IIVG Papers Veröffentlichungsreihe des Internationalen Instituts für Vergleichende Gesellschaftsforschung Wissenschaftzentrum Berlin IMPACT OF NEW TECHNOLOGIES ON EMPLOYEES AND THEIR ORGANISATIONS by Harley Shaiken IIVG/dp/79-202 Februar 1979 Publication series of the International Institute for Comparative Social Research Wissenschafts zentrum Berlin Steinplatz 2, D 1000 Berlin 12 030/313 40 81 - I - Vor b e m e r k u n g : Der Aufsatz von Harley Shaiken stellt einen Problemaspekt bei der Einführung von NC-Technologien dar: den Verlust an individueller und kollektiver Kontrolle über den Arbeitsprozeß. Die zentralen Thesen lauten, a)' daß Ne-Technologie. zu einer Zen.tralisierung der JobControl des Management führe und dessen Dispositionsmöglichkeiten über die konkreten Bedingungen ~er Arbeitsverausgabung erweitere, b) daß diesI;;1 Zentralisierung eine Schwächung der individuellen und kollektiven Formen der Kontrolle darstelle, welche die Arbeiter selbst über diese Bedi?gungen haben; die Einführung der NC-Technologie fUhre den Prozeß der Enteignung der Arbeiter von selbstät.igen Entscheidungsfunktionen fort, den der Taylorismus eingeleitet hätte, c) daß sich die Dominanz des Kontrollaspekts gegenüber anderen Aspekten der Ne-Technologie (Effizienz.-Steigerung u.a.) an der Art der Einführung dieser Technologie durch das Hanagement zeige. Die Formen qer Anwendung der Technologie seien nicht saohzwanghaft determiniert, sondern durch die betrieblichen Herrschaftsbeziehungen bestimmt. Hit der Darstellung des Verlustes von Kontrollmöglichkeiten und Kompetenz der Arbeiter spricht Shaiken e~nen in der bundesrepublikanischen Diskussion weitgehend vernachlässigten Wirkungsaspekt der NC-Technologie an. Diel hierzulande vor allem diskutierten Probleme der Freisetzungseffekte bzw. Lohneinbußen (Abgruppierungen) treten demgegenüber aufgrund des uS-amerikanischen Erfahrungshintergrunds des Autors zurück. Eine Diskussion um Abgruppierungen im Zusammenhang mit NC-Technologien gibt es in den USA nicht, weil derartige Abgruppierungen bisher dort kaum vorkommen. Freisetzungen bzw. Umsetzungen aufgrund von NC-Technologien - II - werden in den USA, zumindest in gewerkschaftlichkontrollierten Betrieben, vor allem durch Senioritätsregelungen aufgefangen Pzw. auf Randbelegschaften verlagert und schaffen so keine unmittelbare Betroffenheit der konfliktfähigen Stamrobelegschaft. Vor dem US-amerikanischen Erfahrungshintergrund ist es auch verständlich, daß vor allem der Kontrollaspekt bei der Einführung von NC-Technologie als Problem hervorgehoben wird: Da die Existenz einer Arbeitnehmer-Interessenvertretung in den Betrieben der USA nicht gesetzlich garantiert ist Und auch diegewerkschaftliche Gegenwehr den Betrieben nicht institutionell gesichert ist, haben die Kontrollmöglichkeiten der Belegschaft über den Arbeitsprozeß und die darauf basierende Kompetenz und Bereitschaft zur Organisierung einer betrieblichen Gegenmachteinen entscheidenden Stellenwert für eine Arpeitnehmerpoliti~. Die Erfahrungsbasis des Autors ist die Einführung von NC-Technologien in der AutoI1lobilfabrikation im Raum Detroit. Während der Einführungsgrad von NC-Technologien in der USWirtschaft im Durchschnitt nicht höher zu sein scheint als in der Bundesrepublik, ist er in diesem Bereich besonders weit fortgeschritten. Harley Shaiken ist Werkzeugmacher und hat bis vor kurzem in verschiedenen Werken der Automobilfabrikation in Detroit gearbeitet; er argumentiert also als Betroffener. Allerdings gibt er keineswegs repräsentativ die Sichtweise von betroffenen amerikanischen Facharbeitern oder von Gewerkschaftsvertretern im Hinblick auf die NC'7'Technologie wieder. Weil, wie oben erwähnt', das US-Management die Einführung dieser Technologien nicht· direkt mit Abgruppierungen verknüpft, weil Freisetzungen unter den Bedingungen der stärker segmentierten Arbeitsmärkte der USA weniger zum Politikum werden, und weil die Folgen des von Shaiken beschriebenen Kontroll- uI}d Kornpetenzverlustes langfristigen Charakter haben, stellt - III die Einführung von NC-Technologien in der amerikanischen Arbeiterschaft und Gewerkschaftsbewegung bisher kaum ein größeres Diskussionsthema dar. Der Aufsatz entstand auf Basis eines 'V'lerkauftrags des IIVG für den Schwerpunkt "Physische, psychische und soziale Belastungen und gesellschaftspolitische Bewältigungsstrategien in hochindustrialisierten Gesellschaften". - IV - Impact of New Technologies on Employees and their Organizations Preface 1 1. NC as a Means to Centralize 3 Management Control 2. The Wea.kening of Norker' s Control over th~ 16 Work Process 3. Management l s Strategies to 22 Implement NC-Technology 4. AlternativE; ways in Using the. 30 New Technology Notes 33 - 1 - IHPACT OF NEW TECHNOLOGIES ON EMP,LOYEES Al'1D THEIR ORGAl.'HZATIONS Preface Automation poses serious new problems for workers and the labor movement. In the past, when newtechnology has been introduced, workers hav~ been concerned with gaining a share of the increased productivity that their labqr brings and with guarding themselves against the spectre of unemployment. While these remain important concerns, modern , computer technologies add a new threat as weIl: by making possible a reorganization of the workplace that gives management a qualitatively different and more complete control of the production process, they undermine the job control of workers and may cripple the power of unions. would like to explore the impact of new 'technology on the workplace by examining what at first glance appears to be a fairly narrow area: numerical control (Ne) machines in metalworking. Numerical control of a machine tool means that pre-coded instructions, rather than the machinist, govern the basic operation of the machine. Nhat is', so different about this' type of automation ist that i t attempts to eliminate human input in ther performance of highly skilIed and widely varying work in low volumes. Automation in the past has made the skills of workers superfluous by literally building thoae skills into the machinei but this was only feasable for parts produced in large quantities. Now the goal is Ilthe transfer of man's intelligence to machines 11. 1) I Because of the versatility and power of numerical control as a technology, the ways in which it reorganizes - 2 - work have implications that go far beyond the machine shop. In some ways, it is a paradigm for the impact that computer technology will have on the basic role of labor in society. This raises larger questions about the very nature of technology. We think of technology as the application o'f scientific discoveries to 'solve problems. A key problem that technology attempts to solve, in the workplace is to increase productivity, thatis, producing more goods with the same or less labor. Por the ·purpose of increasing producti vi ty, , one ofthe paramete;-s that govern the selection of one technological method over another concerns maximizing managerial control over the productive process itself. Since theconcern is extending managerialauth6rity, the di~ections of technological change logically leads to the current application of numerical control technology.If the problem were to be defined as extending thecontrol of workers then the technology could be developed in a different way. As it. is, if the creative energies of workers are throttled, it is presented as "inevitable and progressivelI. . This discussion analyzes how a new technology affects workers at the workplace. The important history of numerical control and its full economic impact on the overall society are thus largely beyond its scope. Alternatives that might more fully tap the creative energies of people and deepen their control over their lives are likewise not discussed. This does not mean that these alternatives do not exist; but a fuller analysis of both technology and the social system are required to clarify them. I would like to raise four aspects of the impact that numerical control has on the workplace. First, NC is part of a management system that centralizes authority over the entire work process. Second, as a result of this, NC weakens - 3 - the power of workers individually and collectively. Third, management is.aware of the potential of this new technology, and i8 implementing it in a sophisticated way for maximum long-terrn.gain. Finally, wnile this process cannot be controlled on a trade union level, important actions can be taken that could result in immediate gains for workers, gains that could lead to questioning of the ways technology is used in society. 