Green Design at the Ford Rouge Complex

Part 2 of my trip report on the Ford Rouge Complex in Dearborn, MI ... [Part 1 gives my reactions to the tour inside the Dearborn Assembly Plant]



Vertical Manufacturing—No More
Another aspect of the visit to the Rouge Complex is the understanding it gives of the complexity of the original enterprise. The short movie prepared by the tour company, which is not affiliated with Ford, emphasizes Henry Ford’s experiment in vertical manufacturing. The complex had its own steel mill, plate glass facility, and foundry, owned sources for the rubber that was used, and had its own deep-water port to bring in needed materials. However, the present day complex obtains its parts from many different suppliers, some of which are still brought in at the Rouge port. The steel mill still supplies steel for the stamping plant, but it is not owned by Ford. The tour guide told me that Ford would only buy steel from the on-site company as long as the price was competitive.

Green Building, Brown Product?
A major focus of the factory tour was the “green design” features that had been incorporated in the new assembly building. This included a green roof, featuring layers of material topped by a variety of sedum, designed to lower temperatures in the building and capture some of the rainwater that otherwise would run off. In addition, skylights on the roof were added to increase natural light in the building and lower lighting costs. Rainwater recapture systems, swales and ponds were used for on-site stormwater management (although the guide kept calling it a “storm management” system!).

Wildlife habitat was enhanced with natural plantings, and fruit trees (crabapples and one other that I can’t recall) were planted to provide food for wildlife. Ford even has a beekeeper who manages the bee hive within the planted area, placed to ensure pollination of the trees. Additional green features included the permeable pavement used for employee parking lots, which lessens rainwater runoff, and a system to recapture paint fumes (VOCs) as a source of hydrogen for a fuel cell to produce electricity for the painting facility.

The irony to me, of course, was that the company had built a green building within which it was assembling Ford 150 trucks, not exactly know for their environmentally friendly profile! The other sad part for me was that, despite the hopeful and forward-looking taped message from Bill Ford, the news about tough times at Ford Motor Co. made me fear that all of this effort to be innovative and green would have been for naught.

Stephanie, Webmaster
StillMadeinUSA.com

Ford Motor Co.’s Dearborn Assembly Plant

This summer, rather than head to the beach or something else predictable, our family took a “manufacturing” vacation! I figured I’d better get the kids to some facilities before American manufacturing goes the way of the pterodactyl. We hit several interesting spots, so I decided to write a few installments on “the blog” to share with everyone, and maybe make you want to go check out your local manufacturing facilities.



Dearborn Truck Assembly Plant (Part 1)

As a Ford Taurus owner, I wanted to make my pilgrimage to Dearborn, MI, world headquarters of Ford Motor Co. and site of the renovated Dearborn Assembly Plant (the Rouge Factory) and Henry Ford Museum and Greenfield Village. I was most excited about the opportunity to see inside the truck assembly plant.

I really enjoyed the Ford Rouge Factory Tour, although it wasn’t as complete as I had hoped. Apparently the tour was changed some years ago because of safety concerns, and it no longer covers the welding or painting parts of the work. So, all we were able to see was the final assembly of the F150 trucks. (Another disappointment was that I did not see the Diego Rivera murals—I had thought they were part of the tour, but apparently they are at the Detroit Institute of Arts.)

The new Dearborn Assembly Plant was impressive, with lots of space and natural light. The facility was very clean, and not as noisy as I had expected. The workers did not seem rushed as they did their work on the passing vehicles. In fact, they seemed almost leisurely as they stepped on and off the moving line. When I commented on that to one of the guides, he smiled and said “yes, but remember they only have 43 seconds [to work on each vehicle as it passes by].”

I was also surprised to see how much of the work was still done by hand, by humans. We did see robots positioning the front windshield onto the frames, and there was a noisy and impressive point where the truck cab and bed came together. But, in general, we saw the workers putting on interior components of doors, pressing on rubber seals, and wiring up lights.

When 11:30 a.m. came, the line stopped and workers began to leave their stations for lunch. I noticed that each finished up the vehicle he/she was working on, rather than bolting for the door. I also noticed that a few of the workers stayed at their stations, opening lunch bags they had brought from home. I wondered if this was a way of being frugal, and whether it would make me lonely not to sit down to lunch with my coworkers.


The workers I watched were much more diverse than my stereotype of a UAW member; many were women, and many were minorities. Apparently the power tools, which were pulled down for use, were light enough that they were easily handled by the women. I also noticed that the workers were young, or at most middle-aged. I wondered it the age demographic was a result of the buy-outs and early retirement packages that Ford has been offering, or perhaps just a reality that work of this type (which requires one to stand, walk, and bend all day) takes its toll on a body after years.

Despite the good working environment, I thought I would be quickly bored by the repetitive nature of the job and the inability to “chat” with coworkers because of the noise.

Each worker or team had a work station with orderly stacked bins of parts needed for their part of the assembly. I read that these stations were supposed to have a 2-hour supply of parts. I assume this is part of the “Lean Manufacturing” ethic, but it seemed like it would have been more efficient to have a day’s worth. Watching the long assembly line, and the extremely large number of small parts involved, gave me new appreciation for the complexity of the relationship between assembly and parts suppliers. If any single part were to run out, the entire operation would have to shut down. Talk about pressure!

The end of the assembly process involved filling the vehicles with fluids, and testing them in various ways (e.g., on a dynamometer). What an interesting idea—that such a complicated piece of machinery could be put together by many hands, in many steps, and the final test that all worked is whether or not the truck starts and drives as intended!

Stephanie, Webmaster
StillMadeinUSA.com

American-Made Tools

Sorry to be such a girl, but my idea of tools is hammer, saw and screwdriver (and yes, I know about the slotted vs. Phillips head thing). Thanks again to Practical Machinist, I now know that there are machine tools, air tools, and tool companies that only sell from trucks (“mobile tool sellers” like Snap-On and Cornwell). Not to mention specialty tools (e.g., for manufacturing of autos and aircraft, for working on railroad equipment and tracks) that are mostly for industrial use (not that it stops the hard-core DIYers from wanting them in the home shop!).

