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The encyclopedia · Engineering & Operations · Strategic decision · 2011

Western Digital bet its hard-drive output on Thailand — then the floods came

Thailand made much of the world's hard drives in 2011. When record floods hit its factories, Western Digital's output collapsed and a shortage sent prices up.

Western Digital · Seagate · 2011-10

What happened

By 2011 Thailand had become one of the world's main hubs for making hard disk drives, accounting for a large share of global output. Western Digital and Seagate both ran large factories there, drawn by low costs and an established electronics supply base. The concentration was efficient — right up until the water arrived.

The 2011 Thailand floods, the worst in decades, inundated industrial estates north of Bangkok in October. Western Digital's factories were swamped; the supply chain, as the BBC put it, ground to a halt. With Thai output offline, the global supply of hard drives fell sharply, computer makers could not get drives for their machines, and retail prices for drives roughly doubled.

Western Digital was among the hardest hit, shipping far fewer drives than planned and estimating hundreds of millions of dollars in lost sales, while rivals with more diversified production gained ground. The shortage rippled through the whole computer industry and lasted well into 2012. The lesson was plain: concentrating so much of one critical component in a single flood-prone region had turned a weather event into an industry-wide crisis.

Why it happened

  • Hard-drive makers concentrated a large share of global production in one region of Thailand, so a single flood could knock out much of the world's supply.
  • The factories sat on low-lying industrial estates that the 2011 floods inundated, and there was no comparable backup capacity elsewhere to absorb the shock.
  • Because drives were specialised and capacity was concentrated, the shortage lasted for quarters, pushing up prices and costing the makers lost sales and market share.
What it costoutput sharply down; ~$200M hit; a global drive shortagecostly

The lesson

Clustering production is a fair-weather gain. Concentrating one component in a single region buys low costs until that region floods — then there is no backup, and a storm becomes an industry crisis.

Aftermath

Western Digital recovered and remained a leading drive maker, but the floods prompted manufacturers across electronics to rethink geographic concentration and to add backup capacity outside single regions. The episode is now a standard supply-chain case study in single-point-of-failure risk: efficiency gains from clustering production can be wiped out in a season when the cluster sits in harm's way.

Sources

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