Toy manufacturing is concentrated in China due to specialized expertise in meeting high safety standards, especially for components like magnets which can be fatal if swallowed. Shifting production elsewhere introduces significant risk of safety failures from a less experienced workforce, a factor often overlooked in supply chain discussions.
The move toward a less efficient, more expensive global supply chain is not a failure but a strategic correction. Over-prioritizing efficiency created a dangerous dependency on China. Diversification, while costlier in the short term, is a fundamental principle of long-term risk management.
Apple's manufacturing presence in China is not driven by cost savings. According to CEO Tim Cook, it is driven by the unparalleled scale of the country's skilled "tooling engineers"—a talent pool he claims would be impossible to assemble in the United States.
After a disastrous first run with a U.S. manufacturer, Wild Rye pivoted overseas. Counterintuitively, they found Chinese partners offered superior quality, sophisticated machinery, and a proactive partnership approach—even flagging potential issues pre-production. They were also more willing to work with a small brand's lower order quantities.
China's durable advantage isn't just its massive workforce but the collective "process knowledge" generated on factory floors. This expertise in solving countless small manufacturing problems cannot be easily written down or encoded in equipment, creating a powerful, hard-to-replicate competitive moat.
Apple's deep reliance on China is not just about cost but a 25-year investment in a manufacturing ecosystem that can produce complex products at immense scale and quality. Replicating this unique combination in India or elsewhere is considered fanciful.
The belief that China's manufacturing advantage is cheap labor is dangerously outdated. Its true dominance lies in a 20-year head start on manufacturing autonomy, with production for complex products like the PlayStation 5 being 90% automated. The US outsourced innovation instead of automating domestically.
China does not oppose the migration of labor-intensive manufacturing to ASEAN countries. With an aging workforce, its strategic focus is shifting up the value chain to high-end industries like green energy. This indicates a deliberate industrial policy to cede low-cost production rather than a desire to control all levels of manufacturing.
While headlines focus on advanced chips, China’s real leverage comes from its strategic control over less glamorous but essential upstream inputs like rare earths and magnets. It has even banned the export of magnet-making technology, creating critical, hard-to-solve bottlenecks for Western manufacturing.
The common practice of offshoring manufacturing, exemplified by Apple, creates a critical flaw by severing the feedback loop between designers and producers. This leads to suboptimal product design and simultaneously transfers advanced manufacturing skills and capabilities to other nations, like China.
The global Christmas decoration market is remarkably centralized. The city of Yiwu in China's Zhejiang province is responsible for producing nearly two-thirds of all artificial trees and decorations sold worldwide, showcasing an extreme concentration in the global supply chain for seasonal goods.