1. NC as a Means to Centralize Management-Control over the work Process NC performs a vital economic function by automating the production of small batches of parts. In the United States, parts produced im small'batches account for 36% of manufacturing's share of GNP. 75% of these parts are made in lot.sizesof less than 50. 2) While not all of this production'will beaffected by NC, conventional automation has largely bypassed this labor-intensive area because small lot sizes Ware not economical to autornate. The actual use of NC today is considerably below potential. Though the reasons for this are largely beyond the scope of this paper, even a few raw statistics indicate the impact of NC: while less than 2% of all machine tools in use today are NC, their increas~d productivity and 10\" cost make them far more significant than the total number of tools shipped, but represented 28.7% of the total value of shipments. 3) I consider it critical to view NC as part of a system that centralizes management authority over the entire work process. Numerical control itself is a computerized method of controlling an individual machine. -YIJhen NC is linked to other computer systems , i t becomes possible- to go from the designer's pen in the engineering office to the actual production of apart wi thout any in·t:ervening human skills. - 4 The system operates effectively even if the design changes dramatically or if the nurnber of parts to be produced is altered substantially. Numerical control au~omates work that was formerly performed by human intelligence in that unique combination of hand and brain that we call skilI. On a single machine it has a profound effect on what the machinist does. When NC i8 part of a computerized workplace, countless other skills, such as those öf the draftsman, are no longer required either. The elimination of the need for the skills of ~'1orkers, however, is only part of the reorganization of management that results in a new domination of the industrial environment. In order to fully understand how NC affects workers, we must analyze how it reorganizes the managerial process. I view the linking of the designers in the engineering office through a computer system to the actual cutting of me tal on the shop floor as a ll vertical integration" of the workplace. Numerical control also facilitates a "horizontal integration" of the shop floor itself through the computerized control of the individual machine tools and the centralized monitoring of key shop floor functions such as the scheduling of operations. Together, they represent a computerintegrated manufacturing mode. Most current applications of numerical control do not involve this extended an integration of theworkplace. It is irnportant, however, to see the considerable power that this technology makes possible. What follows are not isolated, spectacular exarnples, but typical working examples which illustrate in practice the new control that management can obtain over Ble productive process in even the most difficult of areas. - 5 - The comput.er doesn I t change the nature of management but it does alter how management is able to carry.out its functions. Management is a command relation based on making decisions, giving orders, and insuring that those orders are carried out. It is a closed loop, because instructions travel down to the shop floor and information is carried up to management. Until the .advent of the computer in small batch manu~acturing, this loop had some of the characteristics of the wfring in ~n old house. Overloads kept blowing fuses in the system at the most inopportune times. Some of the overloads were technical: for exarnple, keeping track of work in progress or inventories. Other overloads concerned the critical dependence of the skills of workers who at times tended to be less than cooperative .• Among other functions, numerical control attempts to relieve we machinist of his role as a circui t breaker. Let' s begin by looking at the effect NC has on the skills of machinists on the shop floor. "Machinist" is a generic term that covers a wide variety of workers who use machines to alter the shape of metal. I will be referring specifically to highly-skilled machinists engaged in limited production or prototype work, because this 1s the area that is technically most difficult to automate and that, therefore, most clearly demonstrates the power of NC technology. Part of the discussion may seem a bit on the technical side y but it is important to understand in some detail the complexity of what numerical control attempts to automate. After all, any theoretical analysis of how the computer affects manufacturing must be tested against the mundane world of cutting chips and moving parts. Utilizing a machine tool such as a milling machine, the machinist removes excess material from a piece of metal to make it correspond to the shape and dimensions of a finished part. While the rotating cutter on the machine -6 - !';culpts.the metal, the final resu1ts are very much a product of the worker Isskill. This is a skill of the mind that requires careful planning, ingenuity, and ace urate judgement. It is also a skill of the hand and eye that at times ealls for a quick response to some unforseen variable. Actually producing apart requires eareful planning, both before and during the actual cutting of metal on the machine. The eomplexity of the planning involved in settingup the part is sometimes lost on those not fami1iar with a machine shop. Determining howto produce a complicated shape often involves calculating compound angles and til ting the cutter and the wor~piece in delicate and intricate ways. Once the machinist decides how to produce apart, he determines the order in which the operations are to be done, selects the cutting tools, and sets the speed of the cutter and the feed of the machine. After this, he is ready to begin cutting meta1 by guiding the cutterthrough the path that he determines. For the prototype machinist, previous changes in technology increased the power and accuracy of the machine tool,. but did notbasically change the type of planning required. In the actual cutting process, years of experience are needed to accurately foresee all the problems that might come up and to react to them correctly if and when they do arise. A subtle change in the color of the chip may. mean the entire part l,'/il1 warp;. a slight change in the 'sound of the machine could mean a poor finish; a mild chatter of the machine tool might. result in a scrapped part. In addition to his skill on the machine, the machinist plays a critical, if unheralded, role in the design process. His skills fo~m a vi~al link in translating the designer's concept into the actual part. For example, in the construction of a prototype in a tool room, it 1s a familiar sight to see - 7 - an engineer walk in with a stack of blueprints and ask