After doing a little research (i.e., Googling and pestering companies for information on place of manufacture), I am happy to announce my new Tools page. This is the first entirely new category I have added since launching StillMadeinUSA.com 2 years ago.

I always liked ChannelLocks when I was a kid, so I am happy to report they are still around, still made in USA, and now with a sporty blue rubber grip! (I noticed a trend toward more shock-absorbing handles on tools, which is a good thing.) I didn’t find American-made tool sets geared for us girls (smaller handles, maybe some pink?!), but I’m still looking.

So, look for American Made Tools when you shop, and stay tuned as I continue to add to the page. (Recommendations especially welcome on this one!)

Stephanie, Webmaster
StillMadeinUSA.com

Junk-Free Summer Birthday Parties

I thought I was so crafty when I decided to have all of my children in late summer. I wanted my maternity leave to be in the fall, and after the first child I was locked into the schedule by the seasonality of my maternity clothes. Rank amateur! Each time, the break from work was wonderful, with fresh autumn weather and the chance to stand at the bus stop when the older ones went off to school in September.

But somewhere in the calculation, I forgot that I also was committing to an annual marathon of summer birthday parties! When kids are toddlers, the parties are fun because they’re really parties for the parents and their friends. Then, the children get larger and rowdier, and harder to impress. The little invitees are jaded at the age of four by a procession of clowns, magic shows, moon bounces, piñatas, and exquisite ice cream cakes. We ran the gauntlet of Chuck-E-Cheeses, laser tag, bowling, Discovery Zone, until finally I couldn’t take it anymore.

Last summer I decided to have an old-fashioned party at HOME, with a homemade cake and snacks, and kids running through the sprinkler with water guns. It was really FUN! The way kid birthday parties are supposed to be! The truly amazing thing was that the backyard party WAS a novelty to the kids because almost no one (apparently) does it anymore.

The other victory for me was that I was able to avoid the obligatory goody bag filled with cheap imported junk toys. Instead I ordered Wiffle Ball and Bat sets (from The Connecticut Store) for each child as a party favor. We even played a little Wiffle Ball during the party.

Other great party favor ideas made in USA (and sugar-free!), sent in by Bob in Texas:

• Slinky (about $4)
• Stanzel Flying Models (about $6)
• Kazoobie plastic kazoos (less than $1, lots of colors, also available with lanyard)
• Poof foam balls
• Super bubbles
• Rose Art modeling dough

So, my message is you can give the kids a good time without breaking the bank, while supporting American businesses and sparing the local landfill.

American-Made Solid Wood Furniture: Not Just an East-Coast Thing

Perhaps it is my East-coast bias, but I always associated furniture manufacturing with North Carolina/Southwestern Virginia/Pennsylvania, with a nod to New England for smaller scale production of pieces by cantankerous Yankee craftsmen! Some of the better known furniture makers have fallen on hard times in recent years, and as with other sorts of manufacturing, it is getting harder to find American-made solid wood furniture.

I was happy to discover, however, that there is a vibrant furniture-making tradition in the Pacific Northwest. While searching for American-made Windsor dining chairs, I came upon House2Home Furniture
, an online store that carries solid wood furniture from a number of American manufacturers. The site features a number of Oregon-based furniture makers, including John Boos & Co. (makers of kitchen butcher block furniture), John Greenleaf (a wonderful brand of unfinished solid wood furniture), Pacific Woodcraft, and Westview Products.

House2Home Furniture
also carries my favorite lines of wooden children’s furniture: brightly painted Jellybeans, made in America’s Heartland, and Little Colorado (you guessed it—made in Colorado!).

Other American-made brands at House2Home Furniture
include Catskill Craftsman (kitchen furniture), Old Adirondack (natural cedar furniture from New York State), Richardson Bro.s (Sheboygan, WI), Maco Wood Products, Country Furniture Mfg (home office, hutch and buffet furniture), and Quality Craft (solid pine furniture made in California).



In addition to regional differences in furniture-making styles and techniques, biology plays a role. East-coast furniture usually features hardwoods such as maple, cherry, and oak, whereas West-coast furniture makers often use red alder, birch, and pine. For handcrafted Adirondack chairs, expect natural cedar. (A nice site to learn more about America’s native trees and the qualities of various hardwoods is the American Hardwood Information Center)

I can’t leave the topic of furniture without paying homage to the Windsor chair that started it all. The most beautiful example I found was the individually handcarved chairs of David Spero, on his site Vermont Windsor Chairs. I hope Santa is taking notes!

[Disclosure Note: I have joined the House2Home Affiliate program, so a small percent of purchases made from the links on my site will go to support StillMadeinUSA.com.]

Stephanie, Webmaster
StillMadeinUSA.com

King Louie Spared the Guillotine!

American-made polo shirts are scarce as hens’ teeth, but perhaps will be spared the fate of the Passenger Pigeon. Pine Island Sportswear, makers of polo shirts in lots of great colors, recently decided to take their polo shirt sewing off-shore. Then came the announcement by King Louie International that, after 72 years in business, they would cease all production by June. This was “fowl” news indeed! The King Louie brand of polos and other garments are union made in USA, and have been a favorite with “Buy American” shoppers.

Now for the good news! Michael Lerner, son of the founder of the company that became King Louie International, has reached an “agreement in principle” to buy the sewing plant in Baxter Springs, KS. The company will be renamed King Louie American, and will continue to produce the King Louie label using union labor in USA.



Although the company’s market focus has been the promotional products industry, King Louie products have been available to individual consumers thanks to sites like AllAmericanClothing.com and BuyGolfShirts.com. So celebrate the saving of a great label and 163 American jobs by ordering a King Louie polo shirt this weekend.

