Spirit AeroSystems is going full circle, from part of Boeing till 2005 to independent supplier in 2005 (when Boeing sold to a private equity firm) and back to part of Boeing in 2024. It is the perfect example of a realization dawning on corporate America: Outsourcing isn’t all it was once cracked up to be. The deal’s logic of vertical reintegration makes sense in light of recent history, with air-travel safety likely benefiting from centralized supervision and a simpler workflow between plants. Yet it is also an indictment of what executives in most industries have been doing for almost three decades….’

At the core of the outsourcing trend that lasted 30 years was the idea that an “asset-light” firm focused on intellectual property and its “core” expertise would be better run. With this mindset, jettisoning aerostructures operations seemed like a no-brainer….
It wasn’t just aerostructures: In the 2000s, Boeing outsourced more than 70% of the 787 Dreamliner program. But the problems with becoming an assembler of planes, as opposed to a true manufacturer, gradually became apparent. The company lost control of supply, resulting in years of delays and cost overruns…

Aerospace isn’t the only industry to revive vertical integration. Intel is beefing up chip manufacturing in the U.S., General Motors is building battery plants and Sweden’s IKEA is acquiring containerships. One general flaw of the asset-light model is that, over time, firms can lose their innovative edge because a lot of “learning by doing” happens when production processes interact. Another is that low-margin bits of the supply chain get worn down to just a few sources. These may not have the financial muscle to make big investments in times of turmoil, or they may be geopolitically sensitive. Such risks were underscored by post-Covid shortages, particularly in the largely “fabless” U.S. microchip industry, which has outsourced chip making to foundries in East Asia in a way that echoes what happened to aerostructures.

Excerpts from Jon Sindreu, Boeing Calls Time on the Great American Outsourcing, July 2, 2024