), and for workers, the multi-functional,
regulation and process micro-management aspects are increased within a model
which demands co-operation.
Drawn up at the end of the 1980s, it was not by chance that the
IF project, was again first introduced experimentally in the plants of
Termoli and Cassino, in which the HAF had already been introduced, because this
was an organisational model closer to the IF than the traditional northern
Italian plants.
3.2 Restructuring of supply
A further problem was the generalised reorganisation of the
supply system, given that Fiat currently has a level of vertical integration of
about 45 per cent of turnover. It purchased 13 % of requirements directly
abroad, another 25% from Italian branches of foreign multinationals, another 35%
from by independent Italian manufacturers and 27% from elsewhere within the Fiat
group.
This is perhaps the most visible aspect of the eighties and
nineties, and thus explains some of the most visible transformations in the
Turin production system.. It also represents an extreme case in the map of
European car manufacturers. It is for this reason that it is necessary to look
at this in detail.
The changes in the relationship between Fiat and components
suppliers involved a great selection in their numbers and the pursuit of
increasing co-operation and partnership between the two parties, attributing
broader design functions to the suppliers (Camuffo and Volpato, 1997; Pulignano,
1997). Some phenomena, in particular, are capable of explaining together the
fundamental processes underway.
1. Processes of selection. At the beginning of the
eighties, there were about 1,200 direct Fiat suppliers. In the early
years of the decade, a process of selection began based on the capacity to
ensure innovation, competitive prices and reliability, with the result that in
1987 about 350 companies had already disappeared. From that year on, the fall in
the number of suppliers increased notably, falling to a little less than 400 in
1997. At the same time, an intense process of concentrating on a limited number
of suppliers was underway, within which a limited number of companies - 138 in
1994 - provided 90% of supplies (83 of these companies are from Piedmont).
They make up 60% of the overall number of suppliers, and
provide 40% of purchases. Furthermore, they are heavily concentrated in the
Province of Turin (about 90%) and represent a strong financial
concentration: 75 of them (90%) belong to 57 groups, and only 8 companies,
in any case characterised by fairly low levels of sales to Fiat, are independent
(Table 2).
Table 2 - Financial concentration of the most important
Piedmontese suppliers to Fiat Auto.
1994 1997
COMPANIES |
No. |
% |
No. |
% |
Independent |
8 |
10 |
8 |
8 |
Groups, of which |
75 |
90 |
75 |
75 |
Italian |
54 |
65 |
48 |
58 |
Foreign |
21 |
25 |
27 |
32 |
Source: Fiat Auto
The economic concentration of supplies is also high: the first
company covers 15% of total supplies, the first four 33%, and the first ten
51%.
For the purposes of examining the Turin vehicle cluster, the
selection process that has involved the sector in the past fifteen years, is
therefore of fundamental importance. Its rationale can be explained by the
following factors:
1. Reduction in the number of supplier companies
2. Increase in production volumes for the remaining
companies
3. Growing use of economies of scale
4. Increase in productivity
5. Reduction in costs
6. Reduction in component costs
7. Reduction in costs for the final producer.
2. Processes of deverticalisation. The process of
selecting component manufacturers is closely related to the reduction in the
level of vertical integration of Fiat Auto (Table 3) and thus the increase in
outside purchases.
Table 3 - Vertical integration of Fiat auto (%)
1987 1992 1997
Make inside 38 35 30
Purchase from
Fiat suppliers 14 18 17
Outside purchases 48 47 53
Total 100 100 100
Source: Fiat Auto
It is necessary to specify, however, that a considerable part
of the components produced by suppliers is still designed inside Fiat, which
assigns contracts with its own designs, and in some cases even with its own
equipment, such as dies. In fact, if we consider the division of the value of
the parts designed, it can be seen how Fiat’s level of vertical integration was
still very high at the start of the nineties, and has fallen decidedly in recent
years. For example, the share of components designed outside Fiat for the
Uno (1983) was 30%, going up to 55% for the Punto, and to 60% for
the Lancia K (Table 4).
Table 4 - FIAT AUTO: component design (%)
1991 92 93 94 95 96
Internal 76 70 60 50 40 30
External 24 30 40 50 60 70
Source: Fiat Auto
The objective of selection is to reach the situation of only
one supplier, or at most two, for each product line, in other words, the
extension of the relationship of mono-supply: in the case of the Punto,
for instance, 88% of components purchased were done so in this form of
supply.
3. Complex supply. From the technological point of view,
the selection is linked to the transformation of the components manufacturers
left in suppliers of complex systems: a single supplier, acting as main
contractor, thus unites the functions previously played by several companies.
This passage also implies that the Fiat/supplier relationship is becoming
increasingly co-operative, seen in the attribution to suppliers of advanced
tertiary functions, such as research and development and design.
The first level suppliers were also entrusted with the task of
co-ordinating the sub-contractors: all sub-contracting thus ended up converging
on the companies, who had responsibility for assembly and testing before
delivering the component to Fiat.
