Exploring American Manufacturing: A Four-Year Experiment

Introduction

This document outlines the journey of attempting to manufacture a product entirely in America, despite overwhelming market pressures to produce overseas. The aim is to assess the feasibility and competitive viability of local manufacturing within a landscape shaped by global economic forces.

Background

• The global economic shifts post-World War II have incentivized moving manufacturing overseas due to cheaper labor costs.
• Local manufacturing is seen as a key to self-reliance and community stability.
• These challenges became more evident during the 2020 pandemic due to a lack of manufacturing capacity in essential products like N95 masks.

Experiment Objective

The primary goal was to defy global pressures and produce a product locally, specifically a grill scrubber called the Smarter Scrubber, while documenting the stories behind each component.

Motivation

• The creator's parents were union auto workers, instilling a sense of value in American manufacturing.
• Over time, international treaties and economic factors shifted manufacturing overseas, causing local economic decline.
• The pandemic highlighted the critical need for local manufacturing in emergencies.

Challenges Faced

1. High Costs:
   • Significant cost differences between foreign and domestic production were encountered.
   • Specifically, American-made components like bolts could cost over four times more than their foreign counterparts.
2. Supply Chain and sourcing difficulties:
   • The uncertainty of the origin of materials, specifically chain mail meant for the scrubber.
   • Compromised quantity and price when dealing with local suppliers for raw materials.
3. Tooling and Mold Making:
   • Lack of domestic facilities to make molds.
   • The majority of tool and die-making skills are now centralized in places like China, creating a bottleneck in local manufacturing capabilities.

Solutions and Developments

• Engaged with local manufacturers to produce injection molds in the U.S.
• Utilized unique techniques like 3D printed mold cavities for small test production.
• Sought mentorship and support from experienced engineers and toolmakers.
• Partnered with a small business (JJ George) for business expertise in local production.
• Devised a flexible supply chain involving other countries like India to supplement U.S.-made components when necessary.

Part Two: Prototype Development

• Designed utilizing CAD and 3D printing to prototype a grill scrubber aimed to solve the problems with existing products.
• Focused on creating a durable, non-bristle grill scrubber to avoid the health hazards associated with wire bristles.
• Arrived at a multi-component design allowing for efficient assembly.
• Conducted rigorous testing to select the appropriate materials, particularly for high-quality chain mail.

Market Challenges

• The competitive disadvantage of U.S.-made products due to higher labor and material costs.
• Struggles with intellectual property theft when manufacturing abroad, particularly in China.
• Difficulties with securing affordable local suppliers for some components.

Call to Action

• Encourage local manufacturing: Consider the long-term community benefits over short-term financial savings.
• Acknowledgment of the global shift in tooling expertise and encouragement to revitalize local tooling and die-making skills.
• An appeal to support locally manufactured products, such as the Smarter Scrubber, to help sustain the manufacturing knowledge base and economy within local communities.

Conclusion

• The experiment highlights critical insights into the challenges and complexity of reviving local manufacturing in the U.S.
• Calls for more investment in local manufacturing industries and skills development, alongside introducing the Smarter Scrubber, a locally made grill scrubber, aiming for competitiveness and higher quality standards.
• Final pitch for the Smarter Scrubber, emphasizing the importance of local production and encouraging support from communities and wholesalers.

For a complete perspective on the process and challenges faced, viewers are encouraged to watch the full video and follow related content discussing these industry topics.