Sources: The Joplin Globe (Baxter Springs, KS) , King Louie Saved By Son of Co-Founder

Stephanie
StillMadeinUSA.com

All-American Fundraiser

Every year, our elementary school PTA holds a Silent Auction to raise money for various projects and purchases. Last year’s auction raised about $8000. The auction features items donated by areas businesses (tickets to sporting events, spa weekends, Disneyworld passes etc). In addition, each class is responsible for putting together a themed basket with a value between $75 and $250. I volunteered to organize the class basket for my youngest son’s class because I saw (another!) opportunity to raise awareness about where products are made.

I share the final results in hopes of inspiring others who have fundraisers and have an interest in helping to save American manufacturing. Not to mention, it’s fun to go shopping with other people’s money!

I sent home several flyers with suggested products, prices, and where to buy them. Some American-made products are available at local retailers like Kmart and Lowe’s. Many others needed to be purchased on-line. I suggested that parents go shopping with their children and use the exercise as a chance to talk about where things are made. (I don’t get the feeling that many parents did this.) Parents were also given the option of making a cash donation and leaving the shopping in my expert hands.

Without breaking the bank, I could not find a basket made in USA so I painted a wooden craft crate and used that for my “basket.” I attached a list of contents, including information on the manufacturer for each item. The final basket (shown below) had a value of $225 and contained the following items:

At Home
Product		Manufacturer
Martha Stewart Bath Towels (2)		WestPoint Stevens
Hand-painted mugs and matching bowl		Hartstone Pottery (Zanesville, OH)
Cast iron griddle for pancakes, pizza, or biscuits		Lodge Manufacturing (S. Pittsburgh, TN):
Colonial Treats: Sally Lunn Bread Mix, Syllabub Mix		Colonial Williamsburg Foundation
Backyard fun: Miracle Bubbles, Cherry Water Bombs, Wave Hoop, Wiffle Ball/Bat		Imperial Toy Corp. (Los Angeles, CA) Pioneer National Latex (Ashland, OH) Maui Toys (Youngstown, OH) Wiffle Ball, Inc. (Shelton, CT)
Fashion Socks (childs and adult)		Wheel House Designs (Stowe, VT)
Sterling Silver Charm Bracelet		Hook-a-Charm

On the Road
Product		Manufacturer
USA Travel Guide, Great American Vacations		DK Eyewitness Guides, Fodor
Half-gallon Beverage Cooler		Igloo Products (Katy, TX)
Camping Mess Kit		Open Country Campware/NESCO (Two Rivers, WI)
Snoopy and Batman Playing Cards		United States Playing Card Company(Cincinnati, OH)
Crayons and Crayon Case		Crayola (Easton, PA) Eldon (Madison, WI)
Mary-Kate and Ashley Notebook		Mead (Dayton, OH)

Storage Crate by Contempo Industries (Woodstock, IL)

Celebrate an Anniversary with Hartstone Pottery

I have written before on this blog about Hartstone Pottery (Zanesville, OH), and it’s a great comeback story! A pottery closed, then reopened. Workers laid off, then rehired. Working hard to preserve an Ohio tradition of hand-painted pottery. Battling low-cost imported pottery for a place in the American market.

After being closed by its corporate parent, Hartstone Pottery reopened last year thanks to six earnest investors who believed in the product and the workers. A growing number of their wonderful designs are once again available on plates, bowls, mugs, and bakeware. If you haven’t checked out their on-line store, this is a great time to visit.

In honor of their One-Year Anniversary back in business, Hartstone Pottery is offering a 40 Percent Discount on all web orders! (Enter code FRIENDS2006, good until May 11). So, if you need a special gift for a special Mom (HINT, HINT), or just want to refresh your dinner table, take advantage of this discount and show your support for the workers and owners of Hartstone Pottery.

[Disclosure Note: I am not affiliated with Hartstone Pottery.]

Kinder, Gentler Wal-Mart?!

Wal-Mart has announced a new plan for entering the urban market, which has in the past been unreceptive to the retailer. The company plans to build Wal-Mart stores in inner-city areas that historically have been served by smaller “mom and pop” stores with a smaller range of goods. To help cushion the potential impact on existing businesses, Wal-Mart says it will hold workshops with area stores to offer business strategies and with local suppliers to offer advice on doing business with WalMart.

The debate continues on whether the benefits of having a Wal-Mart (e.g., those low, low prices! and service jobs) are offset by the disadvantages (e.g., those low, low wages, anti-union corporate mentality, and Goliath-type competition for smaller businesses).

Wal-Mart is the nation’s largest employer, with 1.8 million employees and $11.2 billion in profits in 2005. Wal-Mart knows it has a public relations problem, and the new urban strategy seems partly a response to that. The company has become such a lightening rod for criticism, however, that it seems unlikely that any single move will transform its image. Still, maybe this heightened awareness can lead to positive changes?

Your Turn: vote in the blogpoll to the right. What do you think about Wal-Mart's new leaf?

Stephanie, Webmaster
StillMadeinUSA.com

Marketing to Moms

Selling happiness. Marketers never sleep, as evidenced by the mailer today from Safeway. “Joyful people are more compassionate toward others, which in turn makes the world a better place.” Attached to the flier—a packet of Pepcid AC. “ENJOY! Life. Food. Fun. Just One Tablet.” How many tablets for world peace??

Sport Utility Vacuum. Hoover recently started marketing their new high-end vacuum, designed to compete with Dyson. The Hoover SUV will be made in USA, so I took a look. Because of its high price, the marketers decided that “the man of the house” would have to be in on the purchase. The result is a flash ad that makes the SUV sound like a monster truck. My reaction to this is that the “man of the house” may get involved in the purchase, but I bet the “woman of the house” will be the one pushing the thing around!

Mothers’ Revenge. Here’s a marketing idea I am developing for SPAM. For all the cooks who have suffered the pained moans and groans of kids who do NOT like anything with onions, anything with olives, anything with capers, anything with freshly picked rosemary (I’m giving you my secret recipe for Italian Country Chicken…), I have devised the following reality slap.