the machinist if this job can be done. The machinist carefully studies the prints, looks at the engineer, and says, "WeIl, i t can be done like this, but your way will never work. '.' The machinist might then grab a pencil, mark up the print and, in effect, redesign the job based on his experience of what will work. The price management pays for this information is a reliance on the judgement and cooperation of the machinist. When workers feel harrassed, in fact, they often begin producing parts "according to the print". Ironically, this "refusal to redesign" is seen by management as nothing short of sabotage. A significant problem of contral of the working environment comes down to the fact that management must talk to tlle machinist before it can communicate with the machine tool. Eventhe most precise instJ;'uctions are still mediated through the independent judgement of a craftsman. Numerical control alters this. The decisions that the machinist traditionally made based on skill are now programmed into a tape or fed directly into a minicomputer that controls the operation of the machine tool. Planning how t.he part will be machined, guiding the cutter taol through its path, and determining the actual conditions under which the metal will be cut - such as the speed af the cutter and the feed rate of the machine - all become part of the tape. The central control over the machine tool resides with those who prepare the instructions, not with the machinist. The machinist, in Ne theory, merely loads and unloads the machine and stops it if something goes wrong. In practice, an important distinction exists between the planning skills of the machinist, which include setting up the job and guiding the cutting tool, versus the feedback - 8 - skills which include reacting to the actual cutting conditions. This distinction is critical because we are analyzing the impact of NC based on how it actually works rather than how itshould work. The planning skills are successfully auto.... mated by NC, which of course eliminates the machinist as a link in the design as well. The feedback skills are less successfully automated sinee the cutting of metal consists of so many unpredictable 'variables. What this means is that in prototype work the operator of the machine retain a monitoring function. As larger production quantities are encountered, the role of the worker becomes less critical even as a monitor, since the pattern of cutting conditions may be optimized. The successful automation of the planning skills results in a qualitative change even if the feedback skills are never fully automated. The basic planning deci~ions are made by the part programmer, who codes the design of apart into a language that will control the operation of the machine tool. The prograrnmer maymanually punch a tape for the operation cf a simple program, or he may use a computer-assisted language such as APT (Automatie Programmed Tool) to guide the cutter on a complex.five-axis maehine tool. The programmer may reeeive the information that he codes into a machine-readable language from an engineering drawing of the part. However, in other applications, he may receive the description of the part from a computer - which has important implieations diseussed later. Removing control of the maehine tool fromthe machinist aehieves through technology what Frederick W. Taylor attempted to aehieve through the reorganization of work - a drastically reduced reliance on the skills of workers. Iron Age magazine, a leading managemen t..... week ly, drew the __paralle 1 be tween NC and Taylor: - 9 - IINumerical control is more than a means of controlling a machine. It is asystem, a method of manufacturing. It embodies much of what the father of scientific management, Frederick Winslow'Taylor, sought back in 1880 when he began his investigations into the art of cutting metal. tOur original objective,' Mr. Taylor wrote, 'was that of taking the control of the machine shop out of the hands of the many workmen, and plc;l.cing it completely in the hands of management ••• '. ur. 4) a method of manufacturing, Ne does more than remove decision-making from the machinists and give it to programmers. It is the first rung of a vertical integration of the workplace that seeks to locate all creat:tva deaisions as alose to the design management part of the manufacturing hierarchy as possibla. Alo.ng the way, the skills of many workers are knocked off the ladder. What management strives to eliminate is any uncontrolled input into the system. It· obtains production.3control at the expense of the creativity and independence of the vast majority of workers who are excluded' from the' decision-making process and at the level of jobcontrol they formerly exeraised. Aß In a technology that abounds with acronyms, this vertical integration of the workplace is often called Computer Aided Design (CAD). Not only does the technology move the locus of decision-making off the shop floor and into higher levels of management; it also results in an integration of management fu.nctions such as design and production. Formerly, the staff of engineers who designed the product and the staff of engineers who determinded how the product was to be manufactured operated almost as indep~ndent fiefdoms. Now, many decisions on how to produce a ..oart that the skilied worker formerly made can be made at the level of design by an integrated management team. - 10 - Utilizing CAD methods, the design of the part and the programrning of the machine tool that will produce the part become centralized. Sitting in front of what looks like a television set, the designer draws the part onthe screen with a light pencil. This video screen is linked to a computer with which the designer interacts. He can blow up sections of the part for a better view, shrink it for ,perspective, rotate it, smooth out lines, and manipulate the date, in coun tless other ways. Once the design is comple te, the designer programs the part for manufacture on an NC machine. 'Simulatingthe machinecutter with ''1:he light pencil, he traces the outline of the part on the video screen and the computer automatically programs, :the path that the cutter will fol&ow on the machine. The designer becomes aware, in a qualitatively different way, of how the part is to be produced. Numerical control, aso part of a larger' computer system, makes possible much more 'than automating the skills of the machinist. Some parts that could not be manufactured at all or only with great difficulty and exacting handwork, can be machined by numerical control methods. All that is required is a mathematical definit..imn of the shape which is then translated into machine motion by the computer. An example of this, is the complex contours of a turbine blade for a jet machine. While the world of the manager on the level of design expands and becomes integrated, other skills in the production proce.ss shrink or are eliminated entirely. Programming either becomes integrated with the design itsslf as ws have seen, or becomes literally built into the control of the' machine tool. The programmers who replace machinists as controllers of the machine themselves become controlled. Dr. Edwin N. Nilson, manager of Technical and Management Data Systems at Pratt and Whi tney aircraft, summarizes - 11 - the trend: 11 Right now there are press ures to get designers to describe their geometry in APT, for example, thus making it convenient for the Ne programmer. As we have seenabove, however, APT and associated prograrnming languages may weIl. disappear. 