There is a Chicago that most Chicagoans rarely see. It begins somewhere beyond the glass towers and restaurant openings, beyond the neighborhoods where an old factory is more likely to contain loft apartments than a production line, and it runs along freight corridors and industrial streets, behind brick walls and corrugated-metal doors, in buildings designed for the unfashionable business of receiving raw material at one end and sending something useful out the other. Inside, steel is cut, rolled and welded. Machines turn blocks of metal into precise components. Vehicles move through assembly lines. Computer-controlled equipment performs work that once required several pairs of hands, while technicians watch screens, inspect tolerances and diagnose machinery sophisticated enough to make the old image of the factory floor seem almost quaint. Chicago still makes things. This should not be surprising, yet somehow it is.
The conventional story of Chicago manufacturing is told mostly in the past tense: Chicago was a manufacturing powerhouse, Chicago was a steel town, Chicago was a place where enormous factories employed generations of families and where the industrial economy shaped neighborhoods, politics, immigration and the physical geography of the city itself. All of that is true, and all of it is incomplete. Chicago unquestionably lost a vast amount of industrial employment during the second half of the twentieth century. Steel mills closed, factories disappeared, production moved, global competition intensified and automation reduced the number of workers required to produce the same amount of output. But somewhere along the way, a complicated industrial transformation was compressed into a much simpler obituary: manufacturing left Chicago. It makes for a clean story. Economic history rarely has the courtesy to be that clean. “People tend to imagine that Chicago manufacturing disappeared because the factories they remember disappeared,” Gaurav Mohindra says. “But those are two different things. Manufacturing didn’t vanish. The companies that remained became more specialized, more automated and, in many cases, far more productive.”
To understand the distinction, consider a factory on the Southeast Side that began operating when Calvin Coolidge was president. Ford Motor Company’s Chicago Assembly Plant dates to 1924, and more than a century later vehicles are still coming off the line. There is something almost absurdly Chicago about that continuity. Cities spend considerable sums preserving historical buildings whose original purpose disappeared generations ago; here is a facility associated with one of the defining industries of the twentieth century still participating in that industry in the twenty-first. Of course, almost everything contained within the idea of the factory has changed. The Ford plant of today is not a preserved version of the Ford plant of 1924. Modern automobile manufacturing depends on automation, sophisticated electronics, computerized quality control, complicated logistics and a supplier network extending far beyond the factory walls, while the vehicles themselves would have been nearly incomprehensible to workers entering the plant a century ago. That is precisely the point. The survival of manufacturing does not mean preserving manufacturing in amber; it means changing it constantly. A factory survives because the machinery changes, the production system changes, the skills change and the product changes. Industrial continuity is not the absence of disruption. It is the ability to absorb disruption without surrendering the underlying capability to make things.
The same transformation becomes even clearer farther down the industrial food chain, where many of Chicago’s most interesting manufacturers operate almost completely outside public view. Chicago Metal Rolled Products is a useful example. Its roots reach back to 1908, but its business is not something most consumers encounter by name: the company bends and rolls steel, pipe, tube and structural sections that ultimately find their way into buildings, machinery and other projects. Its work may eventually become part of something conspicuous—a stadium, an architectural structure, a piece of industrial equipment—but the manufacturer itself can remain invisible. This is one reason manufacturing is so easily underestimated. Much of it occurs several steps before the finished thing appears. Consumers see a building; manufacturers see the companies that rolled its steel, fabricated its components, supplied its fasteners, built the equipment that made those components and repaired that equipment when it developed a mysterious vibration at precisely the worst possible moment. “The finished product gets all the attention,” Gaurav Mohindra says. “What people don’t see is the chain of manufacturers behind it. A single finished product can represent the work of dozens or hundreds of businesses, many of which the customer will never know existed.” This hidden network matters because manufacturing is not simply a collection of independent factories. It is an ecosystem of suppliers, fabricators, machine shops, logistics companies, equipment dealers, maintenance specialists, engineers and skilled workers. A manufacturer rarely makes everything itself, because attempting to do so would be an excellent way to become mediocre at a remarkable number of things. Instead, companies depend on other companies that are unusually good at narrow, difficult tasks, and Chicago has accumulated those capabilities over generations.