The Search for E-Quality

No surprise that the Internet is littered with junk sites. The worst are the automatically generated lists of links, based on a few keywords. The resulting pages are usually just an excuse to run Google ad boxes, with no original content or even meaningful groups of links.

As an example, here’s a few of today’s new “sites” linking to StillMadeinUSA.com:

• a site purporting to be about Honda Accord replacement parts—includes a link to my blog post that mentions the terms “thermostat” and “Honda” but is really a discussion of energy saving techniques
  
• a site masquerading as a pottery information site—includes a link to my Kitchen/Dining page—the page is almost totally ads
• or how about a site called Beds Info—Find the best information on beds here—again, the page is almost totally ads

Even worse than these link fields are the sites that “scrape” entire pages from my site and post them, surrounded by Google ads. These make me so mad I’m not going to post the URL.

Why does this bug me? Because I spend a lot of time building content for my website, and in most cases I do NOT use Google ad boxes because the ads served would not be for American-made products. Why in the heck should someone else get financial benefits from my work? Grr… Also, although these junk sites are fairly apparent, they clog up the search engine results so that true sites are harder to find. So, is the Internet democratic or anarchic? (And, is “anarchic” a word?!)

Back on the Job

Cancel the APB, the missing blogger has been found!

I took a sabbatical of sorts, and was hanging around machinists. I felt a bit like Alice in Wonderland when I googled into the Practical Machinist bulletin board. Lots of talk of tapers, lathes, tig welding, turrets, and tailstock. Although I can argue global warming with the best of them, I confess I had no idea what most of the discussions were about. All was not a loss, however, because I discovered that some machinists like to buy American-made, and some have a sense of humor. To whit, the following example of board banter:

Machinist 1: I was watching James Bond, The Man with the Golden Gun. James visited the shop of Mr. Lazare, who has a custom weapons design shop on the show, and I saw a small lathe in the right hand side of the room. Can anyone identify it?

Machinist 2: Naked women in every scene and the machinists go: "Hey, didja see that scene where they had a palm tree growing up through a 4 jaw chuck? Was it a Cushman about 1933?" No wonder machinists are dying out. They're too dumb to breed.

On the manufacturing front, it looks like Hedstrom Corp. (Ashland, OH), makers of spring horses, teeter-totters, and other fun kids toys, is out of that business. The only remnant of the company I could find is Hedstrom--Ball, Bounce, and Sports Inc., makers of sports balls, and Hedstrom Plastics, specializing in rotational molding for custom applications. I also discovered that Dura-Craft, the Oregon-based maker of wonderful dollhouse kits, has gone out of business after 30 years.

Each company that I take off my site feels like another knick. I know these are businesses that were people’s lives and livelihood. As a consumer, I have lost the opportunity to buy their products. The truly discouraging thing is that I am surrounded by well-off folks who don’t care at all where products are made, or under what conditions.

So, forgive me for losing my sense of purpose. The good news is I’m back on the job and it could have been worse! https://www.berkeleybreathed.com/Images/fav_strip9_full.jpg

Stephanie, Webmaster
StillMadeinUSA.com

USA WORKS Update and Product Reviews

A few months ago, I wrote about the dilemma facing customers and retailers who liked USA WORKS jeans but were concerned that they were being temporarily imported due to a fire at a Sapko sewing plant. Many readers participated in a blog poll on this topic, and a majority of you said you would feel better about continuing to support Sapko if the company would talk about their plans on their website.

Yesterday I noticed that the company has done just that—the Sapko website even has photographs of the burned facility. Since we got what we wanted, I think we should tell them thanks. I like this company and I like their jeans. I’m looking forward to the day when I can once again get USA WORKS with the pocket tag that says “Made by Hard Working Americans for Hard Working Americans.”

Product Reviews
In the interest of product research, I’ve been shopping again. (You wouldn’t expect me to recommend something without trying it out myself, would you?!)

• I’m loving my Truck Jeans because of the stretch denim, though I confess I am having to get used to low-rise jeans. Needed a longer belt, so Natural Reflections to the rescue! Conard made me 2 belts, and a special-order child’s length too. Very nice leather and quick service.
• C&C California: I was very happy with the clingy fit of the extra long sleeved tee, though the sheer tee really needs to be layered, which effectively doubles the price—ouch! The best selling point is the wide range of colors and the very quick shipment. I am layering with A.S.Tees.
• American Apparel: The Classic Girl Sustainable Edition tank is totally soft and made from 100% certified organic cotton. It makes a great layer under tees. Thanks to my niece for that one! (Buy Classic Girl T-Shirts from American Apparel.)
  
• Perfect pj’s: I teamed up Boxercraft tartan flannel lounge pants (available from BuyAmerican.com) with Wickers mid-weight tees to create cozy pj’s that didn’t make me look like my grandmother. I love my Wickers!! They’re almost sinful.

More later on new additions to StillMadeinUSA.com.

Do Buy: Danish Havarti

With all due respect to my friends in the Wisconsin dairy industry, I recommend that all of us go out and buy something Danish in support of the good people of Denmark.

I regret the offense taken by Moslems to cartoons featuring the Prophet Mohammed. I support the right of any people to march in protest and to use the economic power of the boycott. That said, the publication of ANY cartoon is no justification for violent public displays and the torching of embassies.

I am weary of hearing “Death to (fill in the blank)” in the name of religion and/or national pride. We humans share the globe. We hold a variety of religious and life views. Mutual respect and tolerance are needed if we are ever to understand one another. Dividing the world into “us” and “them” in the name of religion, governing philosophy, physical appearance, or whatever is surely taking us down the wrong road.