From the standpoint of the supplier, however, the situation of
the sub-contractors themselves changed: these were not just small
companies, without any particular design capacity, but even leading firms in
their field, whose product was inserted into a system supplied to Fiat by
another company. This has stimulated, and will continue to stimulate even more,
companies to move towards establishing groups and towards a policy of
technology and research agreements .
The size of sub-contracting (there are 14,900 sub-contractors
of the first 140 Italian suppliers of Fiat Auto) and its importance in the
filière make this segment of companies a field of intervention for Fiat itself
from the perspective of rationalisation and cost reduction: in effect, the
dispersion is very high (only 12% of sub-contractors’ sales is made through
relations within the top 140 Fiat suppliers, and only another 12% concerns
purchases from suppliers shared with Fiat Auto), encouraging action to
concentrate sub-contracting in a smaller number of companies, to achieve
economies of scale both in production and design. It is worth underlining that a
"spontaneous" process of selection of sub-contractors is already underway: in
the last five years, on average the first level suppliers have reduced the
number of their suppliers by 23%.
To summarise, what Fiat has asked its suppliers has been: a)
improvement in levels of quality, promptness and reliability; b) increase in
their design capacities; c) higher capacity of co-ordination with Fiat
technicians, both in times and methods; d) the consequent development of
investment capacity in machinery, technology, research and development.
The final image is not dissimilar to the arrangement that its
competitors have adopted: from the hierarchical filière of ten to fifteen years
ago, to a structure that can be broken down into at least three levels,
with the formation of a fabric of large first level suppliers (almost equal
interlocutors with the final producer) to whom management of sub-contracting is
delegated.
For suppliers, the need to sustain high levels of investment
(machines, research and development, property, organisation, information
system, training) thus becomes crucial, resulting in a process of selection on
the basis of which it is it is likely that only the most financially and
economically solid first level suppliers will survive. In terms of size, this
tends to be translated into the marginalisation of small and medium-small
companies from the direct relationship with the manufacturer and their
relegation to a second level of supply.
4. A NEW STRATEGIC SYSTEM OF VALUE
Starting from company behaviour and strategies, we have thus
highlighted some dynamics typical of the Turin system. The story is not yet
finished, however. When faced with the employment crisis, the processes of
restructuring and upgrading the system, the problem is to understand the more
complex scenarios that are appearing on the horizon for a region of old
industrialisation. It is obvious that these cannot be comprehended without
understanding the technological, social and institutional legacy that has
historically been dependent on the automobile and its dominant corporation. Two
phenomena regarding this are of essential importance.
1. In the mid eighties, for the first time, the presence became
apparent in the Turin metropolitan area of a major concentration of companies
(about 200) operating in a series of activities connected to the automation of
industrial processes. More recently, other companies working in robotics and
electronics components have established themselves. This whole set of
entrepreneurial activities goes back mainly to the seventies and eighties at the
time of the introduction of numerical control and robots. The Fiat Group and its
suppliers have played an important role in this evolution, not only because they
represented an important area of demand, which attracted from outside purely
commercial initiatives (sales representatives, commercial offices both for
machine tools and above all for electronic and computer products and components
like CAD stations), but also as a technological incubator, in the sense that
many neo-entrepreneurs are technicians or workers who started out at Fiat or in
its supplier companies.
The role of the Fiat Group has gradually been reduced, however,
both because its strictly industrial activity in the Turin area has diminished,
and because of the emergence of Comau, which is now Europe’s largest company in
this sector.
Seen as a whole, these activities differ greatly from one
another. Despite the fact that this concentration is unrivalled in Europe, its
visibility is relatively restricted because of the limited size of many
companies and because of their location within a metropolis where other
industrial activities of often significant size are present.
Leaving aside quantitative aspects, a number of interesting
considerations can be made from the qualitative point of view:
i. mechanical engineering is a major factor of Turin
production;
ii. although there is good coverage of all types of machine
tools, milling and grinding machines remain important;
iii. dependency on the local market (and on Fiat in particular)
has diminished in favour of international markets;
iv. the solidity of mechanical and machine tool suppliers with
significant international positions has increased;
v. the leadership positions held by some electronics and
robotics companies has been reinforced;
vi. sub-contractors capable of covering the most varied needs
have strengthened and diversified (in engineering, electronics and
computers);
vii. Turin has become the Italian centre of industrial
metrology, with private companies operating alongside public and university
research institutions.
2. A cluster of industrial design and engineering has been
established definitively, revealing itself to be fundamental in the recent
dynamic of Turin’s economic system. Its roots lie in the city’s manufacturing
tradition, the widespread know-how that can be traced back traditionally to
vehicle and machine tool production. More in particular 104 companies of fairly
varying size have been identified in the area which, effectively, have no
international competitors. It is not stretching things to say that almost the
entire design activity external to the style centres of the main vehicle
producers happens in Turin (Bertone, Italdesign, Pininfarina, Stola, Idea). It
is concentrated not only in the stage of conception, but also covers a series of
practical aspects that demand certain technical capacities and close relations
with production.