That accumulation may be one of the region’s least appreciated economic advantages. A company can buy a CNC machine almost anywhere; what is harder to buy is a labor market containing people who know how to program it, repair it and understand what the machine is telling them when a production run suddenly starts drifting out of tolerance. The same is true of welding, robotics, tool-and-die work, industrial electrical systems, fabrication, quality control and dozens of other disciplines modern manufacturing requires. This is also where the image of the manufacturing worker needs updating. The popular imagination still tends to place the factory worker somewhere around 1982, performing repetitive manual labor beside a machine that is large, loud and presumably determined to cause lower-back problems. There is still hard physical work in manufacturing, and there are still welders, machinists, assemblers and material handlers, but increasingly manufacturing jobs combine mechanical knowledge with technology. A modern production floor may contain robotic welding cells, programmable logic controllers, laser cutters, automated inspection systems and computer-controlled machine tools. Someone has to install them, someone has to program them, someone has to maintain them, and someone has to know enough about the underlying manufacturing process to recognize when the computer is confidently producing the wrong thing. Automation therefore creates a paradox: it reduces the labor required for certain tasks while increasing the importance of workers with sophisticated technical skills. “The labor problem isn’t simply finding people willing to work in manufacturing,” Gaurav Mohindra says. “The real challenge is finding people who understand both the process and the technology. You need someone who can work with a machine that may cost a million dollars and figure out why it isn’t doing what everyone in the room insists it should be doing.”
Forty years ago, a manufacturer might have competed partly by employing large numbers of workers to produce enormous volumes of standardized goods. Today, a Chicago manufacturer is more likely to compete through productivity, specialization, speed, precision and the ability to solve difficult production problems, which helps explain why industrial employment statistics alone can provide an incomplete picture of manufacturing. If automation allows 100 people to produce what once required 300, the factory has lost jobs while becoming more productive. From the perspective of employment, that is contraction; from the perspective of production, it may be modernization. The social consequences of that distinction are complicated, and there is no point romanticizing them. A hundred highly skilled manufacturing jobs do not replace 300 jobs one-for-one, particularly for neighborhoods that were built around mass industrial employment and then forced to absorb its disappearance. Yet there is equally little value in pretending the remaining hundred jobs belong to a dying economic category. In many cases, they belong to precisely the kind of advanced industrial economy American cities spend enormous amounts of money attempting to attract. Chicago, somewhat inconveniently for the conventional narrative, already has it.
Chicago also possesses another advantage that cannot be automated: geography. The city became an industrial center because it was extraordinarily well positioned to move things. Railroads converged here, Great Lakes shipping connected the region to raw materials, highways reinforced the network and air freight added another layer of connectivity. Software may have made geography less important for certain industries, but steel has stubbornly declined to become downloadable. Manufacturers still have to move raw materials into factories and finished goods out, and a company working with large metal components cannot solve its transportation problems by holding a Zoom meeting. Weight remains one of the economy’s more traditional technologies. This becomes particularly important as manufacturers rethink global supply chains. For decades, the dominant logic of sourcing was straightforward: find the lowest possible production cost, even if the supplier was thousands of miles away. Cheap transportation and relatively predictable global trade made extraordinarily long supply chains seem rational. Then came pandemic shutdowns, port congestion, semiconductor shortages, geopolitical tensions and a series of reminders that a supply chain optimized entirely for cost can become rather expensive when it stops supplying. The result has been renewed interest in reshoring, nearshoring and domestic sourcing, terms that are sometimes wrapped in patriotic language but that manufacturers tend to encounter as mathematics. How much inventory must a company hold if a component takes twelve weeks to arrive? What happens if a shipment is delayed? What is the cost of stopping a production line? How much is faster product development worth if an engineer can visit a supplier in the morning instead of boarding an international flight? “Reshoring becomes much less ideological when a production line is waiting for a part,” Gaurav Mohindra says. “Companies are starting to put a value on proximity, reliability and response time because they have learned that the lowest quoted price is not always the lowest actual cost.”