Farewell to Dan River Mills

Almost unnoticed, the Dan River Inc. textile mill slipped quietly under the waters of the global economy. Dan River was best known for its bed-in-a-bag comforter, bed skirt, and sheet sets. It’s hardly news when a U.S. textile mill ceases production, but this time it feels personal. Virginia-based Dan River filed for Chapter 11 reorganization in 2004, and emerged from bankruptcy a year ago, only to be purchased by an Indian firm this year. The small paragraph in The Washington Post (Metro Section, January 15) read like an obituary: “Plant Closing to Cost 500 Jobs.”

Gujarat Heavy Chemicals, which bought Dan River last month, plans to idle the Virginia mill and move the remainder of production overseas where it is cheaper. Maybe U.S. labor and environmental standards will be applied, but how will we know?

As with Timex, Pfaltzgraff, Levi and others before it, the brand will survive but the American jobs will not. There will still be Dan River comforters and sheets, but they will be made in China, India, and Pakistan. I wonder if consumers will even notice? In March, nearly 500 former Dan River employees will line up at the unemployment office and I will keep reading labels and looking for products still made in USA.

American-Made Blue Jeans

It’s hard to imagine a wardrobe without denim jeans. What started out as hard-working wear for men has evolved into a fashion basic for men, women, and children. The old-style dungaree (from the Hindi “dungri” meaning a coarse cloth) is still around, but increasingly the jeans market is dominated by stretch denim that dresses up or down.

Denim trivia: if you look closely at your jeans, you will see that the denim has a diagonal pattern in the weave. As every school kid knows, weaving takes a filling yarn over-under-over-under the warp yarns (the same technique applies to lattice pie crust!). For denim and other twill fabrics, however, the filling yarns go under and over two or more warp yarns. This creates an offset pattern from one row to the next. The addition of spandex fibers allows the denim to "give."

American jeans used to mean Levi, Wrangler, and Lee, to name a few. Today, Levi jeans are made overseas. Wrangler and Lee brands are owned by VF Corporation, which also owns Chic Jeans, Riders, and Rustler brands. VF Corp. has manufacturing plants located in the United States, as well as other parts of the world. So, while MAY be possible to find a pair of Wrangler or Lee jeans made in USA, it’s a bit like looking for a needle in a haystack. Likewise, jeans made for LLBean, Landsend, and the GAP are imported.

Luckily, there are a surprising number of American-made jean options available. For a definitive (almost) listing of jeans still made in USA, see Stephanie's Guide to American-Made Jeans. (I tried to include the tables here, but blogger doesn't seem to like them!) I have divided the brands into two categories: traditional “serious” jeans and up-scale luxury jeans. Admittedly, my groupings are somewhat arbitrary, but jeans that cost over $100 a pair (and some up to $200 a pair) cry out for special treatment!

There is a confusing array of these luxury jeans, featuring hand sanding, grinding, and “destroyed effects” (i.e., the price includes having someone wear them out for you!). I did not find much to distinguish among the high-end, couture jeans; all the brands I list appear to be made in USA from imported (primarily stretch) denim. One stand-out is Truck Jeans, a brand of fashion jeans made in USA from imported denim, offering blasted and “destroyed” effects for under $50. The label in my Truck Jeans says “Made with American hands in the USA.” How cool is that?!

Here's an interesting article on the booming luxury jeans market: Explosion of pricey premium-jeans market has created intense competition and, some say, a bloated inventory for retailers. By Jennifer Davies (San Diego Union Tribune, October 5, 2005)

One final note. I did not include USA Works jeans in the table because they are presently being imported. However, Sapko International, which makes USA WORKS, says they are on track to restart USA production (in Wisconsin) and hope to begin shipping domestic USA WORKS by late third or early fourth quarter 2006. I’ll update the table as soon as I get confirmation that American-made USA WORKS jeans are once again available. (I took down the Blog Poll on whether or not we should buy imported USA WORKS to show support for the company. The results were 50% in favor, 42% opposed, and 8% undecided. Since that time, the company has posted a note on their website with their commitment to restart US production as soon as possible--yeah!!)

As always, I welcome comments, additions, and corrections. Let me know what you think of Stephanie's Guide to American-Made Jeans.

Village Traditions: Celebrating Craftsmanship and Natural Materials

Visiting VillageTraditions.com is like taking a leisurely trip through the unspoiled countryside of northern Vermont. The site offers simple, beautiful products made from clay, wood, and leather. Creamy pottery and hand blown glass by Simon Pearce, bowls of cherry and walnut, pieces of Vermont slate, and handspun pewter bowls and vases. The pieces seem carefully selected to please the eye and sooth the spirit, and many are made in Northern New England.

For the Italiano-files among us (just call me la Bella Stephania!), VillageTraditions also offers a sublime selection of handmade Italian pewter cutlery and soft Italian leather goods. The shopping experience is made perfect by the many beautiful photographs of the Shelburne area. Take a trip with your mouse, feel the tranquility, and reconnect with the timeless beauty of goods made by hand from natural materials.

Organize This!

Today I received an email that shouted: “Make Your Home Clutter-Free!” “Tackle Your Toughest Storage Tasks!” “Shop Our Problem Solvers Collection Today!” Now how in the heck did they know? Have they been peeking??

Okay, I admit to having an “organization problem.” Not for lack of purchasing various organizers, however. Just last week (and, no, this was NOT a New Year’s Resolution!) I went off to Staples and bought a lovely storage/filing container (HOMZ, made in USA) and some pocket folders (made in Mexico). The idea was that I would file newspaper clippings, story ideas, USA-made product information, and correspondence and reintroduce myself to my desktop. As evidence that buying organizers can motivate, energize, and organize me, I attach the following Before and After photos. Can you tell the difference?!





[January 21, 2006: UPDATE! I received an email today about an organizational "life-in-a-binder" system called JOYS: Just Organize Your Stuff. The website says "JOYS is committed to providing high quality, fairly priced, made in the USA products." It looks like a very well thought out set of checklists and reminders, packaged in a beautiful binder. Check it out! Maybe there's hope yet . . .]

Music to get you going on Friday after a tough week—and it WAS a tough one. (Though I am thankful not to live in Russia, where temperatures are 20 below, and not to be a coal miner.)

