Europe’s auto capacity is staggeringly underutilized, as political pressure to protect jobs stacks overcapacity upon overcapacity. Analysts lay out the gory details at Automotive News [sub]: Global Insight says European production capacity is currently at 59 percent, while PriceWaterhouseCoopers figures excess production is 6.8 million vehicles. Assuming an average production of 300,000 units per plant, over 20 of Europe’s 100 major auto plants will have to go to bring supply back in line with demand. Though Saab’s seemingly imminent closure should take a first step towards a European coming-to-terms with its unreformed auto industry, the Opel deal is starting to look like an opportunity that GM could be too state-aid-dependent to take advantage of.

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It’s been a while since we’ve heard the word “buyout” echoing out of Detroit, as 2008 marked the year in which auto industry employees finally started to be fired like everyone else: without a hefty severance kiss-off. Ford, on the other hand, did not get a shot at free house-cleaning in bankruptcy court, so it’s bringing back buyouts. According to Market Watch, the Blue Oval is offering blue-collar employees a $50,000 lump sum payment and a $25,000 voucher for a new vehicle or another $20,000 lump sum, as well as six months of health insurance coverage. There’s even an extra $40k for workers of “a certain age.” But this being Detroit, employee benefits are either feast or famine. While Ford’s workers are being offered cash for their jobs, the former Ford parts division Visteon announced today that it is seeking to dump pensions for 21,000 retirees in bankruptcy, following Delphi into yet another stealthy yet popular form of indirect automaker bailout.

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Almost exactly a month ago we asked:

Fiatsler is bringing Fiat back to the US as a one-model-brand (500) with a dedicated sales and support staff just to meet one of these government benchmarks… will they be crazy enough to build an engine in Michigan and ship them to Mexico to meet another?

The short answer: of course. Fiat gets five percent of Chrysler’s equity for building the engine in the states, but unless there are unrevealed US-market applications for an engine with 92 lb-ft of torque, they’ll all be shipped to Mexico and installed in Fiat 500s. According to Marchionne, half of the Toluca, Mexico Fiat 500 production will be sold in the US with the other half going to Brazil. For a guy who regularly bemoans the poor strategic positioning of Fiat’s factory sites, Marchionne is surprisingly willing to bend a few principles for five percent of Chrysler’s equity. Will it work? Sergio is still asking for time, telling reporters “by the end of 2011 and in early 2012, you should be able to tell how our plan is working.”

In Italian tradition, there’s not a lot of love lost between the Southern and Northern parts of the country. In part, because the North has always held the majority of the wealth and in part, because the two cultures are so very different. In this light, Sergio Marchionne’s plans, straight from Fiat’s Turin headquarters, to end production at their plant in Sicily, probably didn’t do much to help North-South relations. But don’t worry, the Italian government (and possibly Indian automakers) are here to help. The Times of India reports that the minister for economic development, Claudio Scajola, invited Indian firms to invest in the Italian automotive industry. More specifically, the invite was to take over Fiat’s unprofitable car unit in Sicily, which is being eyed for closure. “We are absolutely happy and open to any Indian investment in the automotive industry as well as in any other industry,” Claudio Scajola told reporters in Mumbai. “We do hope that Indian investors come to Italy.” Tata Motors declined to comment and Mahindra & Mahindra said they do not comment on speculation. Chinese firm Chery has denied being in talks to buy the plant. Looks like Claudio Scajalo needs a harder sell to bring those Asians westward.

UAW Boss Ron Gettelfinger plans to retire next year, and the search is on to replace the man who led the union through the political minefield that was the auto bailout. But the union’s support for Bob King, who led negotiations with Ford, could open up divisions within the union, reports Automotive News [sub]. King followed the Gettelfinger line, offering Ford many of the same concessions it granted GM and Chrysler during the government bailout that transferred large stakes in those companies to the union’s VEBA fund. Those concessions to Ford, which would have preserved the UAW’s decades-long policy of treating the Detroit automakers equally, were rejected by the same union rank-and-file that must now ratify King’s nomination.

