Thursday, Feb 20, 2020 at 10:54
There's only a few crucial differences between American and Australian car manufacturing, and Japanese car manufacturing - but they are the factors that make all the difference to longevity and performance.
1. The Japanese attention to detail is world-renowned. These are the people who will set about ensuring reliability, by covering every possibility of potential problems in use.
If I buy a Japanese-built vehicle, it has every wiring harness connector carefully designed with seals to prevent ingress of mud, dust and moisture.
But buy an American or Australian-built vehicle, and it has the cheapest harness connector they can produce, with no interest in sealing the connector.
As a result, you get mud, dust and moisture, along with salt and other naturally-occurring chemicals in the soil, wreaking havoc in electrics and electronics with corrosion in harness connectors.
The Japanese will take care to ensure that harnesses are fully protected and secured every 100 or 150mm along their length.
American and Australian-built cars got wiring harnesses with little protection, and inadequate securing points, and draped like spaghetti through the vehicle.
Who can recall the HQ to HX models where the main wiring harness had a firewall connector bolted together, that wasn't sealed properly most of the time, and which was a source of electrical "glitches" when they were driven in adverse conditions (mud, deep
water, dust)?
It took GMH years to get rid of the firewall harness connector, and make the harness one piece by the HZ models.
Who can remember when GM and GMH took years to produce high spark intensity distributors?
Previously, we had to put up with constant misfiring and spark tracking from poorly designed distributors, caps and wiring.
Japanese vehicles didn't have the problem, their ignition systems were carefully designed.
GMH designed oil breathers that were directly in line with distributor caps and leads.
When the engine got a little worn and started to produce oil fumes from the breather, these oily fumes would coat the distributor cap and leads, and lead to spark tracking and misfiring.
Who can remember the crap paint jobs on American and Australian-built vehicles?
Japanese paint jobs were always far superior in finish and durability.
Who can remember the poor panel fit of American and Australian-built vehicles? Japanese panels always fitted perfectly and evenly.
Assembly faults came as part of the deal with American and Australian-built vehicles. I bought a new HQ Holden in early 1972.
I picked it up in the morning, drove around
Perth most of the day, then when I got
home in the evening, it refused to start - because of a flat battery.
I took it back to the dealer, and they promptly found the problem - the integrated wire from the alternator to the battery had been left out of the wiring harness! The alternator had no way to charge the battery.
They had to replace that section of the harness with a new one. What great GMH QC!
2. The Japanese work ethic is world-renowned - so much so, the Japanese Govt had to pass laws preventing company employees from working themselves to death, by doing vast amounts of overtime.
Japanese company employees were working 18 hr days to ensure that the product was fault-free.
In Australia, the work ethic is all about how soon you can knock off, and bugger the companys requirements! A Thursday or Tuesday holiday always becomes a reason to have a 4 day holiday weekend.
3. The Japanese design durability into components. Engines last 50% longer (or more) in Japanese vehicles.
With the 50-odd Holdens I've owned, I was always struggling to get 200,000kms life out of a 6 cyl Holden engine.
In Japanese vehicles, switches, knobs, actuators and controls are designed to keep functioning correctly without breaking for 25-30 years or 400 to 500,000kms.
But buy an American or Australian-built vehicle and it was pretty
well guaranteed, you'd be replacing switches, knobs, actuators and controls within 120-150,000 kms, and often as low as 18mths or 2 years after you bought the vehicle.
Who can remember GMH producing plastic distributor drive gears, that replaced the former metal ones?
Within a short time, there were sheared distributor drive gears everywhere, and owners were looking for the metal ones as replacements.
The simple fact is, that Japanese vehicle manufacturers provide the vehicles the buyers want, and the build quality, that buyers want.
This is the reason that Toyota is the richest vehicle manufacturer in the world, with $50B in cash in the bank - and GM went bankrupt, and is still teetering on the edge of bankrupcty.
But Toyota made a serious mis-step in the early 2000's, when some American thinking invaded the company management.
They set about becoming the worlds biggest vehicle manufacturer (as regards total production numbers), to topple GM.
But their "vision" of becoming the worlds largest manufacturer was clouded when they failed to address the need for more engineers - and as a result, there was major failure in keeping up QC, in the drive for bigger production numbers.
As a result, the famous Toyota quality was seriously eroded by 2010, and it took several more years before they realised they had made a major error in ignoring QC failures, and set about correcting the problem.
Toyota had to appoint another 900 new engineers, and bring back retired employees to recover their old "attention to QC".
There is little chance that GM or any American manufacturer will ever get near Japanese brand vehicle quality, because of the lack of attention to design and build quality.
This is very evident in the fact that the Japanese have built factories in America and Thailand and even China, that produce Japanese-brand vehicles, that have equivalent build quality, to vehicles built in Japan.
Cheers, Ron.
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