"Everything, everything will be just fine
Everything, everything will be alright"

--from The Middle, by Jimmy Eat World, the “Bleed American” album released July 2001.

New additions to StillMadeinUSA.com this week:

Stephanie's Valentine Gift Picks!

Auburn Leathercrafters (Auburn, NY)

Drew’s Boots (Klamath Falls, OR)

Eldreth Pottery (Lancaster Co., PA)

Hartstone Pottery (Zanesville, OH)

Louisville Stoneware (Louisville, KY)

Our American Heritage (Paoli, PA)

Soft Star Shoes (Corvallis, OR)

Keep those emails coming—it’s great to hear about companies that I can list! Next week: Product Reports and a summary of American-Made Blue Jeans. Have a good weekend!

Hartstone Pottery is Back!

My first virtual catalog, posted for Fall 2004, featured hand-painted pottery by Hartstone Pottery of Zanesville, Ohio. I loved their Pumpkin Patch pottery design for autumn celebrations. I also included their Funny Farm pattern in the StillMadeinUSA.com 2004 Holiday catalog.

Then, in 2005 I was distraught to hear that the pottery was being closed by its parent company, Carlisle Home Products. In past years, Hartstone Pottery had made blueberry pottery for LLBean and hand-painted soup tureens and other pieces for Crate and Barrel. As these larger accounts were lost to cheaper imported pottery, the Pottery struggled to remain profitable. Finally, Carlisle Home Products decided to pull the plug.

The closure of Hartstone Pottery not only meant the loss of jobs in Zanesville, but the potential loss of an artistic heritage in an area with a long history of handmade, hand-painted pottery. I also learned that the closure was impacting local potters who had relied on the Hartstone kilns to have their own pottery fired. I resorted to EBay to buy up a few pieces of Hartstone Funny Farm, while sending offers of free web advertising to Carlisle and Hartstone, and urging support for the company on local web boards. I didn’t have much hope that the company could be saved.

But, finally some good news. An article in the local Zanesville paper reported that a group of investors was working to save the pottery. Today I checked back, and was delighted to see that the Hartstone website is back on line! The Original Hartstone Pottery has reopened and is producing a limited number of their pottery patterns. I am hoping that more will come on-line as they grow the business. If you love hand-painted pottery, here’s your chance to support a wonderful enterprise. Welcome back, Hartstone Pottery!

Why I'm Drinking More Coffee in 2006

For those who felt that I set my sights too low for 2006, here is an important "news story" (Disclaimer: not a true story) by David Deckert. Enjoy!

SEATTLE (PA) -- SEATTLE MAN ARRESTED FOR INDECENT EXPOSURE -- Police in downtown Seattle arrested a man for indecent exposure today. Mr. Michael Feldman of 714 SE James St., was arrested after police determined that he was carrying neither a cellphone nor a latte. He was taken into custody and cited with criminal non-possesion of caffeine and failure to provide an annoying ring melody in a public place. He was later fined and released under his own recognizance.

Police first became suspicious of Mr. Feldman after they observed him briskly crossing a busy street at a crosswalk while failing to stop and hold up traffic. The officers reported that since Mr. Feldman did not seem to be carrying any sort of coffee they stopped him for questioning. A brief search determined that neither was he carrying any sort of communication device.

"He didn't even have a pager," said Officer "Buck" Simmons of the Seattle Police Department. "We figured he must be one of them anarchists, so we gassed him just to be on the safe side."

Mr. Feldman apologized for his actions and said that he hoped that no innocent bystanders had been affected. He explained that the unexpected sunny weather had "put him out of sorts" and that he had neglected to don his cellphone before leaving the house. Mr. Feldman later told reporters, "I guess I was too busy looking at that blue sky." Said Officer "Buck" Simmons, "He just kept looking up. Like at the sky or something. We thought he was a psycho."

A similar incident happened last month when a Mr. Jeffrey DuChamp was arrested and faced the same charges. Those charges were later dropped when it was discovered that Mr. DuChamp was Canadian, and he was summarily deported.

Mapping Visitors to StillMadeinUSA.com

Yesterday I discovered a really COOL little web techy tool that produces a map of the most recent 100 visitors to my website, StillMadeinUSA.com. The service locates IP addresses on top of Google maps to provide a geographic view of the location of visitors to my site. There is no end to the wonderful bits of code that are available for free!

Check it out by clicking on my visitor log. If you’re looking for yourself, be aware that the data only updates every few hours. Isn’t this fun??!!

While on the topic of websites and techy developments, I pass along this prognostication from Scott Adams (quoted from his 1997 book, The Dilbert Future)

“In the not-too-distant future, anybody who doesn’t have their own home page on the World Wide Web will probably qualify for a government subsidy for the home-pageless.”

So, if you are webpage-deprived, make 2006 the year that you get a homepage, get a blog, or at least get a mapped visitor log! Happy New Year (again, still)!

Happy New Year, 2006!

That popping sound was the housing bubble bursting, but I’m not worried because I’m diversified (I own GM stock). All the columnists (the paid variety, that is) are reminding us of Tsunami and hurricane aftermaths, union-busting, outsourcing, wars and death. I choose to leave 2005 summarizing and hand-wringing to them, and focus on 2006.

Back when I worked in cubicle land, I used to post my New Year’s Resolutions outside my work station to forewarn my co-workers. Heading the list every year was “Be nicer.” Number 2 was usually “Keep my workspace clean,” followed by “Exercise more.” My friends know that I never kept any of these resolutions. Now that I am older and wiser, my resolutions are much more practical. So here goes:

2006 Resolutions

• Drink more coffee, and make sure it’s not tested on animals.
• Stop donating money to every cause that knocks on my door. (This per my financial advisor, Bob Tresley.)
• Start as many projects as I want without feeling guilty if I don’t finish all of them.
• Apply my Type-A, detail-oriented, dictatorial skills to helping people who don’t even know they want help.
• Write to politicians.