11 5) When the prograrnming is built into the machine tool controller or the computer itself, the b.asic configuration of a frequently-produced part.is i~cluded in the -software in what is called a canned cycle. The designer, the programmer, or even the machinist inserts a code number into the computer to call up the part, inserts the proper di111Eulsions on. command cf the computer, and then the prograrnmed tape that will run the machine tool is produced automatically. The draftsmen and designers that detailed the conceptions of the senior engineers on bl'ueprintsalso disappear. In same aases, the work that the' engineerdoes on the video screen makes a drawing unnecessary. Where drawings ~ necessary, they can be produced by n ume,rically controlled drafting machines. The integration of some of the machinist',s skills on the level of design may seem to be of little direct importance to the machinist • In one sense, i t does not make any difference to the machinist where his skills are exercised if he no longer exercises thern. In a deeper sense, if his skills are part of the design process, reappropr±ating those skills requires input and control at the level af design which is a more fundamental challenge than seeking the return of prograrnming tasks. The complete vertical integration of manufacturing, fram the designer to the finished part, exists in few places today and will never totally automate eve.ry factory. What - 12 - is significant i5 that elements of this complßte integration are already having a wide impact, and the overall treri.d is unmistakable. The next ~tage of development consists of linking working systems into a more unified whole. As a working technology, computer aided design is transforming operations as diverse as a small machine shop o,r an in-' dustrial behemoth like General Motors. One,srnall machine builder that I visited in Detroit is using a computer aided design system in a plant that employs fewer than 100 people. The virtually automatie prograrnming can produce 106 machines tapes inabout 6 1/2 hours. Before NC" a template thatrequires over an hour to make was used instead of each tape. 6) A visit to the sprawling General Motirs Technical Cen ter and the adj acen t Fisher Body Engineering Cen te~ near Detroit reveal the extent·to which this t'echnology may' come to trans form the operations' 'cf the largest industrial corporation in the world. Engineers proudly boast about the largest computer center in the Uni ted States si tting in the basement. Tied to it are video similar to the ones that I described. This system was used on over 75% of the releases from the design department on GM 1977 full-size cars. Over 90% of GM die models were produced from a combination of this design process and NC technology. 7) A die itself is a complex steel form, often weighing' many tons, that is used to stamp out the sheet metal parts of a car. The numerical control machines used to produce these dies can now be linked directly into the design process. It is true that relatively feTt! skilied machinists - "die:makers" - were necessary in the past to produce all the dies for General Motors; but what i8 at issue is control and not only the number of workers involved. - 13 - Let's briefly'look at how dies are made and its implications for managerial control. A m~rnmoth machine called a digi tizer runs a probe ove·r the contours of a clay model of a car, recording all the complex surface characteristics of the body in the computer. Using this information as a data base, engineers perform design, engineering, and manufacturing functions. Sitting in front of video screens with their light pencils, some engineers finalize the design of the body, some test its struct~ral characteristics, and others design the dies that will produc~ the parts. Once the design of a die is complete, tapes can be generated that will control Ne machines in any GM plant that has wem. Paradoxically, this centralized control over design and production can be exercised through decentralized operations. The centralized control in this oase results from the computer data base and not the geographical Ioeation of the people using the:computer. From the standpointof control, the computer and telephone wires put all GM managers and engineersusing the system in the same location. The computer doesn't know if the engineer using it is sitting ina building directly overhead at the Technical Center near Detroit or is workingat the Opel plant near Frankfurt. If some aspects of the design, for example, are more efficiently done at the.plant level, plant engineers can access the computer to finalize designs and generate NC tapes closer to the actual work. In one of the largest die manufacturing plants in the world, located 60miles from Detroit, two engineers utilizing this system are able to program seven enormous machining center~ on two shifts in between other related design ac~ tivity. At one time, more than seven programrners painstakingly prepared son~ of these tapes manually before programrning itself became integrated with design through the central data base. The design work on the dies can begin - 14 - oefore the design of the part has been completed through the use of the same data base by the die.engineer and the part engineer. The productivity gains are staggering. The time it , takesto go from design to a prototype model was reduced from 51 weeks in 1971 to 32 weeks in 1978. The gain is even more impressive, considering tha t some computer.i.zed me thods were also used in 1971 and that the model itself was more c.omplex .in 1978. In some applications, 40 hours of manual drafting time is reduced to 20 minutes as NC drafting machines utilize t...~e digi tized data from the clay models. 8) This uni ty of design, engineering, and manufacturing that the computer makes possi'ble gives management a new control over the working environment. Althoughthis integration is far from fully achieved in an organization the . size of GM today, GM president E.M. Estes outlined the corporation' splans for ~e future: "An internal study re.cently· found that the use of computers in manufacturing now lags benind both design and data processing uses in GM. But the study concluded that the use of computers in manufacturing would increase by as much as 400% in the fi ve yeär period e.nding in 1982, compared to just 40% increase for design functions and 9% growth in data processing. I ,think it is fairly safe to say that within 10 years computers will control about 90% of all the new machines in GM's manufacturing and assembly plants. This doesn't mean computers will be replacing men nearly as much as it means they will be helping our employees do a better job. 11 9) . I'Helping our employees do a better job" means minimizing their control over the workplace. The vertical integration of manufacturing from design to production is coupled with a horizontal integration of the shop floo~ itself. The control of the machining process through NC machines is combined with a computerized monitoring of other shop floor .functions: where work i8, what - 15 workers are doing, etc. In a factory where many different kinds of parts are produced, even a simple problem such as knowing where a.given part is can assume mind-boggling proportions. In an aircraft plant, 150,000 parts might be circulating. Tighter control of where' parts are also provides management more complete control of what workers are doing and how long it is taking them to do it. In short, different forms of management control collapse into generalized .control. For management, computer-integrated manufacturing creates a more unified and controllable workplace. One of the ironies cf Taylorism i~ that, in totally fragmenting the work process, it creates a complex, fragmented hierarchy of managers as weIl. Layer upon layer of authority and overlapping responsibilities create impressive organizational charts, out a cumbersome chain of command. The computer reintegrates ski II requirements for management even-as it "dis-integrates ll them for machinists. Joseph Harrington, the leading management consultant in the area of NC,becomes almost lyrical in describing the impact NC has on the manage:rial process: "... everyone above the foreman level will find hirnself working in an area of largely non-departmentalized decision making. The old barriers will dissolve under the irresistible demands of tha new technologias, and communications will flow freely within the boundries of the company. 