As far as design support activities are concerned, the
quantification is rather difficult as these are often small studios or
individual professionals. There is, nonetheless, a confirmation of the
importance and quality of the sector in the Turin area, considering the fact
that the activities connected to design (CAD, modelling, prototypes, control
etc.) are effectively contained in the local Turin system, as they are run
inside the companies or delegated to local suppliers.
Automobile design, in particular, is split into two levels: on
the one hand, the Turin system includes the major designers that work for the
world’s leading manufacturers; on the other hand, a significant number of
subcontractor small and medium size designers has developed that works for the
big designers and for first level Fiat component suppliers. In the 1980s and
1990s there was a considerable expansion of both levels, with the development
and embedding of high level skills.
The growth of the automobile component of the cluster is
closely linked to changes in the relations between the final vehicle
manufacturer and its suppliers: in fact, the involvement of suppliers in the
design of the component and the consequent increase in investment has meant that
specific skills once developed inside the final manufacturer have spread and
been embedded locally, thus laying the foundations for the independent existence
of a design and engineering cluster.
One extremely delicate aspect, but of great interest, is
education, which, in the Turin system, is the responsibility of three main
bodies: the Architecture Faculty of the Turin Polytechnic, the School of Applied
Art and Design, founded in 1978, and the European Design Institute, whose
teaching centre in Turin was established in 1989. Observing the history of these
teaching programmes the strong bond between Turin design and the automobile and
machine tool clusters appears evident.
The situation is different for technical design staff, an
activity that is done almost exclusively nowadays with CAD (Computer Aided
Design) programmes: in this field, training is mainly run through vocational
courses, often organised in the framework of training/employment programmes. One
of the main issues for the development of the cluster in the coming years is
linked to the specialisation of training courses for designers: in fact, while
the education of the designers reflects the domination of the automobile cluster
in Turin manufacturing, the very theoretical and generic training of technical
designers does not seem to respond to the real needs of design studies.
These three clusters together - automobiles, machine tools and
design - in the Turin that looks to the new century represent a full-blown
strategic system of value. It is founded explicitly on localised and
active conditions of competitiveness (i.e. intensely exploited by existing
companies), and also on latent conditions, in other words, not exploited
but potentially capable of being activated by coherent industrial policy action.
In Figure 2, the colours corresponding to the three strategic clusters, and the
conditions of competitiveness are found in the overlapping areas. In brief,
these emerged from a survey conducted by questionnaire with over 300 companies,
on which I shall not spend more time here.
1. Active conditions. Among the first, we obviously find
the major automobile company (the reasons for its impact on the other systems
that have formed does not need to be underlined further at this point) and
highly skilled workforce, itself the expression of the manufacturing history and
the engineering culture.
But there are other components of great importance for
establishing a fairly integrated production system: entrepreneurial
embeddedness, the presence of a diffuse fabric of small and medium size
engineering companies. Other conditions are, instead, factors of specific
competitiveness, i.e. key elements in the production and competitive capacity of
the individual clusters (infrastructure accessibility for Vehicles, consolidated
intercompany relations for Design and engineering, logistics for Machine
tools).
2. Latent conditions. Among the second, are the
conditions whose activation is held possible, and which would constitute a vital
strategic outlook for the economy of the region when faced with future
competitive challenges. However, systematic strategies of local industrial
policy are required for these. Again, some factors - such as specialisation of
vocational education and materials innovation - have a general value, providing
support shared by all three clusters involved and to all the support companies
operating in the area. Other conditions, for which spin-off effects for the
entire system should not be ruled out, of course, assume specific meanings (they
are cluster-oriented, in other words): support for electronics research and
support for synergetic relations between enterprise and university are essential
for the strengthening of the Machine tools, robotics and industrial automation
cluster; services to assist product development appear vital for the Design and
engineering cluster.
Conclusions
In the last twenty years, the functional regeneration of the
regional economy, while respecting its historical legacy, has occurred in a
fairly spontaneous manner, and has been insufficient to block the loss of jobs
in manufacturing, and only partially successful in creating the conditions for
an effective functional differentiation of Turin’s production structure. A
medium to long term strategic design needs to be defined to "accompany" the
changes already underway in the system, providing support for them.
The regeneration of production structures must not be
approached by trying to attract what are conventionally defined as high-tech
industries (biotechnologies, semiconductors, aeronautics, software etc.).
Obviously, this does not mean not pursuing a technology policy. However, and
this is the important aspect, it must be directed to the use and "regeneration"
of technological resources historically embedded in the region’s economy.
This means that the regeneration of the regional economy cannot
happen by promoting unlikely new activities, but by pursuing the relaunching of
manufacturing. If the region already possesses an integrated industrial
structure of varying degrees of complexity, the solutions are to be sought
in the respect of (as well as support for and regeneration of) these production
situations, promoting specialisation and functional
differentiation together. The road to be followed, in this case, is a
network strategy aimed at encouraging and supporting interaction between
actors (between companies, and between companies and others).
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First International Humboldt Meeting. Buenos Aires, Argentina.
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