I have an unshakeable conviction that 2006 will be a great year. People (and I include Republicans here) are basically good, talented, and hard-working. We have a lot of things to work on (raising living and working conditions, educating our kids, decreasing our effects on the environment), but we’re going to get there. I’m confident that I can make a difference, and have fun doing it. So I raise my glass of Sparkling Cider and wish all of you a Happy New Year!

Childhood in a Tin Box

Christmas is a lot about nostalgia and memories. My mom serving my grandmother’s suet pudding with hard sauce. The Christmas stockings that my other grandmother made for us kids. Remembering the year that Santa brought me the small white portable record player, and the stack of Nancy Drew Mysteries (which I sat down and read cover to cover).

This year, Santa brought my son a set of Jacks. They are beautiful gold and silver jacks, with rounded points and a heavy feel. They came in a tin with 2 red rubber balls. My sister and I sat down on the floor to demonstrate how to play. It reminded me of days sitting on the linoleum floor of Mom’s kitchen playing jacks, only ours had sharp ends and we had used a high-bouncing superball.

This time we found that we had lost the knack. Our tosses were wild, we scooted for position on the floor, we strategized over which jacks to pick up, we dropped some, our hands felt stiff. We were playing like middle-aged women. But after a few games, we stopped thinking so much and fell into the rhythm of the game. Our hands remembered what it felt like to be a kid. Toss, swipe, bounce, catch. I always loved the sound of the game. Of course, by this time the kids had wandered off to play their electronic games.

I picture Santa with a special twinkle in his eye as he dropped the jacks into my son’s stocking. Maybe, just maybe, they were really meant for me. Thank you Santa, and thank you Channel Craft.

Buying American for Christmas

Last week, the Commerce Department announced that the U.S. trade deficit reached $68.9 billion. This is such a large number that most of us can’t really comprehend it. A significant part of the trade deficit arises from our nation’s insatiable demand for imported oil. Another component of the trade deficit, however, is consumer purchasing of imported clothing, electronics, and toys.

As we send our consumer dollars overseas, our textile mills fall silent, our furniture makers struggle, and our potteries close. Quintessential American brands--like Levi's, Singer, Lionel, Timex, and Oneida—are no longer made in the USA. What’s more, most consumers don’t seem to know or care where things are made.

StillMadeinUSA.com is my attempt to help consumers find American-made consumer products. I don’t spend a lot of time trying to convince people to buy American, but I try to make it easier to do. I also try to lead by example, so here is an update on my holiday shopping: of the total dollars spent, 84% made in USA, 9% made in Mexico, 7% made in China.

Vendor	Product Origin
BuyAmerican.com	USA
Union Jean Co.	USA
Northeast Knitting Mills	USA
TheUnionShop	USA
Hasbro Games	USA
Cardinal Games	China
JCPenney	USA
CWDKids	USA
ColumbiaKnit	USA
GC game	USA
DS game	Mexico
Skooter	China
FisherPrice	Mexico
Flying Shuttle	USA
Channel Craft	USA
Fisher Space Pens	USA

We can choose to support American companies and American workers.

Putting the "Ho" back in Holiday

Don’t we have real issues to debate, or must we argue about how to greet each other during the holiday season? And yes, the phrase “holiday season” implies (correctly) that there is more than one holiday being celebrated this time of year. I have no problem with people who want to wish non-Christians a Merry Christmas, or gentiles a Happy Hanukkah. It’s the thought behind the greeting that counts. (I’m still feeling teary-eyed over the email I received today that says “Happy Holidays from Pizza Hut!”.)

As we rush around in our busy lives, saying Happy Holidays, Merry Christmas, and Happy New Year is shorthand for “I hope you are well and happy, and safe within the circle of friends and family.” So let’s stop fighting the Culture Wars, be nice to each other, and get back to shopping!

The Shipping Grinch

Like many of you, I have been doing a lot of holiday shopping on-line, mostly at StillMadeinUSA.com (shameless plug for my site!!). I was keeping an eye out for high shipping costs because of higher gas prices this season. Sometimes I find that sites with lower product prices have higher shipping or vice versa, so it pays to check the final totals before deciding where to buy. (Note that the shopping comparison sites don't take into account shipping costs...)

I did encounter an unexpected glitch associated with the “buy American” sites—total shipping charges were much higher than those charged by major retailers. For example, on an order where my purchases totaled $167, the shipping charge was $31! By way of comparison, typical shipping charges (by LLBean, REI, etc) for this purchase total average closer to $12! The reason for this became apparent when I completed the order and was notified that the products would be shipped from the individual manufacturers. In other words, the shipping savings normally associated with consolidating orders had been lost.

So, why is this happening? The advent of the Internet has meant that “virtual stores” can be set up where orders are shipped directly from manufacturers rather than from a retail middleman. This practice is called “drop shipping.” A benefit of drop shipping is that e-retailers are not required to invest in goods up front, and thereby forgo the risk of getting stuck with merchandise that doesn’t sell. There is also much less capital investment required. The e-retailer, in this scenario, becomes more of a service that coordinates transactions between customers and manufacturers. More of the burden for order fulfillment (tracking and shipping) is shifted to the manufacturer.

The absence of a “brick and mortar” store does have benefits for consumers because these e-stores potentially can offer a wider array of products. For the “buy American” niche, this is particularly helpful since many American-made products are not carried by traditional retailers. (I suspect this is because the profit margin is much lower than for imported products, but that’s another post.) All in all, then, I concluded that the extra charges were worth it because I saved shopping time by having all of the items available in one purchase transaction. However, it still came as a shock at check out. I think these stores need to better prepare customers for the Shipping Grinch.

Elves Organize, Join UAW

North Pole. This week Santa’s Elves voted to organize and form a union, reacting in part to concerns that “The Boss in Red” might decide to outsource toy production. In the words of one elf, “If that happens, the jobs go south!” The small workers researched possible unions to affiliate with, but in the end decided on the UAW. “We make cars and trucks, as well as trains and dolls, so it seemed like a good fit” said an elderly elf. Rumor has it that the other deciding factor was that Ron Gettelfinger is just so darn good looking!

