Nicola Shepheard

Niche work is key to future of manufacturing

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Prime Minister Helen Clark says the closure of a Fisher & Paykel plant in Auckland is the "way of the world" and that the future of manufacturing in New Zealand lies in design, research development and niche products.

Kiwi whiteware maker Fisher & Paykel announced last week it was moving production of its washing machines and clothes dryers to Thailand, at the cost of 350 jobs in the next year.

The company said many of its competitors were already making machines in low-cost Asian countries. It expects the move will deliver annual benefits of $10 -$15 million.

Clark said yesterday: "It's the way of the world... For a long time, processing work like the type Fisher & Paykel does has been migrating from western centres to low-cost centres..."The key for [New Zealand] is where the company is based, and where the high-value design R&D work is done, where it's branded, where the export revenue comes."

The F&P news triggered a warning from Sleepyhead that manufacturers were being squeezed out of New Zealand by interest-rate hikes and the high dollar. It said others would be forced to move offshore if conditions didn't improve. Clark said: "That's a business decision for them."

The Green Party and the Engineering, Printing and Manufacturing Union both say the Government's sole reliance on the official cash rate as a brake on inflation is hurting exporters.

Clark yesterday conceded the official cash rate was a "blunt instrument". But she said there was no cross-party consensus on workable alternatives. She also dismissed suggestions Government spending was driving the dollar upward.

Cross-party talks called to aid manufacturers

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Labour was isolated yesterday as two coalition partners and the National Party called for cross-party talks to solve New Zealand's manufacturing crisis.

It follows the announcement by iconic New Zealand manufacturer and exporter Fisher & Paykel that a significant portion of its manufacturing sector would be sent overseas, costing 350 jobs.

As New Zealand First, the Greens and National said they were prepared to talk and find a solution, Prime Minister Helen Clark had a stark message for the sector: "All western economies have seen manufacturers migrate to lower cost centres. It's been the way of the world for a long time."

Manufacturing employs 235,000 people, accounts for more than 65 per cent of our exports, and 15 per cent of GDP.

Last night, National deputy leader and finance spokesman Bill English said National would consider cross-party talks but only if they led to actual policy change.

"We would need to see an indication that the Government was willing to change its policies to make these industries more competitive and stop treating them as a cash machine for Labour to spend their money."

English said current policy had been of no benefit to manufacturers, despite the industry providing a strategy to the Government. He said flexible labour law, less red tape and competitive ACC are essential to making the industry more competitive. He also said if the Government hauled back their spending programme it would take pressure off interest rates and lower the dollar, easing pressure on exporters.

English said he believed there was a future for manufacturing in this country. "New Zealand manufacturing has proven to be very resilient. They've had a decade where they haven't had any protection at all and they've changed enormously in that time. I don't believe they're doomed. I don't think it's the end for New Zealand manufacturing.

"They're getting good at finding their niche and they don't have to be high-tech. As Fisher and Paykel proved being more sophisticated doesn't get you out of China's grasp. There's no doubt that a US75-cent dollar is a crisis for some manufacturers and they need all the help they can get."

The Green Party's Sue Bradford, who's driven the Buy New Zealand Made campaign, said manufacturing would be saved by addressing big-picture issues - especially how we tweak the value of our dollar through monetary policy. Bradford agreed that New Zealand needed to focus on the high-skilled, high-value elements of manufacturing - design, research and development - and niche products. She said the low-tech end was also important - specialising in the brainy stuff won't be enough as the Asian economies, with their bigger populations and good universities, become more sophisticated and move in on this territory.

Although global economic forces were beyond our control, New Zealand needed to retain the ability to manufacture here to avoid becoming more open to those external forces.

Fisher & Paykel bowed out with reasons that were an echo of those from other major New Zealand manufacturers - it was tired of trying to keep up with competitors who had already taken advantage of the cheap labour and other savings offered by China and other developing Asian economies. At home, high interest rates and the high dollar have also squeezed profit margins.

