Global Manufacturing Outlook 2013 KPMG
Global Manufacturing Outlook 2013 KPMG
Global Manufacturing Outlook 2013 KPMG
Manufacturing
Outlook
Competitive advantage:
enhancing supply chain
networks for efficiency
and innovation
An Economist Intelligence Unit
research program sponsored
by KPMG International
Interviewees
We would like to thank the 335 executives who participated in
the survey and the 4 interviewees below for their valuable time
and insight.
Carol Burke Paul McGartoll
Managing Director, Unipart Vice President of Strategy and
Manufacturing Group Business Development, Textron
© 2013 KPMG International Cooperative (“KPMG International”), a Swiss entity. Member firms of the KPMG network of independent firms are affiliated with KPMG International. KPMG International provides no client services. All rights reserved.
About the survey
This report is based on a survey of 335 senior executives, conducted in November
2012. Executives represented 5 industries: Aerospace and Defense, Automotive,
Conglomerates, Engineering and Industrial Products, and Metals. Forty-six percent
were C-level, including board members. Respondents came from companies of many
different sizes: nearly 30 percent represent companies with more than US$5 billion in
annual revenue. Respondents are distributed globally, with nearly a third each from the
Americas; Asia-Pacific; and Europe, the Middle East & Africa.
1. What are your organization’s global annual 2. Which of the following best describes your title?
revenues in US dollars?
1% Head of department
Other C-level executive
4% CFO/Treasurer/Controller
5%
12%
$25bn and over SVP/VP/Director
9% 28%
8% $10bn to $24.99bn Manager
37%
$5bn to $9.99bn COO/CIO/Technology director
7%
9% $1bn to $4.99bn Head of business unit
$500m to $999m 10% Other/Board member
CEO/President/Managing
24% director/Executive director
34% 11%
3. In which region are you personally based? 4. What is your primary industry?
1%
4%
6% Asia-Pacific 17% Engineering and industrial
products (including
30% North America
29% industrial electronics)
Western Europe
Automotive
30%
Latin America
Conglomerate
18%
Middle East and Africa
Metals
Eastern Europe
18% Aerospace and defense
30% 18%
iii
© 2013 KPMG International Cooperative (“KPMG International”), a Swiss entity. Member firms of the KPMG network of independent firms are affiliated with KPMG International. KPMG International provides no client services. All rights reserved.
Foreword
The market headwinds of intense global competition, slow to modest growth,
public sector budget constraints, and Euro-zone instability continue to challenge
industrial manufacturing companies to transform their business models and their
cost structures in ways unimaginable only a few years ago. In the midst of the
continuing focus on cost, some might say that manufacturers have hunkered down
to weather the storm. To the contrary, we believe this year’s Global Manufacturing
Outlook (GMO) reveals that these companies are positioning themselves for a new
era of growth driven by innovation, collaboration across the value chain, and rapidly
changing manufacturing and decision support technology.
On the innovation front, nearly one-third of the respondents to this year’s survey
indicated that they intended to pursue “breakthrough” or “disruptive” innovation
strategies in the product development area. Further, there was a marked (15 percent)
increase in the number of respondents increasing their R&D budgets to 4 percent
or more of their revenue, an upward trend we believe will continue over the next
2-3 years. Finally, the innovation process is quickly shifting to a “partnership model”
bringing together internal resources, customers and suppliers, third party research,
and external funding sources. Speed to market, enhanced products, and the right
innovation business model will ultimately be the differentiator in the battle for global
market share.
The economic impact of the evolution of the supply chain over the past few years has
been dramatic. The concept of nearshoring or sourcing/manufacturing closer to the
end market to reduce cost and risk was a hallmark of the post-recession recovery.
As the recovery gained momentum, new models of cooperation and collaboration
between OEM’s and the value chain helped to optimize processes and further reduce
cost. As you will see from the 2013 GMO, the next wave of supply chain gains will be
the most dramatic yet, with a new spirit of partnership, transparency, and visibility
across the value chain creating enormous economic value from a technology-enabled
demand-driven supply chain.
