Apple Computers Used to Be Built in the U.S. It Was a Mess (2018)

Summary

In 1988, when Jean-Louis Gassée took a close look at Apple’s “highly automated” Macintosh factory in Fremont, Calif., what he saw was not pretty. Mr. Gassée, a French specialist in office automation, had just been promoted to president of Apple’s product division by John Sculley, then Apple’s chief executive, and was responsible for the company’s engineering and manufacturing work. When he first started, Mr. Gassée decided to spend two days learning how the company actually built its products by working on a factory production line.His experience assembling a Macintosh computer display and then stuffing chips into a computer motherboard is an important part of the story behind the artful language on the iPhone box — “Designed by Apple in California. Assembled in China.”After Apple announced a large new campus in Austin, Tex. — creating as many as 15,000 jobs, none of them expected to be manufacturing — it’s worth looking at the company’s flirtation with advanced manufacturing in Silicon Valley in the 1980s. Apple’s co-founder, Steve Jobs, had an abiding fascination with the tradition of Henry Ford and the original mass manufacturing of automobiles in Detroit, as well as the high-quality domestic manufacturing capabilities of Japanese companies like Sony. But his efforts to replicate either in California were examples of his rare failures.In 1983, Mr. Jobs oversaw the construction of a state-of-the-art plant where the new Macintosh computer would be built. Reporters who toured it early on were told that the plant, located just across San Francisco Bay from Apple’s headquarters, was so advanced that factory labor would account for 2 percent of the cost of making a Macintosh.“Steve had deep convictions about Japanese manufacturing processes,” recalled Randy Battat, who joined Apple as a young electrical engineer and oversaw the introduction of some of the company’s early portable computers. “The Japanese were heralded as wizards of manufacturing. The idea was to create...