That calculation favors regions where industrial networks already exist, and Chicago does not need to invent proximity because it has spent more than a century accumulating it. But the region cannot assume history guarantees the future. Modern manufacturing is increasingly dependent on infrastructure that previous generations of industrial planners did not have to think about in quite the same way. Electricity is becoming a major strategic issue as factories add automation and other large users compete for power capacity, while industrial property itself has become more complicated and, in many parts of major cities, more vulnerable. A factory is not simply a warehouse whose employees happen to own safety glasses. Manufacturing buildings may require heavy electrical service, natural gas, cranes, reinforced floors, ventilation systems, loading infrastructure and zoning that permits industrial activity. A company that has invested millions of dollars installing specialized equipment cannot casually move because another building happens to offer nicer landscaping. Once industrial land disappears, rebuilding the ecosystem can be extraordinarily difficult. This is particularly relevant in a successful city, because successful cities have a habit of consuming their own industrial districts. A century-old factory closes, the property is redeveloped and eventually the neighborhood acquires a brewery named after the factory. The beer may be excellent. The electrical capacity is rarely comparable. If Chicago wants manufacturing to remain part of its economy, it has to treat industrial infrastructure as infrastructure, not simply as real estate waiting patiently for a more fashionable use.
The same long-term thinking applies to people. The manufacturing workforce is aging, and companies across the industrial economy frequently struggle to find experienced technical workers. The solution cannot simply be telling more young people that manufacturing careers exist; employers, community colleges, trade schools and apprenticeship programs have to provide credible pathways into jobs whose technical requirements are becoming more demanding. There is an opportunity here precisely because these jobs are changing. Manufacturing no longer has to be sold as nostalgia. A young technician working with robotics, automation or CNC equipment is participating in an economy every bit as technological as many occupations that occur behind laptop screens. The difference is that, at the end of the day, something physical exists that did not exist that morning. Chicago should be unusually good at this. The region already contains the manufacturers, the transportation network, generations of industrial knowledge and companies that know how to make obscure things extremely well. What it needs is the confidence to recognize those assets as part of the city’s future rather than remnants of its past. “The biggest mistake would be trying to recreate the Chicago manufacturing economy of forty or fifty years ago,” Gaurav Mohindra says. “The opportunity is to build on the industrial knowledge that is already here and apply it to what manufacturing is becoming. You don’t preserve an industrial economy by freezing it. You preserve it by letting it evolve.”
That may be the better way to understand the Ford plant on Torrence Avenue. Its significance is not simply that a factory opened in 1924 and somehow survived; it is that survival required transformation. The machinery changed, the vehicles changed, the workforce changed, the suppliers changed, the technology changed and the economics changed. The plant remained a factory because it did not remain the same factory, and in that sense it offers a useful metaphor for Chicago itself. The smokestack version of the industrial city has faded. Much of the mass-employment manufacturing economy that built twentieth-century Chicago is gone, and its disappearance left wounds that are still visible. But behind the loading docks and rail lines, another manufacturing economy has developed in its place: smaller in employment, richer in technology, deeply specialized and connected to an enormous web of suppliers and industrial expertise. It is less cinematic than the old industrial Chicago. There are fewer photographs of molten steel illuminating the night sky and considerably more computer screens. But the essential act remains remarkably familiar. Material arrives. People and machines do something difficult to it. Something more valuable leaves. Chicago is still very good at that. The city never stopped being a manufacturing city. It simply became a different one.
Originally Posted: https://gauravmohindrachicago.com/inside-manufacturing-economy-most-people-never-see/