Underpinning the new models in innovation and supply chain is the extraordinary
advancement in the technology to support everything from the R&D and
manufacturing processes to decision support and data analysis tools, as well as
supply chain visibility and other business intelligence needs. The emergence of
niche players coupled with the capabilities of the traditional players will make this a
technology-rich environment for global manufacturers. Exploiting these technologies
and managing the resulting explosion of data will be critical to remain at the top of
the competitive heap.
One thing we know for sure, the volatility that we have seen the past 5 years will
continue and the strategies, relationships, and tools to compete in this ever-changing
environment must become much more sophisticated. We hope that you will find this
year’s GMO thought provoking and stimulating as you consider your company’s plans
for driving growth and prosperity in the continuing “manufacturing renaissance.”
Jeff Dobbs
Global Sector Chair, Diversified Industrials
iv
© 2013 KPMG International Cooperative (“KPMG International”), a Swiss entity. Member firms of the KPMG network of independent firms are affiliated with KPMG International. KPMG International provides no client services. All rights reserved.
Contents
Executive summary 2
Positioning for opportunity 4
The future is in the supply chain 8
The visibility imperative 12
Innovation: forging ahead 16
Conclusion 24
1
© 2013 KPMG International Cooperative (“KPMG International”), a Swiss entity. Member firms of the KPMG network of independent firms are affiliated with KPMG International. KPMG International provides no client services. All rights reserved.
Executive summary
innovative. horizons.
This Economist Intelligence Unit
shale gas revolution, are convincing
some to revisit the US, with its
technological prowess, attractive
study, written on behalf of KPMG,
talent pool and scaling opportunities,
finds global manufacturers redoubling
as a primary base. For similar reasons,
their efforts to become more
China continues to be a magnet for
efficient and innovative, both to stay
global manufacturing companies:
competitive in mature markets, and
although economic growth there has
to capitalize on growth opportunities
decelerated and costs have risen, the
in the emerging world. Firms are
economy remains one of the most
looking to deepen their relationships
dynamic in the world; as a production
with partners, invest in innovation and
base it offers tremendous efficiency,
strengthen their operations to prepare
and a strong engineering skills pool.
for growth.
KPMG Insight
UK Open for Business
The 2013 survey ranks the UK 4th as a country pound over recent years which has made
where global companies expect sales growth British exports cheaper.
in the next 12-24 months. This is an increase in
The UK government has launched initiatives
ranking from the 2 previous years (5th in 2011,
to encourage local production and foreign
and 6th in 2012), and whilst this may be linked to
investment in UK manufacturing. Examples
recent UK government initiatives to encourage
Stephen Cooper such as the Patent Box regime which gives tax
both exports from the UK, and investment
Partner, incentives for companies to register patents
into the UK by foreign companies, it may also
Head of Diversified in the UK and reductions in the UK corporate
be reflective of the recent weakening of other
Industrials and income tax rate (reduced by 2 percent since
countries such as Germany and Brazil.
Automotive, 2010) are part of the UK Government’s stated
KPMG in the UK The Eurozone has traditionally been the objective of the having the lowest corporation
UK’s biggest export market. With the Euro tax rate in the G20. The UK has recently seen
Crisis impacting European demand, the UK numerous automotive manufacturers investing
is increasing its focus on emerging markets. in plants in the UK such as Jaguar Land Rover,
From 2007 – 2012 British companies more Nissan, BMW, Toyota, General Motors, Honda
than doubled their exports to the fast growing and Nissan.
BRIC markets, supported by UK Government
The UK is showing the world that it is ‘open for
trade missions, and the weakening of the
business’.