The newly formed UAW Local 90N invited me to become an honorary member and informal spokesperson because of my elfin qualities, extreme interest in toys, and years of experience dealing with bad little boys. I promised to help get the word out about the need to improve working conditions at the Pole. For the most part, Santa is a beneficent taskmaster, but thinning of stratospheric ozone and global warming have the elves worried. “We’re also running short on coal for stockings of bad little girls and boys,” said one elf. “We’re trying to develop a solar-powered substitute, but it just doesn’t have the same impact.”

So, you heard it here first. Collective bargaining at the North Pole. What next—health care for everyone? Support your local elves this holiday. Do your shopping at StillMadeinUSA.com!

No More Parenting Tips--Please!

Every month our elementary school sends home a newsletter that gives updates on all the activities at the school (including a lot of long-term homework projects that I haven’t heard about…) The newsletter usually has a section with useful little tips on how to “Help Children Learn.” The tips always seem to be written by earnest young education professionals who HAVE NO CHILDREN, or at least only have girls.

This week’s tips included a call to “Build your child’s school skills during family meals.” By family meals I assume the author means the placement of food on a centrally located table so that children can come and go and take whatever meets their exacting culinary standards and eat it in front of the TV?

My favorite tip was the one about suggested activities during mealtime, and--as Dave Barry would say--I am not making this up!:

“Place an interesting object in the center of the table to encourage conversation.”

I don’t know about you, but the interesting object in the center of my table is a Lazy Susan, placed there to allow 360-degree access to the ketchup bottle. It does tend to be a conversation starter, though, since the favorite activities involving the Lazy Susan are:

1) Turn it just as a brother is about to grab the ketchup bottle;

2) Spin it so that the handle of the serving spoon in the bowl of peas knocks over a brother’s glass of milk; and

3) Jiggle it so that the petals of the dead rose in the “vase” fall into a brother’s food and/or the pepper mill falls over and rolls off into the mashed potatoes.

Maybe I should start a parenting newsletter of my own.

Woolrich, Inc.---Then and Now

The Woolrich, Inc. website has an inspiring Flash history of the company, from its early days in the 1830’s as a supplier of rugged, warm woolen cloth and clothing to loggers and frontiersmen. Images of steam engines, mountain climbers, and the woolen mill in Woolrich, PA fade out and the image of “Woolrich Today” comes into view. The site proudly notes that the Woolrich Woolen Mill is one of the oldest in the U.S.A. What the history doesn’t say is that the march of progress has included almost total outsourcing of production.

After searching in vain on their website for anything that was made in USA, I resorted to “Live Chat” and here is what I was told:

“For American apparel companies to survive and grow in this past decade and in the future, we have all had to become truly global. Our company has been able to increase American employment in marketing, merchandising, administration, and retail. Although we manufacture many of our garments (or components) overseas, they are designed by us and meet our strict quality standards and specifications. We employ 850 people in the U.S.A, and we strive to keep as much manufacturing here as possible, but companies today have little choice but to compete in a global economy. When consumers choose to purchase Woolrich products, even those products made in foreign countries, they continue to support our 850 American employees.”

The bottom line is that, with the exception of a few huntwear and blanket items, Woolrich (“The Original Outdoor Clothing Company, celebrating our 175^th year”) is now primarily a retail outlet for imported products. Still, I am glad they have managed (so far) to keep the mill going. I notice, for example, that their Civil War reproduction fabrics are still made in the Woolrich, PA mill…

Economists are People Too

For those of you who have noticed my absence from the blogosphere, my excuse is that I have been hip-deep in economics papers. Today I emerge to share a few insights about economists as a group (definitely not referring to any particular economist who happens to be my professor at this time, Dr. Dimitri, and is a wonderful person!).

Economists like to write very long papers, perhaps in the hope that readers will not stick it out through the middle part. The papers begin with broad, visionary statements about how markets function in theory. Then comes a lengthy, dense, mathematical presentation of how this theory would look in mathematical form. Rather than state the obvious in English, there are equations with Greek letters, many tiny subscripts, “dummy” variables, and terms that stand for “everything else that may be important, but which I have no idea about” (called “error” terms).

Then, for readers still standing after the theory section, comes a discussion of why none of the afore-mentioned variables will be used in the actual analysis because such data do not exist. (At this point, one hears screams or cries of anguish.) The conclusions section returns to the visionary statements introduced at the beginning, thus reassuring the reader that the intervening jungle has not lessened the certainty of the economist in the least.

Other observations: In order to be published, all economics papers MUST include the following terms:

• ceteris paribus: this is a problem since I have no idea what ceteris paribus means! (My high school stopped offering Latin the year I arrived.) Based on context, I have decided that it means "assuming away all realistic ideas of how the world works"
  
• endogeneity: something in the “real world” that intrudes on the tidy world of theoretical modelers and causes distress by violating the modeler’s assumptions that it can be specified and held constant
• internalizing the externalities: I translate this to mean “taking account of all of those things which are not being taken into account” (??!)
• marginal social cost: the cost to the rest of us when businesses are forced to “internalize the externalities” rather than take it out of their profits

[Disclaimer: this is just me having fun. If you want the REAL definition of these, and other, economic terms, check out this Glossary of Economic Terms.] The clear implication here is that I need to take more economics classes.

Energy update: Thanks to Bob Tresley, my windows and doors are weather-stripped, MOST windows are actually closed, and my programmable Honeywell thermostat is installed and functioning. I’m enjoying coming down in the morning to find that the room temperature has already risen to a comfortable level. One other electricity saver was installing power strips around the house so that clusters of electronic gizmos (TVs, computers, VCRs, PlayStations) could be turned off over night. However, this latter is not automated and there are serious implementation glitches. (Note to Honeywell: develop programmable husband.)