11 10) Harrington compares the new grasp of managers ovar production with the control the craftsman had over a production operation in colonial days. 1l0bviOuslY, the new system will not be dominated by a single persori such as the craftsman of colonial days, but the same responsibilities will be fulfilled by an integrated group of persons." 11) - 16 - Whether this integrated eontrol ,is exereised in a hierarehieal way that dominates workers or in a demoeratie way that expands their eontrol is a soeial eholee, not a teehnieal' one. This new unity of manufa.eturing. me ans that, to seriously talk about workers eontrol, one must talk about eontrol of the enterprise itself. 2. The Weakening of Worker's Control , over the Work Proeess The reorganization of work that numerical eonti:ol brings about fundamentally weakens the power of workers, both individually and colleetively. On the öob, the worker is simultaneously an individual, part ·of a work group, and possibly a member of a nnion. As an individual, the faet that his skill is no longer needed may cause differing reaetions. For th.e work gr~up and the union, the "end of indispensibili ty" ofskills undermines an important historieal basis for job eontrol and saps the power of the union on the shop floor. Management loses these fetters, and henee gains important new flexibility and control through computer integrated manufaeturing. The effect of deskilling on the individual worker ean be devastating. In E~gland, I spoke to one skilIed maehinist in an aerospace plant who had been a highly-skilled eraftsman for 17 years and who enjoyed his work. For the last 6 mon ths he had been running a NC lathe and feIt a deep frustration. He eloquently stated. his plight: "I I ve worked, at this trade for 17 years. The knowledge is still in my head, the skill is still in my hands, but there is no use for either one now. I go horne and I feel frustrated, like I haven't done ' I wan t t 0 wor k , ma k e th'~ngs aroun d the house." 12) any th ~ng. Creative energies are saeri'fied to hierarehieal eontrol. - 17 - Another worker,in Detroit, had a much different view on the personal effects of NC on hirn. A diemaker in a large auto plant for 20 years, he viewed NC as an 11 easy job 11 and was only too happy not to have any input into the system. Hhen asked how he personally feIt about NC, he responded, 11 Do I feel bad at the end of the day? The answer is no. I don't come to work to have a good time~ I just coma. here and get my pay. In any case, we have ways of alleviating boredom. 11 13) For some workers, conditions on the job are so bad to begin with that the deskilling brought about by numerical contx"ol is not. viewed with any partiC1.üar alarm. Workers who are not particularly concerhed about their own skills feel that they need not be concerned about th~ additional powers that management achieves through the usa of computerized machining methods. They are wrong, of course: control is control, and all workers sacrifice it at their peril. Numerical control makes possible an increased control of workers through technology in areas where even the most sophisticated socialcontrols have failed in the paste SkilIed tool- and die-makers have traditionally been among the most militant and best organized workers within the auto industry. These highly-skilled workers build the tools that position parts in the production and the dies that shape sheet metal. Part of their strength rests on the fact that the complexi ty and variety of their work has resisted effective automation, giving them a rneasure of job control at a particularly critical point of production. Their leverage is increased because they can interfere not only with their own work but with the operation of an entire auto plant. Using on1y the methods of Taylorism to subdivide the work and reorganize the machine shop has thus proved particularly ineffective in dominating these workers. - 18 - The subdivision of work in the plant was coupled with the contracting out of work tosmall "back alley" shops where the owner-manager himself keeps a' 'strict and fast-paced discipline, eften by werking next to his men. This extra measure of supervision not only produced lower production costs but provided a benchmark to measure the performance of the werkers in the large auto plants. Work was contracted out for other reasens :(lower costs via lower wages, for one) than the increased control that these shops provided, but . this was unquestionably an important aspect of a company' s choosing not to expand its own facilities. While the attempt to control production by contracting out work achieves lower costs, it has the dis advantage of sacrificing direct in-house control overan important phase of the production cycle. Ne helps solve this Ly deskilling the work itself so it becomes manageable throughthe use ofthe technology. The increased control comes not only ovar the machinists but over the way the en tire industry i8 organized. Work may sti 11. be contracted out when it is cheaper to do SOi but the small shops lose that part of their cast advantage that Ttlas based on closer pOlicing 0 f the work-force. - Aside from the tool and die shops, small, non-union machine shops in Detroit that produce other compon~nts for the auto industry provide a laboratory for management in how to ·,iJmplement NC. At one mach.ilne shop, where both conventional machines and NC machines are kept in the same building, the plant manager complained about fraternizing among operators. The conventional machines are operated by highly skilIed machinists who have spent years learning the trade. On aboring mill, a large particularly complex mach:Lne tool, it i8 not uncommon to see a machinist sit down with a cup of coffee and carefully plan the exacting moves he will have to rnake on a process sheet. The largely unskilled operators that this company chooses to hire and train to operate its NC machines wander by and observe the ·- 19 - machinist 's manner on the job, the foreman I s dependence on the worker's ability, and the worker's control over his rate of production. If,the same job is later run on an Ne machine, the operator sometimes tries to emulate the attitude of the machinist on the conventional machine, cup of coffee and all, and feels resentful at the additional parts that he produces in this case for a lower salary. 14) A frightening view for laboti of what the elimination of job control based on skill can mean to the power 0 funions 1s found in the printing industry. Computerized processes did more than ellminate jobs; they destroyed the leverage of the workers that remained. l?ublishers today ai;'€: often willing:~ to guarantee the jobs of \<lorkers for life in return for the phenomenal increases in producti vi ty and control that result. In one particular dramatic example, the liberal Washington Post installed advanced printing equipment that it was determined to use without customary union restriction. The Post then taught fifty-five non-union, white-collar employees how to operate the presses, in what amounted to a "school for scabs". During a strike that management precipitated, 25 managers took over the jobs of 125 pressmen. The union was smashed. 