Given FBass's Fender-ish vibe, I thought you guys might be interested in an
interview with Dan Smith, one of the men Fender hired away from Yamaha in 1981 to turn around Fender.
In 1965, CBS Musical Instruments, who also owned
Steinway,
Gemeinhardt,
Lyon & Healy harps,
Gulbransen, etc., bought Fender. Soon CBS required each of Fender's luthiers to make at least 50 guitars and basses a day to get paid. If they could make 75+ guitars in a day, then they were given a higher rank in the union and were paid more per hour.
There was so little automation that Fender needed 90 people to make 120 necks in an 8-hour shift. Standardization was so bad, 30 or so of those necks would be rejected. The way holes were drilled was sloppy and barely measured, resulting in inconsistent finished products. Supervisors knew nothing about manufacturing because they were promoted from the warehouse, as per union rules.
During 1970s, Fender produced about 300 guitars a day, and they had just three quality control inspectors to assure customers were getting a good product. Take a second to consider the time it takes to string, setup, tweak and really test an instrument, how many could you really test in an 8-hour shift?
When Dan Smith arrived, CBS's quality control guy proudly announced that Fender instruments were "97 percent good" and had no problems. Dan grabbed a couple of guys, and together they pulled 800+ guitars from the factory and tested them.
Only 15 percent passed inspection for their existing criteria.
About that time Dan met Forrest White. Forrest was with Leo when they first started Fender. Forrest showed Dan old film of how the factory worked when they first set it up, and it was nothing like what CBS was doing. Somewhere along the way, some CBS MBAs and union guys from the warehouse with more authority than know-how really messed it up.
It took Dan and his guys 4 years to completely retool Fender's Fullerton guitar factory. The Fullerton workers divided themselves into 2 camps: those that really cared about guitars and wanted Fender to make great ones, and those who thought they knew best and despised those forcing change.
Smith and his group also bought a 1957 P-Bass, a 1960 Jazz Bass, and a 1961 Stratocaster and took them apart to study them and inspire their R&D going forward.
They took for granted that the Fullerton could build the instruments, but they struggled to change their thinking. As a result, Smith and his co-owners hearkened back to their Yamaha days and setup a factory in Japan. Smith said the Japanese factors were so well run that they were clean enough to eat off the floor.
While the quality of the instruments was what they wanted, they struggled because players in the USA were prejudiced against the instruments coming from Asia, calling them Fender "copies." Fender primarily sold Japanese made guitars in Japan and oversees, and Smith credits Japan with helping Fender get back on its feet again.
As things improved, CBS started shopping Fender around, but were only getting "low ball" offers. CBS then approached Dan Smith and his associates and said they would rather sell Fender to them if they could raise the capital. They did and they eventually bought Fender from CBS.
The group bought the names Fender, Rogers, and Rhodes, and Squier, and the product that was in stock, the receivables, a lot of machinery, but they heartbreak of the deal was, after they'd busted a gut getting the factory to do the right thing, they learned the Fullerton factory was not part of the deal.
But they did get Fender Japan in the deal.
Fender Japan kept them going until they could set up a factor in Corona, California. Remarkably, it only took them 1 year to start from scratch and build the Corona factor, while it took 4 years to reform the mess that was the Fullerton factory.
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Reading this story puts into context my own experience with Fender instruments.
I started playing bass as a kid in the late 1970s. Living in a remote place in Alaska, I mail ordered in my first bass, a 1977 Fender Jazz bass. I must have got one of the lucky 15 percenters, because not only did I think it played and sounded great, professional bass players would come to town and ask if they could trade their Fender bass for mine.
After owning many basses over time, I started to prefer Yamahas. My main basses were two John Patitucci signature Yamahas, one fretless.
Then I bought my first FBass: a BN5. It sounded better, played better, looked better, was better than every bass I'd ever owned. Before long, all my factor basses were gone (except my 1977 Fender Jazz), and I was playing only boutique hand made basses from FBass, Fodera, Alleva Coppolo, etc.
I've played some good Fenders to be sure, but I've always regarded them as inconsistent. By contrast, I've never played an iffy Fbass!