Alex Shum
Head of Diversified Industrials, KPMG in China
China remains the fastest growing economy in the world and While China provides a large talent pool for R&D, the cost
one of the most attractive investment destinations globally in of recruitment and retaining such talent continues to rise on
many industry sectors, if not all. the back of inflation and high costs of living which – in the
more developed regions of the country – have been driving
Under the 12th 5-Year Plan, the Chinese government’s policies expectations of pay rises for skilled labor. Uncertainty also
remain on course in terms of favoring investments in high-end prevails as to technology platforms and options.
equipment manufacturing, high-tech, energy-efficient products
and new materials sectors. In large part, these measures Investment spending also remains cautious in China, driven
are aimed at modernizing the manufacturing sector, moving by uncertainty as to the timing and magnitude of a global
domestic manufacturers up the value chain and protecting the economic rebound and the potential impact of measures
environment. In turn, this helps divert overseas and domestic recently announced by the new Chinese central government
investments and attracts managerial and R&D talent to these leaders.
sectors; a welcome trend for Chinese companies who are
increasingly recruiting overseas talent for key management
positions.
Over the past few years, European manufacturers have made However, we believe that achieving sustainable cost reduction
great progress in embedding efficiency initiatives and cost- requires a transformational change supported by cross-
cutting programs into their operations, closing unprofitable functional and inter-company programs. In other words,
businesses and divesting of non-core assets. Based on recent Europe’s manufacturers will need to focus on changing the
improvements in margins reported across the continent, it mind-set and the daily routines of their people and suppliers
seems that these measures are taking hold. rather than chasing one-off initiatives.
But while cost reduction remains important and deeply As such, Europe’s manufacturing executives would be well
embedded in the minds of Europe’s manufacturing managers, advised to review their past sourcing and footprint decisions
we expect to see new measures emerge to further improve in light of today’s environment and be willing to take on
operational effectiveness. These may include the optimization radical new approaches such as the re-shoring of outsourced
of existing processes along the value chain in order to build functions, the installation of local R&D departments and the
“clusters” of competence; greater focus on local development development of production facilities focused on individual
and production facilities within existing markets; and the market demands.
development and implementation of incremental and (to a
lesser degree) pioneering innovation as a way to safeguard
product differentiation and reduce time to market.
Eric Damotte
KPMG Global Head of Metals
Metals outlook
All things considered, 2013 will likely be remembered move by many organizations to reduce downstream costs
as a year of foundational change for the metals sector. and capture some of the value lost to intermediaries
Restructuring and cost cutting will continue in the slow by rethinking their distribution and customer service
growth markets of Europe; investment will pick up in offerings. On the upstream side, we expect to see an
the high growth markets in Asia; and consolidation will uptick in the pace of partnering and joint ventures as metals
continue, particularly in China where significant room still organizations look to secure the cost benefits of vertical
remains for the industry to modernize. integration without outlaying massive amounts of capital or
Much like the respondents in the broader survey, metals shouldering too much risk.
companies are keenly exploring new opportunities for cost Likely the greatest competitive advantage, however,
cutting. In those markets where overcapacity is perceived will come from renewed efforts to drive product and
to be more structural in nature, we expect to see a further process innovation. Indeed, as customers become more
restructuring of assets. At the same time, continued sophisticated in their needs and regulators add increased
restrictions on available capital and a temporary drop in pressure for environmentally-friendly products and more
resource prices around the world has catalyzed metals efficient energy use, those organizations that are able
organizations to focus more on the optimization of their to quickly respond to shifts in demand and location will
existing assets rather than the acquisition of new ones. ultimately capture a greater share of the market.