15) The printers are only the pioneers in the loss of power at the workplace through technology. The former labor columnist for the New York Times, A.H. Raskin, maintains that large sections of the labor mevement face a similar fate: "Despite the considerable economic and pali tical clout the unions maintain the balance of power is shifting and management knows it. In no industry is the future more visible than in the newspaper business, where theonce mighty printers' union is being brought to its knees by computer technology." 16) - 20 - The process may be less dramatic in metalworking, hut the structural changes are just as deep. Numerical control brings about increased flexibility for managemeVlt on a world scale. An auto company, for example, is no longer as dependent on a large pool of highly-skilled machinists to produce the tooling. for its automobiles; design can oe largely cornpleted in a centralized headquarters, and the data shipped over telephone wire13 to the plant where the labor market is most convenient. If there is a strike in Germany, the dies for the new Fiesta ean becpmpleted in Spain. With a product as complex as the tooling of an automobile, a company is not suddenly entirely independent of the skills of its workforce. The loeation of millions of dollars of 'capital equipment is in itself a powerful restraint to the unlimited mobility of produetion. Nevertheless, an important and useable measure of flexibJ~lity is obtained due to the alternatives the technology makes possible. We can see the possibilities for the future in an event tilat oecured with Ne at a now surpassed level of development. In 1972-73 an automaker began work on the dies for a' small luxury car which was meant to compete v'li th t·1ercedes on the international market. Most of the work for these dies was contraeted out to tooling shops in the Detroit area rather than being done in the company I s eonsiderable internal faeilities. A strike at these shops in the Detroit area in 1973 threatened to prolong the introduction of the neVl model. Because mueh of the design data was in computer storage, the corporation was able to transfer the data to an internal faeility and produee the dies on numerieal eontrol maehinery without delaying the produetion of any of its other "'lOrk. No physicalevidence had to leave the struck shops in Detroit in order for this major transformation to take place. . - 21 - Reeently the UAW has negotiated agreements with the auto eompanies, making tue ~ubeontraeting of work to outside plants a strikeable issue, if UAW meniliers are on layoff. It does not require mueh imagination to see how an agreement like this, which was won with difficulty at the bargaining table, could effectively be underminedin practice. The impact of numerical control technology is, however, limited by a number of technical and social problems. First, NC is relatively new and still has "bugs". Although the reliability of the system has improved, the complexity of the actual metal cutting process remains an important problem. Second, the struggle of wor:kers tc; maintain a degree of control over their working lives is still a formidable obstable that management faces in utilizing this technology. Tue development of Ne proceeds in response to these ~echnical and social realities. Automation i5 nOt a fixed event, but adynamie process. The, problems that Ne faces today will determine the direction it will go in tomorrow, in the same way that the development of current technology was a response to an earlier generation of problems. Management selects from the available technical,solutiqns those that extend its authority at the workplace to the exclusion of tue independent input of workers. 3. Management's Strategies to Implement NC-Technology Numerical control technology did not entirely be ar out the early extravagant promises of machine tool builders that anyone capable of pushing a button could operate an NC machine. A critical problem in the early units centered on the electronic reliability of the control units and the difficulty in repairing them when they did break down. But - 22 - important strides in the field of microelectronics have resl,llted in vastly improved control systems, such as computer numerical control (a~C), which are inherently more reliable 'and easier to repair when they do malfunction. A more difficult problem is the complexity of the metal cutting process itself. Planning, how to machine even the most complex of shape~ can be easily put on tape, but the problem arises when the cutter begins removing metal. The problem, in some ways, is akin ::.;'to dri ving a car down a fre.eway by remote contro1. tVith a good map, it is relatively easy to plan an adequate route (although if one has driven the route manually, one has an advantage in selecting the best route) .,The problem arises if there' is no way to monitor the road conditions whileone drives. If it's raining, one has to slow down considerably; if there is an obstruction in the road that is not on the map, the best computer-selected route if not full protection against a serious accident. In normal butting operations conditions may varY widely, For exarnple, when a large casting is put on a machine tool, an unexpected hard spot can shatter a cutter on the best of programs. In other situations, a harder than expected grade of metal may dull the cuttin'g tool and cause dirnen ... ' _,' sional inaccuracy in the part. Thelist of variables is almost infinite. In order to solve some of these problems, the operatcbr is given a swi tch to override the speed, and feed that have been selected on tue program, and, thereby adjustthe machine to actual operating conditions. override switch, the operator has the ability not only to adjust the cutting process out to react against management as weIl. At one plant I visited, the shop manager complained about a machinist that consistently ran his machine at 75% of the programmed speed. ~lJ'hen ~~e program itself v/as reduced to 75% of its former speed, the o?erator simply ran it at 75% of the new speed. At another shop, one operator ran the machine at 60% of the programmed value, removing the Wi~~ th~ - 23 - dial and recalibrating it at 100% for the benefit of ariy manager who happened to wander by. The shortfall of parts was apparent at the end of the day, but the managers had a problem p1npointing the cause. On certain jobs, it remains preferable to have a r..;orker who is familiar with the machining operation to monitor the machine, although technical advances make this less important in somewhat higher volumes. This input does not contradict the qualitative transformation of production and elimination of skill that takes place .-. It may be instructiva to look at a sim~lar problem in the history of mass production. In anearlier day, the instalation of fixed automation in the manufaeture of cylinder blocks was plagued with difficulty, as the operation was taken out of the bands of skilled production machinists and placed on a large, complex sa.t of maehinery linked by automatie transfer equipment;. Today, 50 years after the development of this teehnology, new transf~r lines are still plagued with problems. The boring, reaming, and honing of parts of the engina block to extremely high finishes and tolerances, is a complex process. Despite these continuing technical difficulties, it is a remarkable, but real feat, that millions of engine blocks can be produced today by a few people who do little more than monitor an automatie operation. Management is aware of the power of numerical control to reorganize the workplace, and 1s 1mplementing it in a Sophisticated way for a maximum long-term gain. In public discussions and popular articles, tnere is pious concern over the loss of skills of some workers and optimism for the new skills that will be created. All of this is guided oy a clear implication that the new technology is socially neutral and inevitable. Eugene Herchant, director of Research planning - 24 - for Cincinnatti Milacron, quotes an international survey that saysfuture systems must be designed in "such a way as·to maximize the use of human mental capabilities and human qualities of workers." 