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Zacks Investment Research reports that Ford will invest $500 million in Michigan for developing and building batteries for their hybrid and electric vehicles. In return, they have asked the Michigan government for a tax break between $85 to $120 million. Michigan haven’t confirmed whether they’ll give this tax break, which is handy because Ford have indicated that they will look elsewhere if the tax break isn’t given. This investment will create 1000 jobs. Each job will cost at least $85000? Shocking!

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As the world recedes, South Korea grows. First Hyundai registers double digit growth in the United States and now other automakers want a piece of the South Korean action. The Korean Times reports that Renault-Nissan announced that they will increase the amount of their South Korean parts suppliers from 28 to 100 by 2013. 108 major subcontractors took part in a conference along with officials from Renault-Nissan’s purchasing organisation.

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Asiaone Motoring reports that Toyota are now pushing forward on their constructions of plants in the United States and China which had previously been put on hold. It should come as no surprise that part of the reasoning behind this decision is to meet growing demand in China. More importantly, Toyota needs to protect itself from the strong yen, a consideration that now apparently outweighs weakness in the US market.  The report says that Toyota is expected to invest and additional 100 billion yen (about $1.1b) to get these plants completed. Although these plants will increase capacity by 200,000 units, Toyota plan on halting production on lines in Japan and the UK, as the firm must still reduce capacity by 1 million units in order for this investment to work. Though the move is a clever one, it highlights the enormous pressure the world’s number one automaker finds itself under: overcapacity is bad enough, but when so much of its production is based in Japan, it deal with reduced production while paying for expansions in cheaper production zones. The upside? This plan could lead to US production of the Prius at the under-construction Mississippi plant sooner than expected.

Toyota had slammed hard on the brake when it came to capital expenditures. So hard that ToMoCo (and Sony) were rapped on the knuckles by the Japanese Ministry of Finance for hobbling Japan’s economy. Suddenly, Toyota starts pouring concrete and installing machinery again. Not because of newfound faith in the auto market in general. Two factors made them do it: The Yen has become so expensive that manufacturing in the USA is cheaper. And China is gobbling up cars faster than Toyota can make them.

According to the Nikkei [sub], a Toyota plant in the US and one in China will increase ToMoCo’s annual output capacity by 200,000 units before the Japanese 2010 fiscal ends on March 31, 2001. The construction will cost Toyota a little over $1b, depending on the vagaries of the greenback and its pegged follower, the Chinese Yuan. Here are the blueprints:
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Having planned to idle production plants for a mere ten days over the winter break, Chrysler is responding to weak sales by extending the holiday shutdown of several plants to three weeks or more. The WSJ reports that Chrysler’s Windsor and Brampton plants (minivans, 300/Charger/Challenger) will shut down starting December 21 and will idle through January 18. The Toledo plant (Jeep Wrangler) will also idle beginning on December 21, and will resume production on January 11. Chrysler is also said to be considering extended production shutdowns at its Detroit Viper factory (which is entering final production anyway) and an unspecified Ram plant. Unless December sales numbers turn out to be humdingers, this winter vacation could possibly go on even longer, as Chrysler struggles under falling sales and a 64-day supply inventory.

After writing about Spyker transferring production from the Netherlands to the United Kingdom, I thought I’d seen it all. Well, now I have. Production going OUT of Germany and into the United States. After much debating, Daimler have finally decided to switch some production from Germany to the United States. According to Reuters, roughly a fifth of Mercedes-Benz C-Class models will be built in Alabama by 2014, in hopes of protecting against currency fluctuations and maintaining profit margin. Naturally, the unions weren’t happy, in fact they downed tools in protest, claiming it was a “blatantly wrong decision.” Dr Z saw it differently, especially considering the move is said to be worth $100m in incentives from the state of Alabama.