The supply chain has also come sharply into focus for
metals companies. Over the past year, I have noted a
Operational
improvement 1
41%
2 Demand-driven
planning
56% 36%
3 Integrated
planning
business
Operational
improvement 1 46%
2 Centralized
procurement
58% 39%
3 Supplier
management
49%
32%
4% 9%
KPMG Insight
Demand-driven supply chain
As manufacturers look to become but rather philosophical. Do current
Rob Barrett
leaner, more cost efficient and more processes and policies reflect
Managing
customer focused, we have seen a a demand-driven culture where
Director,
growing trend towards “demand-driven” information is willingly shared and
Advisory,
supply chains where all planning, all material movements are driven
KPMG in
purchasing, and replenishment by consumption? Have trusted
the US
decisions are aligned with actual relationships and agreements with
demand at the furthest point of partners and suppliers been properly
Amit Gupta consumption. To get there, companies established? How will the added
Partner, are establishing multi-tier visibility and value be measured for customers,
Advisory/ reducing information latency across suppliers and partners, and how
Management the supply chain, resulting in inventory- will this value be shared among the
Consulting, related, operational and capital cost participants?
KPMG in savings while simultaneously improving
the US Experience has proven that the best-
delivery performance and customer
designed demand-driven networks
service.
are those developed in collaboration
Adopting a demand-driven supply with key suppliers/customers
chain model is a journey and therefore and rolled out through an iterative
the demand-driven processes will approach with continuous process
evolve over time. However, this improvement measured against a
new model does require a shift in shared benefits model.
thinking away from traditional “supply
Business leaders should note, however,
chains” towards the concept of
that this is often an emotional journey
highly integrated “supply networks”
replete with its own highs and “valleys
where multiple tiers of companies are
of despair.” But those that are able to
working off the same shared view of
manage the transition effectively will find
total demand and total available supply
that demand-driven approaches allow
with common processes and metrics.
companies to leapfrog their competitors
The greatest challenges for most and sustain a competitive differentiation
organizations may not be technical, for an extended period of time.
Web-based
1
39%
partner portal
40%
37%
3 Traditional B2B/EDI network
Contract
call-offs 1 46% 2 Email, fax, or mail
25% 40%
3 Traditional B2B/EDI network
R&D investment
70
63%
60
Percentage of participants
50 48%
42%
40
30 28%
20
9% 10%
10
0
0-3% Greater than 4% Don‘t know
R&D investment as a percentage of revenue
Last 2 years Next 2 years
Source: Economist Intelligence Unit survey, Nov. 2012.
1 Aligning innovation
to company strategy
2
Complexities in
collaborating with suppliers and partners
3 Executing
on innovation – on time and on budget
4 Shortage of ideas
to drive innovation
5
Incomplete view of/difficulty understanding the
needs of our customers
Source: Economist Intelligence Unit survey, Nov. 2012.
Respondents selected top three.
Doug Gates
KPMG Global Head of Aerospace and Defense
Marty Phillips
KPMG Global Head of Management Consulting for Diversified Industrials
Competition heats up
Clearly, the world of manufacturing has become much more developing lower-cost products or creating greater value for
competitive. With minimum positive growth on the horizon, the end customer.
companies continue to compete on cost and – as a result –
Both are a challenge. Driving further costs out of an
are searching for new approaches and models that will trim
already tight structure requires companies to look beyond
any remaining excess out of the product cycle. No wonder
the back office towards the actual costs of engineering,
then that manufacturing executives have turned their eyes
manufacturing and procurement. At the same time, adding
towards reworking their engineering, design and supply
more value to their products requires manufacturers to gain
chain processes with a view towards greater collaboration
ever-clearer insight into the needs and preferences of their
both upstream and downstream.
customers, requiring them to not only understand how their
Everything I see in both this report and the actual market competitors deliver value, but also how to predict what
indicates that competition is only going to heat up from customers will want in the future.
here. According to this report, manufacturers are seriously
Ultimately, this year’s report shows that – to win in
rethinking their plans to expand into new and unfamiliar
this complex and constantly evolving environment –
markets and product lines. And while this will effectively
manufacturers will need to focus on 2 key priorities going
reduce risk and capital costs, it also narrows the scope for
forward: process innovation and customer insight and
new growth. Indeed, in this hyper-competitive environment,
service. Those that get it right should eat well; those that
any gains in market-share must, by necessity, be taken off
don’t will simply be eaten.
the shoulders of competitors. This can only be achieved by
China
85% China
32% Hong Kong
9% India
US
89% US
18% Canada
13% UK
13% China
Japan
87% Japan
29% China
16% US
16% India
Germany
70% Germany
32% China
22% India
UK
59% UK
29% US
29% China
Collaborating with partners and suppliers on innovation helps to bring the best ideas to the table
quickly and gives manufacturers an edge. Choosing the right partners and opportunities is critical.