17) w11.en the managers talk about the technical posSibilities of NC in literature meant for other managers,. however, t11.e message is somewhat different. Joseph Harrington, an NC consultant., states that a sentence often heard about NC is that "management has at last regained control of the' factory·." 1 8) In a sober book c'alled Management Standardsfor Numerical Control, written t6 introduce managers to the benefits of Ne technology, the message is equally clear: "Ta a great.extent, computer and numerical controls were designed to minimize t11.e number of processing decisions made on the' shop floor.' Such decisions, whet11.erthey are good or bad, are nearly always . suboptimal. Since the machine operator is largely outside of ·the machine control loop, manufacturing by aut.omatic controls makes tighter managementcontrol both possible and imperative." 19) What is particularly enlig11.tening about the control poss~bilities of the new technology is not only what managers say but w11.at hapFens when t11.e technology develops in a direction where a clear c11.oice develops between increased control.over the warkplace and increased satisfaction and job con trol for the \vorker. In certain aases, manage.rs are \villing to sacrifice increased productivi ty in the short-run for tighter control in t11.e lang-run. One important part of that lang-run arrived in t11.e 1970's with the development of Computer·Numerical Contral, , mentioned earlier. Advances in microprocessor technology have made it possible to place a mini-computer at the machine tool to guide the machine operations. Instead of a - 25 - hard-wired machine controller reading a punched tape, the tape is fed into the mini-computer and the stored information operates·tne machine tool. This seemingly small technical change has major implications. For example, there is now the capability to edit programs at the machine tool. On some jobs" it is of great advantage to be able to correct errors or make improvements in the program at the machine rather than in the engineering office., The programmer is able to immediately modify the program through buttons on the machine control panel in a system called manual data input. '.T"here i8 na technical reason VJhy thisediting facility cannot be used by the operator as weIl as the programmer. In fact, it is possible to use manual data input to program as weIl as edit. It is too faeile an argument, however, to say t,hat the machinist having aceess to progr.amming would regain his former posit'ion in produetion. As I have tried to illustrate, the teehnology is a far more integrated than that. Aceess to programming does return an important element of job eontrol to the shop floor. The deeision as to how mueh input the operator should have is based on social as weIl as technieal faetors. In this case, the teehnolo~l does not qompletely rule out job controli it is management's use of the teehnology that eliminates. Don Smith, chairman of the Industrial Development Division of the University of Michigan, cautioned that ~t vlOuld be Il very undesirable to have the operator do any programming. This would take away the eontrol of the pro. 20) duetion environment. 11 The owner of a contraet manufacturing, shop eehoed these sentiments: III don' t want any operator fooling around with ~rogramming. That should be done only in the engineering department." 21) One of the themes underlying this paper is that technology such as nurnerical control could be developed in a - 26 - vlay that would enhance the control of workers. The development of computer n umerical con trol to enhance management flexibility has also resulted in an opening for workers to regain some controL The, cnd.ef prograrnmer of one small shop I visited cornmented rather forcefully on this possibility: litt sucks. Any t§ipe I put out there is not safe. Sometimes they (the operato.rs) change things not knowing what they' re doing." 22) At one large plant I visited in England, a running battle was going on between programmers and machinists about alte ring tapes on CNC machines. The social ,Situation was complex, because both ware in (different divisions of) the same union. What was interesting is that the machinists were paid on "group bonus 11 , and feIt that they could produce more by programming their own tapes. Management, realizing that the ahility to produce more also meant. the ability to produc~ less, was sidil'lg wi,th the prograrnmers in keeping the machinists out of the editing process. The machinists, however, had learned how to do substantial alterations on the tapes and were doing them whenever possible toensure the higher wages associated with increased production. One worker on a less sophisticat~d NC machine had actually obtained a tape punch and secretely made his own tapes at the machine tool to optimize his production. His immediate supervisor knew about the practice, but was reluctant to intervene because of the increased production. While in most shops that I have visited CNC is used to keep the operator in the same position that 11e would be in with conventional Ne equipment, in a few CNC-equiped shops the operator is given a mo're important role in editing or in programming. Often, this has a lot to do witn the type of work being done.On one-of-a-kind production of complex parts, it is advantageous to have the direct intervention of an experienced person. So much of the planning is removed - 27 - by the nature of NC teehnology that to give the operator some input is viewed as productive and socially beneficial. After all, lt gets pretty boring to be considered totally out of tne planning process. The important factor is not whether, in every instanee with CNC, management chooses to totally eliminate the role of the machinist, but that CNC gives managers the choice as to how mueh control to give up. It is productive to give some, but unsafe,to give up too much. This power of cholce is syI!1l:Jolized by a key on the control panel that can lock it from the operator's reaeh. As ane engineer told me, "The key belongs to the man who owns the machine." The int.roduetion of NC equipment has led to far less resistance than the p~ofound changes it brings about might prediet. Worker's attitudes have been dulled by the early historyof the technology, the piecemeal w.ay it is riormally introdueed, and a feeling of resignation to what appears to be an inevitable event. Management has been eareful to cause a minimum of disruption, by introducing the technology in boom times, when there is the least direct displacement of workers. When NC made its major debut during the 1960's, it was heralded with extravagant prornisses of the immediate elimination of all skilied workers. In some plants, management treatsd the new machines with the secreey accorded a new weapon system, nidden by newly built fences and run only by seleeted personnei. Workers quiekly saw that not only didn't the new maehines replace skilied workers, but that very often the machines themsel ves did11' t funetion. The fact that the teehnology didn't work up to expeetation instilled a eertain cynicism in