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Nissan’s UK plant could lose the production contract for Nissan’s Leaf EV, thanks to the London 2012 Olympics’ committee. Production of the Leaf at Nissan UK’s Sunderland plant would almost certainly have been confirmed, sources tell Autocar, had the Olympics picked Nissan’s bid, creating instant demand for some 2,000 Leafs. Because they chose BMW to sponsor the 2012 Games, production of the Leaf in the UK is no longer a sure thing. Though Sunderland is still said to be in the running as the European Leaf production site, Nissan have plants in Portugal and Spain that are bidding for the job. And after the London Olympic committee’s implication that Nissan’s bid lost because they couldn’t rely on its EVs, Nissan seems ready to make all of England pay for the insult.

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The Brazilian-American Chamber of Commerce reports that Volkswagen AG has announced it plans to build (cue “Dr Evil” voice) 1 million vehicles in Brazil by 2014. To help this grand notion become a reality Volkswagen will invest €2.3 billion (about $3.5b) into the endeavour benefiting its two assembly plants in Anchieta & Taubate and its engine plant in Sao Carlos. Volkswagen aren’t far off this target; this year Volkswagen expects to manufacture 800,000 vehicles in Brazil. Brazil is also Volkswagen’s third largest market after China and Germany, respectively, so there’s plenty of demand for the Wolfsburg Warriors’ offerings, with deliveries to customers up 70% since 2005. If Volkswagen cars are suffering from alleged reliability issues, it doesn’t seem to be bothering our Brazilian friends.
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Alfa Romeo was founded in Milan some 99 years ago, but as a division of Fiat, it’s pulling up its roots to relocate its remaining 232 Milan-based employees (out of 20,000 employed there twenty years ago) to the mothership’s hometown of Turin. CEO Sergio Marchionne explained that the move is strictly business, saving the company costs by consolidating operations, but the move has one minor rub: Alfa had planned to revive the “Milano” nomenclature for its 147 successor. Obviously this proud reference to a local heritage that no longer exists caused a few problems with employees, prompting Fiat to hastily announce a last-minute name change. Rather than Milano, the name Giulietta will be used for the new hatchback. But the last minute irony-avoidance maneuver pushed back the launch of the new Alfa, which was supposed to debut with official images today. As Automotive News [sub] reports, “the decision left some monthly magazines scrambling as they had already received pictures of the car, which was badged the Milano.” Whoops! Time to re-order those decklid badges… unless the decision to go with Giulietta was inspired by the discovery of boxes of unused badging. Fiat made another such last-minute name change in 2003, when the ill-advised name “Gingo” was dropped in favor of “Panda” because its was deemed too similar to Renault’s Twingo.

General Motors made one point very clear, 100 percent clear, the restructuring plan could only be achieved when European member states with Opel plants give some financial help. So the plan works only with state aid. The idea that General Motors can finance this on its own was not shared by General Motors, this possibility does unfortunately not exist

EU Industry Minister Guenter Verheugen reveals to Automotive News [sub] that GM does indeed seem to be trying to limit the amount of US taxpayer money spent on its $4.9b rescue of Opel. GM’s Opel fixer Nick Reilly explains “we have indicated that we will inject some GM funds into that requirement too. That is quite difficult because we are also going through a restructuring of our U.S. operations and other parts of the world.” We’ve already seen loans for jobs floated in the UK, where Reilly came up just short of offering to save Vauxhall jobs for government restructuring loans on a quid-pro-quo basis. And GM will have to continue walking that fine line, as EU competition rules forbid member states from offering financial support in exchange for jobs, especially if the saved jobs come at the expense of jobs in another EU member state. But Germany’s leadership was humiliated by GM’s decision to drop the sale of Opel to Magna, and has already ruled out funding an Opel restructuring that would keep the automaker under GM control. Will Belgium, Spain and the UK be able to come up with enough money to make the restructuring happen? Or will GM simply be forced to dip deeper into its taxpayer-funded escrow account? GM’s plan will be announced this week, and we’ll be watching.