Who works best with our company? Do we have the right processes to ensure speed to market?
Moving past business as usual is essential to succeed in the new economy.
Ken Seel
Global Head of Conglomerates,
KPMG in the US
Reverse innovation
Savvy manufacturers seeking to enter new markets are rethinking and re-engineering their products
to meet the unique needs and price points of the emerging markets. In a trend known as ‘reverse
innovation,’ manufacturers are locating their R&D efforts in countries like India and China and
creating simpler, lower cost designs better suited to a number of emerging markets. For
example, GE Healthcare’s initiatives to develop designs and products for the Indian market is
expected to create new demand segments at lower price points for the company, while Honeywell
is reportedly building innovation hubs in India and China to develop systems and solutions that may
drive its growth in several regions.
Richard Rekhy
Chief Executive Officer,
KPMG in India
And while this may be good news for global companies (and Japanese manufacturers) attempting to
develop global supply chains, it also raises a distinct risk of commoditization of products. Historical
evidence suggests that Japan will only achieve price competition once manufacturers have identified
the unique value that they offer to the markets that they serve.
The challenge for Japan’s global companies, therefore, is to balance the need to be globally cost
competitive while still being seen as unique and value adding.
Given the expectations of decreasing domestic consumption, it seems increasingly likely that
Japanese companies will need to be the front runners of the movement to establish a new global
business model that satisfies both of these critical demands.
Mina Sekiguchi
Associate Partner,
KPMG in Japan
Governments across the globe are looking to partner with industry by offering R&D tax incentives that
specifically promote and target innovation and growth. Over 40 countries are now offering R&D
incentives that provide tax-effective options for locating and structuring R&D operations. This is a win-
win situation for both the countries, who can reap substantial spin-off economic benefits, and the
businesses, who can benefit from increased innovation to bolster their growth and profitability.
Carlo Ciaramitaro
KPMG’s Canadian and Americas R&D Tax Incentives Leader,
KPMG Canada
In part, this mismatch between local market economics and the performance of the industrials
sector has been the result of difficulties related to competitiveness and the appreciation of the local
currency which dampened export growth. But competition for skilled and qualified professionals is
also hampering growth by pushing up the cost of labor.
Recently, the government has taken steps to respond to slow growth in the sector including
initiatives to increase production, tax rate reductions, tax incentives and greater control over
foreign exchange, all of which should set the tone for 2013 and bring some relief to the sector.
The first budding signs of recovery can already be seen. In January, industrial output grew by
2.5 percent over last December, the greatest monthly advance in almost 3 years (and 5.7 percent
growth year-over-year), according to the Brazilian Institute of Geography and Statistics IBGE’s data.
And while February 2013 may have resulted in a slight decline, the overall picture seems to indicate
that good news is on the horizon for both Brazil’s manufacturers and foreign investors.
Charles Krieck
Partner in Charge, Audit,
KPMG in Brazil
At the center of all this is fine tuning supply chain links to work
more effectively with partners. Companies that make the most of
their supply chains have the potential to become more profitable
in the years ahead. As Carol Burke from Unipart puts it, “Supply
chain effectiveness is the invisible advantage.”