Bedmaker Sleepyhead has come out saying Fisher & Paykel's departure shows the sector has reached tipping point. Unless things change, expect more firms, including the bedmaker, to shift their factories - and jobs - offshore. "Manufacturers are not asking for hand-outs," says Sleepyhead's Graeme Turner. "They are asking for economic policy that assists them to be globally competitive."

The sentiment was echoed by the Engineering, Printing and Manufacturing Union (EPMU), which estimates that in the past 12 months the high dollar was behind 1200 redundancies, either through cheap importers pushing local firms out of the domestic market or exporting costs becoming too high. The smaller manufacturing businesses tended to simply shut rather than outsource overseas.

Under the shadow of the big box

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"You get a bit bitter and twisted," says Ken Earby wearily behind his glass cabinet counter. Earby and his brother Philip have been running Huntly Hardware Supplies for 30 years, 17 years from these premises, but now the wretched whiff of extinction rises from the Hitachi drills and hunting knives. Late morning, midweek, and not a customer in sight.

Since The Base, Hamilton's latest big-box shopping complex, opened on the city's northern fringe last year only 20 minutes' drive away, sales here have plunged 30 per cent. Road-works outside are compounding the problem.

"We're going to take another hit because the big Mitre 10's opening up there," says Earby. On some prices, his store beats the big chains like Bunnings Warehouse, but he's annoyed that shoppers have stopped bothering to check.  "People have got a built-in Warehouse culture, unfortunately, these days. They think The Warehouse will supply everything, and if it doesn't, they'll make do with what The Warehouse has got."

He's hoping the new Countdown coming to Huntly will bring shoppers who'll browse the main street after they've filled their trolleys. New subdivisions should also help. "You gotta hang through," he says. "Within six months it should start picking up."

Up the road $5 Max and Mr Max is a different world. Merchandise clutters tables and racks in a twinkling confusion of colour and plastic. A steady flow of shoppers comes to hunt out their bargain; a thin middle-aged man buys a thin-bottomed saucepan.

Huntly has three of these ultra-cheap, lucky dip-style shops that have sprung from the ashes of more traditional local stores in New Zealand's small towns and suburbs since the 1990s.  Owners Clive and Jan Quintal are unfazed by competition from the likes of the Red Shed. "Competition has always been there, it's just getting a bit more aggressive, and the opponents have got to be a bit smarter," he says. "You've just got to go with the flow, wherever you can make a buck, that's what you've got to do."

Since New Zealand's big-box retail revolution spread to Waikato in the 1990s, Huntly's shopping strip has slowly but surely changed. A forlorn Deka sign still towers on spindly poles above K Beez' grocers-cum-$2 shop - the department store chain an early Red Shed casualty.

David Lane is stoical. He and his wife Doreen have run D & D's Family Footwear for 11 years, and Lane is chairman of the local business association.

"We are still surviving. A lot of the shops have changed, but there's only two empty," he says. Huntly is on the up - a new surfwear store has opened across the road; the money-lenders who moved in a few years back have moved out again.

They've had to downsize - Rebel Sport's pulling power resulted in Adidas cancelling its supply to the store five or six years ago, and when The Warehouse in Hamilton started stocking slippers, D & D's had to stop. The Warehouse was selling them for less than the shoe shop used to buy them for. But in a twist, "Now the suppliers can't supply at the price The Warehouse is selling them for, so The Warehouse stopped getting those slippers." He shrugs. "The shoe shop's surviving - it's got good stock. But we just need a bit more foot traffic."

"The Warehouse is a way of life for countless New Zealanders. We make a difference to people's lives, especially family life, by making the desirable affordable." - The Warehouse core purpose

"In everything we do, we're driven by a common mission: to improve the quality of life for everyday people around the world." - Wal-Mart website

Call it the Wal-martisation of New Zealand. On once-pastoral town fringes and in far-flung suburbs, see the monolithic malls and super-sized discount chains sprawl. Last year, the Property Council counted 151 shopping centres nationally. Their combined shop space alone totals 183 hectares. Australian companies such as Westfield own almost all our centres, with the notable exceptions of the Palm Shopping Centre and Ngai Tahu's Tower Junction mega-centre, both in Christchurch. Then there are the big boxes: 87 Warehouse stores, 43 Warehouse Stationery stores, 38 Briscoes stores.