workers as to how much of a threat it really posed. Even when it did work ?roperly, very seldom were entire plants shifted over to the new - 28 - teehnology, t-1etalwork~ng is innerently a eautious industry that prefers to rely on established methoo.s. Unlike the printing industry,where entire plants were eonverted to eomputerized teehnology all at onee, in maehining, one or two maehines ware brough t in at a time. As one '(Ilorker mentioned, hmvever, "The equipment is a joke - right up until they get it to work." Some of the vast ehanges the teehnology brings about are also hidden from the workers that operate it. When new maehining centers are introduced in an auto,tool room, the toolmakers are not Ileeessarily aware of the outside shops that are eliminated. Even workers who realize that the technology is going to revise the traditional rols of skilied workers feel that they have no ehoiee but to learn ho\'/ to opea:ate the new maehines and get on the bandwagon for what the future has to offer. It is often a logieal response for the worker to seek to defend himself as an individual, particularly if there is littlechance for eolleetive defense of workers';!. skills in the produetive pro~ess. Onee the teehnology is introdueed, it is difficult to aehieve any alteration in the way it is used. A study done by the !1assaehussets Institute of Teehnology expressed surprise at the little resistanee to ths introduction of NC that was found in a study of 24 small and medium NC users in the eastern and midwestern United Sta.tes. 23) As managements have shown in the printing and oeeanshipping industries, coming to terms with workers eurrently ernployed is a bargain if it ensures teehnologieal dornination ;for the future. - 29 - 4. Al ternati ve Ways in Using the New Technology In conclusi~n, the long term consolidation of managerial'power e1at numerical control makes possible, comoined with the negative effect it has on workers, provide a formidable challenge for labor. Numerical control when linked to other computer systems so fully integrates the work process that the only effective control is over the entire process itself. Joseph Harrington, the Ne management consultant, captured the extent of this integration when he compared it to the control over the wark process that the craftsrnan exercised 200 years ago. But, rather than being exercised by a single person today, this more eomplete control over production is shared by integrated teams of managers. Nothing inherent in the computer, however, mandates that this control be limited to managers: that is a soei'al choice. In order to extend this control to workers, the design, development, and deployment of the technology would have to shift towards the'goal of increasing worker control. In my opinion, this would require a fundamental change in the society that transcends wnat can be achieved at the bargaining table. Nevertheless, what happens at the 1?argaining table can result in real victories for workers and raise broader issues about technology in a relevant way. The necessity for structural change does not mean that achieving anything less, takes the character of rearranging the deck chairs on tne Titanic. The attempt of unions to have input into the usa of technology, however, challenges tlle most sacred of sacred cows: management prerogatives. In general, management i3 far more willing to bargain over wag~s and benefits than the organization of v-lOrk. In the case of technology, management seizes the ideological initiative by posing the question as accepting progress or returning to the dark ages. This of course masks thereal issue, which is not - 30 - opposition to technology per se, but to the development of technology in a way that:further dominates people. As we have seen, managers are willing to sacrifice productivity if it conflicts with their control, because they realize that in the long run an extension of managerial authority will be to their benefit. For workers, it is equally vital to defend whatever control they now have at the workplace. The less of this control can undermine. all' other gains that are won at the bargaining table. Trade unions in Nor'!,'1ay have provided important directions in maintaining job control. In 1971, the Iron and Metal Workers union contracted the Norwegian Computing Center,'a government agency, to investigate the implJ.cation of new computer.related technologies. Based on these investigations, the union struggled for and won formal "data agreements" which defined the roleof the union in decisions that concern te,chnology. In practical terms, this has resulted in the creation of a new union position, "~ata shop steward". This steward monitors the introduction of new technology and attempts to identify those features whicil erode the po"ver of the ""orker and the union. In one ,plant, the union has succeded in winning access to the computer based production and inventory systems for the workers on the shop floor. In the same plant, all NC operators are trained as programmers and do their own e'diting on CNC machines. 24) 1;"1hat is most impressive about the NorNegian trade union experience is not so much the specific demand,s, as the attempt to demystify technology for workers in a way that mobilizes them to influence tne directions Qf technological change. A realizationof the importance to workers of how things are produced cannot be divorced from what - i~ -produced. By unifying production at t:he level of design, numerical - 31 - control technology focuses on the use of ;?roduction. \'lorkers at the Lucas Aerospace subsidiary in England have approached these questions by linking the right to work on socially useful ~products with a method of production that maximizes the control and creative input or workers. 25) - 32 - Notes: 1) Dr. Bernard Chern, director of NSF (National Science Foundation) .program on' Production Research and Technology, quoted in Iron Age, Vol. 221, No. 43-0ct. 23, 1978 p. 113 2) American Machinist, Vol. 121, No. 11, Nov. 1977, p. I-1 3) "Numerically Controlled Hachine Tools and Group Technology: A Study of U.S. Experience", Center for Policy Alternatives at the Massachussetts Institute ofTechnology, CPA-78-2 Jan. 13, 1978, p. 39 4) Iron Age, "The Machine Tools That Are Building America," Vol. 218, No. 9, p. 158 .5) "The CAD!CAM Interface: Problems and Solutions", Dr. Edwin N. Nilson, in Proceedings 15th Numerical Control Society Annual Meeting and Technical Conference, April 9-12, 1978, p. 12 6) Interview, Detroit, Mich, Dec. 1978 7) The Staff Operations of the General Hoters Technical Center (undated G.M. Public Relations Brochure) 8) Interview, 1978 9) Robert W. Decker, "Computer Aided Design and Manufacturing at GH," Datamation, May 1978 10) Joseph Harrington, Jr., Computer Integrated- Manufacturing, 1973, New York,p. 35 11) Ibid. p. 35 12) Interview, Nov. 1978 13) Interview, Oct. 1978 14) Interview, Oct. 1978 15) A. H. Raskin , "The Big Squeeze on Labor Unions 11 Atlantic, Oct. 1978, p. , 16) Ibid. 17) Eugene Merchant, llThe Inexorable Push for p.utomated Production" I Production Engineering, Jan. 1977, p. 49 - 33 - 18) Harrington, Ibid. p. 10 19) Donald N. Smith, Lary Evans, Management Standards for Computer and Numerical Controls, Ann Arbor, 1977, p. 247, (emphasis my own) 20) Interview, 1978 21) Iron.Age, Vol. 221, No. 35, p. 108 22) Interview, Dec. 1978 23) Ibid. p. 31 24) David Noble, "Social 'Choice in Hachine Design: The • of Automatically-Controlled Hachine Tools, and Case aChallenge for Labor", rnimeograph 25) Mike Cooley p "Desigh, Technology and ProductioJ:1 for Social Needs" in The Right to Useful ~1ork, Spokesman Books, Landon 1978
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