Global/USA
Jeff Dobbs
Global Sector Chair,
Diversified Industrials
Sweden +1 313 230 3460
Björn Hallin jdobbs@kpmg.com
KPMG Partner/Head of
Industrial Markets
KPMG in Sweden
+46 8 723 96 26
bjorn.hallin@kpmg.se
UK
Stephen Cooper
Partner, Head of Diversified
Industrials and Automotive
KPMG in the UK
+44 20 73118838
stephen.cooper@kpmg.co.uk
Canada
Don Matthew
Partner, Canadian Lead
Diversified Industrials
KPMG in Canada
+1 604 527-3770
dmatthew@kpmg.ca
Netherlands
Tom Van der Heijden
Partner
KPMG in the Netherlands
+31206 567520
VanderHeijden.Tom@kpmg.nl
France
Philippe Grandclerc
Partner
KPMG in France
+33155686952
pgrandclerc@kpmg.fr
Spain
Manuel Parra
Partner/Head of Diversified
Industrials
KPMG in Spain Brazil
+34914563400 Charles Krieck
mparra@kpmg.es Partner in Charge, Audit
KPMG in Brazil
+551121833102
ckrieck@kpmg.com.br
Switzerland
Bryan DeBlanc
Partner
KPMG in Switzerland
+41 58 249 2944
bryandeblanc@kpmg.com
Italy
Roberto Giovannini
Head of Consumer and
Industrial Markets, Advisory
KPMG in Italy
+390514392611
rgiovannini@kpmg.it
Japan
Osamu Matsushita
Head of Diversified
Industrials
KPMG in Japan
+81352188768
omatsushita@kpmg.com
China
Alex Shum
Head of Diversified
Industrials
KPMG in China
+862122122508
alex.shum@kpmg.com
India
Richard Rekhy
Chief Executive Officer
KPMG in India
Australia
+91 124 307 4303
Cameron Slapp rrekhy@kpmg.com
Sector Leader, Diversified
Industrials and Building
Materials
KPMG in Australia
+61 (2) 9335 7258
cslapp@kpmg.com.au
Additional contributors:
Robert H Barrett Loek Helderman Mina Sekiguchi
Managing Director, Advisory KPMG Head of Global Tax Efficient Associate Partner, Business
KPMG in the US Supply Chain Management Strategy and Development
+1 480 459 3535 KPMG in the Netherlands KPMG in Japan
rhbarrett@kpmg.com +312 06 56 1415 +813 32 667 007
helderman.loek@kpmg.nl mina.sekiguchi@jp.kpmg.com
Carlo Ciaramitaro
Canadian and Americas Charles Krieck Michele Hendricks
R&D Tax Incentives Leader Partner in Charge, Audit Global Executive for
KPMG in Canada KPMG in Brazil Diversified Industrials
+1 519 251 3522 +55 112 183 3102 KPMG in the US
cciaramitaro@kpmg.ca ckrieck@kpmg.com.br +1 203 406 8071
mhhendricks@kpmg.com
Stephen Cooper Richard Rekhy
Partner, Head of Diversified Chief Executive Officer Martha Collyer
Industrials and Automotive KPMG in India Senior Marketing Manager
KPMG in the UK +91 124 307 4303 KPMG in Canada
+44 20 73118838 rrekhy@kpmg.com +1 416 777 3505
stephen.cooper@kpmg.co.uk mcollyer@kpmg.ca
Dr. Alexander Riedel
Amit Gupta Partner, Advisory
Partner, Advisory, Performance & Technology
Management Consulting KPMG in Germany
KPMG in the US +49 89 9282 1210
+1 847 274 4533 ariedel@kpmg.com
agupta10@kpmg.com
kpmg.com/socialmedia
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rate and timely information, there can be no guarantee that such information is accurate as of the date it is received or that it will continue to be accurate in the future. No one should
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© 2013 KPMG International Cooperative (“KPMG International”), a Swiss entity. Member firms of the KPMG network of independent firms are affiliated with KPMG International.
KPMG International provides no client services. No member firm has any authority to obligate or bind KPMG International or any other member firm vis-à-vis third parties, nor does
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Publication number: 130103. Publication date: May 2013