Retail's biggest concentration of power lies in our supermarket chain duopoly. Foodstuffs, a privately owned New Zealand co-operative, gives us New World, Pak'N Save and Four Square and claims 54 per cent of the supermarket market. Progressive Enterprises, owned by Australian's second-biggest retailer, Woolworths, gives us Foodtown and Woolworths and claims the other 46 per cent market share.

We spend $11 billion a year at the two supermarket groups - nearly $1 in every $10 spent overall. Is all this just the latest phase in retail's inevitable evolution? A bargain-basement boon for low-income shoppers?

Or is it a retail cancer poisoning our small businesses, our towns, our land, increasingly bleeding profits out of New Zealand and turning the screws on local suppliers?

Warren Snow managed the Tindall Foundation, The Warehouse founder Stephen Tindall's charitable arm, until he grew deeply disillusioned by the Red Sheds' impact.

Now he heads sustainable-development group Envision that helps small businesses fight back. "We have allowed a destructive model of retail sprawl to crawl over the land, where mega-retailers battle amongst themselves for market share by selling ever-cheaper, non-repairable, unrecyclable, sweat-shop-made junk that all ends up in our landfills. Cheap junk for quality of life - what a bargain!"

And it's no thanks, he says, to the Resource Management Act and Environment Court, where the parties with the deepest pockets tend to win protracted legal wrangles.

Meanwhile, main streets that used to be the heart of their community, where shopkeepers were in the same sporting clubs and school committees as their customers, where locals could get most of their daily needs, are now colonised by some mix of bargain-bin stores, takeaways, bric-a-brac shops and cafes for tourists and chain stores. (At least chain franchises retain a kind of local ownership, Snow adds.)

We've already seen the first wave of casualties from The Warehouse revolution, he says. But wait, there's more. "Buoyant farming and tourism of the last few years have stopped many town centres from declining into dead ghost towns, but if these twin pillars collapse for any reason, there will be a second wave of small business closures... in a long-term Wal-martisation (read pauperisation) of the New Zealand economy."

He's turning his attention to helping local retailers "claw back business that the big guys took from them" by pushing their advantages: their profits go back into the community, they participate in the social life of the community, they know their customers' needs, and they can provide genuine service and product back-up.

Laila Harre, head of the National Distribution Union, believes the jury's still out on the impact of big retailers on local economies. But it's a different story for suppliers. "As retailers become bigger, they're dictating terms of supply in a way that's unprecedented." Most pressing, she argues, is the threat our supermarket duopoly poses to New Zealand food producers. Harre is worried that we're underestimating it.

Woolworths Australia is particularly aggressive when it comes to driving down wholesale prices, she says. Local producers who can't weather the squeeze on their profit margins lose out. And it goes wider. "If we can't produce for the domestic market, we won't have the base for export."

Harre says we're a way off the kind of food-plus-general-retail domination of United States titan Wal-Mart.

The Warehouse Extra, which includes a supermarket, is a baby next to the Wal-Mart. But a step in that direction looms in the shape of either Woolworths Australia or Foodstuffs buying a controlling share in The Warehouse. Both supermarket chains have sought Commerce Commission clearance to make their bids, and the authority has promised a decision in coming weeks. Harre adds that if either gets the go-ahead, this would quash the threat to the duopoly.

There's speculation that Wal-Mart may get a foothold in New Zealand through buying parts of the Coles Group, the remnants of Coles-Myer, Australia's biggest retailer, which would mean more profits going overseas. The group is Kmart's parent company.

Wal-Mart has been widely attacked for shutting out unions, crushing local stores, playing hardball with suppliers, paying low wages and providing poor working conditions - all criticisms vehemently denied by the company. Says Harre, "If Wal-Mart gets a stake in New Zealand through Kmart, then I think we need to be very afraid."