Instrument makers in USA

When a Yamaha trumpet, trombone, cornet or flugelhorn is sold in the United States, it is in the great majority of cases an instrument from the Grand Rapids factory. Imports of finished products from Japan — about 20% of the total for brass instruments — are mostly top-of-the-range models of these instruments or else instruments not in the Grand Rapids production programme, such as horns, tubas, euphoniums etc.

Together with that first group of brass instruments — the main object of this article — the Grand Rapids factory also produces woodwind: flutes, saxophones and clarinets. Counting woodwind and brass together, the factory has an annual capacity of up to 70'000 instruments.

It was pointed out to me with satisfaction (no doubt justified) that "when we started up production here eleven years ago, as a Japanese firm we had to prove ourselves in every way. Now the ice is broken!" Mr. Tom Williams, whom I interviewed, added, "This factory is also a part of our large corporate family. We are aware of the responsibility associated with that because our reputation is closely linked to that of our sister companies."

But let us get back to making brass instruments. The main components are series produced in Japan. These then come to Grand Rapids, where the individual instruments are assembled, adjusted and finally lacquered or silver plated; I was told that all this accounts for 60-70% of the value of the finished product. It is above all valves, mouthpipes, bell sections and mouthpieces that are imported. In some departments these figures should eventually change in favour of the American share of production; in others — trumpet valves, for example, for which Japan by herself can meet a large part of the world-wide demand — no change is expected.

As already mentioned, the main preoccupation is the quality of instruments produced. Great importance is therefore attached to employees' training. Time studies, carried out by specialist consultants, are generally used as a basis for in-house studies. Individual employees' performance is then monitored for three months; this provides the basis for a suitable average. Those who produce less, but whose work is careful and reliable, have nothing to fear from this because experience has shown that good people usually produce above average so long as they feel free and not tied to a norm. According to this hypothesis the shortcomings of their slower working colleagues is soon compensated for — and high quality is still preserved.

I was assured that with this work atmosphere the firm has a very low turnover of personnel. This was not always so, however, for to begin with some employees cared little for the demand of quality. All the more reason to be proud of the workforce today. Until 1979 the Grand Rapids factory, Yamaha's first in the United States, produced organs as well as wind instruments. These are now in Thomaston, Georgia, and another factory produces the well known Everett pianos.