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| HAM’s Flagship Motorcycle |
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Opinions varied widely concerning which model should be manufactured at HAM. Considering the fact that large motorcycles had long dominated the American market, the most desirable model for production was the Gold Wing GL1000, a flagship bike built by Saitama Factory’s Sayama Plant and exported to the U.S. It was therefore decided that production of the Gold Wing would be discontinued in Japan and transferred to HAM, which would be its exclusive maker. The Gold Wing GL1000, however, had many parts and would be quite difficult for the associates at HAM to assemble, given that it would be their first opportunity to produce a motorcycle. It was also very possible that a skilled labor force would be required in order to achieve the promised level of product quality. Therefore, it was decided that manufacturing operations would begin with the CR250R, a motocross bike having a much smaller number of parts than the larger, more complicated GL1000. The operation would then shift gradually to production of the Gold Wing. Japanese engineers began arriving in Ohio in 1979. They decided to disperse throughout the area in order to integrate as residents of the regional community. Yet, this was to prose considerable difficulty for the Japanese staff and their families, including problems with the English language. However, it was Honda’s attitude toward assimilation that became the foundation of HAM’s acceptance as a member of the local community. The associates at HAM began their training in motorcycle production under the tutelage of the Japanese engineers, who handled the areas of technical orientation without interpreters. Key words and gestures were repeatedly used to convey the importance of quality control, which was considered the single most important element in the entire manufacturing operation. It was a process that inspired the enthusiasm of HAM’s Japanese instructors. The American managers meanwhile were sent to Japan so that they could acquire essential knowledge about Honda’s manufacturing processes. For welding operations requiring special techniques, associates were sent to a vocational training school in Ohio to learn the basics, after which they were sent to Japan for two weeks of on-the-job training. Training was also ongoing for other critical production tasks. In order to prepare for actual plant operations other issues, including the shipment of parts from Sayama Plant, were considered from various perspectives. This extended to the tiniest details, such as what types of parts should be packed into sets, and in which quantities, in order to ensure product quality and production control. The first CR250R produced at HAM rolled off the production line on September 10, 1979, thanks to a process that had indeed secured production quality as the number one goal. Honda had even promoted a “discover and report” system, in which the associates were encouraged to report any defects in order to prevent such problems from carrying on to subsequent processes. Honda also asked its parts suppliers to be careful when handling their product for delivery. When parts did not meet Honda’s strict requirements for quality, the company would work with the vendor to resolve the problem. It was thus that HAM’s manufacturing operation gradually got under way. And, April 1980, the Gold Wing GL1100, a highly anticipated new model, was being assembled by the associates at Honda’s new Ohio plant. |
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