WWII: Germany starts total war mobilization earlier

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Iosef Cross
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Re: WWII: Germany starts total war mobilization earlier

Post by Iosef Cross »

Sea Skimmer wrote:
Iosef Cross wrote: I admit I don't have data about the costs of storing oil in the 1930's. So I don't have anywhere to go if you want a detailed financial study of the feasibility of storing 1 billion barrels of oil in preparation to WW2.
The German government spent every cent it had already. As early as 1934 the Nazi government was down to only a few weeks foreign exchange reserves, and had to seize all private gold and currency stocks. German citizens could not even leave the country with more then 100 reichsmarks worth of currency because the Germans did not physically have the foreign exchange to allow them to do so. This was actually a major problem when the SS tried to simply force Jews to leave German, before concentration camps or death camps were politically acceptable. You want a giant pile of German oil, then you've got to cancel something else that was imported of equal value. That's pretty much going to have to be either food, hardly an option, or rare strategic minerals like molybdenum which was used for making armor plate and weapons.
The Germans had a problem with lack of foreign reserves in the 30's because they maintained an artificially highly valued RM. They maintained the RM at such high value for political reasons, however, there is no rational economic reason for keeping the RM artificially valued.

Just let the RM fluctuate and you have all the the foreign exchange reserves that you need.
Imports were already tightly rationed, and this plus the very tight credit supply even for German currency created by the massive arms programs made everything worse because it precluded an expansion of exports that would have earned more money. As it was the Germans very much DID try to build reserves, and expand synthetic oil production. They failed dismally because it was too expensive to stockpile anything, and the synthetic oil plants were hugely expensive, and produced far more expensive fuel while taking years to build.
As I said before, imports were rationed because the country maintained the RM artificially high. As result, the price level of Germany was higher than the price level of the rest of the world, with meant that entrepreneurs could profit from buying in the rest of the world and selling to Germany. Since the Germans need foreign exchange to buy goods from the rest of the world, the demand for foreign exchange is higher than supply, with creates a tendency for the depreciation of the RM. Since it was a political move to keep the RM at fixed rate, because Germany needed a "strong currency", the supply of foreign exchange had to be rationed.

But that's the standard outcome of market intervention: If the price is keep artificially low (of foreign currency compared to the RM), demand is greater than supply.

The RM became had the tendency for devaluate because Germany was the first major economy to get out of the great depression, while the economies of the other major powers suffered from deflation, while Germany's supply of money increased. As result, prices in Germany rose relative to the rest of the world, with created the tendency for devaluation of the RM, or a disequilibrium between the supply and demand for foreign exchange.
And also the fact that since oil consumption was a very small part of German resource consumption, to store several years of oil equivalent consumption wouldn't be much, considering that the Germans consumed dozens of times as much coal as they consumed of oil in those days, oil was not like today in the US, were several years of oil consumption is an absurd quantity, in 1938 Germany produced over 300 million tons of black and brown coal, 50 times their oil consumption.
Today we have a far more evolved oil industry to deal with the problem, and the Germans never had enough coal anyway, some had to be imported before the war began.
1- Today is would be much more difficult to store several years of oil consumption than in Germany of the 30's. Since for Germany in the 30's, oil was a secondary energy source, today the US for example, consumes much more oil than Germany for the size of their economy. Germany consumed 7 million tons of oil per year, second to Simon, the US today consumes nearly 1 billion tons of oil per year. However, the US consumes today less than 1.1 billion tons of coal, while Germany consumed 300 million tons of coal and lignite in the 30's. So for Germany in the 30's, coal was 40 times relatively more important than oil, if compared to modern US.

2- Germany was a net exporter of coal, their net export was 45 million tons before the war. They exported coal to France, for example, with produced only 1/5 of the coal that Germany produced. However, Germany's newly conquered European empire consumed slightly more coal than they produced, but it was a small difference, second to Wages of Destruction, page 414, they consumed 3% more coal than they produced.
Once the war started the coal shortage just kept getting worse because of insufficient food for miners, German and slaves alike. If the Nazis could have afforded more oil, they would have spent the money on more tanks and bombers to try to win wars more quickly anyway. The German empire was fucked in a long term war and they knew it, which is why Hitler wanted to just seize most of Europe and eliminate any credible threat prior to the as yet unknown atomic bomb.
However, if Germany wanted to go to war, it would be a long term war, since Germany would be at war with the US, if they managed to defeat France and UK in the short term (with they did). And you cannot defeat the US from Europe in a few months. Hence, they needed to stock rare resources, like oil and minerals, with they didn't have in their territory.

Historically, the Germans planned to conquer the USSR and get their oil, to fight a long term war. The original plan was to conquer most of Europe, including the vast natural resources of the European part of the USSR, and fortify agaisnt the western allies, to reach a stalemate. They never planned to invade the US and didn't have serious plans to invade UK.
So were a fuckload of other strategic resource stocks. That's what you get when you mobilize in peacetime to wage massive wars of conquest. If the Nazis had somehow been willing to adapt a defensive posture in Europe then building up large stocks would have been possible. You can't expand an economy, which stockpiling resources is part of, and mobilize for war at the same time. It just will not work.
Depends on the quantity of resources that you store. The price of a barrel of oil in the 30's was around 1 dollar per barrel. That's 2.5 RM per barrel, Germany's GDP in 1939 was 115 billion RM (source: Harrison, The Economics of WW2), though since the RM was overvalued, if they devalued the RM to their equilibrium value, it would be around 3 RM per barrel.

So, if Germany stocks 10 years of their annual oil consumption (about 500 million barrels), it would be 1.5 billion RM, or less than 1.5% of their GDP of 1 year. If they planned to go to war, they would stock such oil reserves for about 4-5 years, mobilizing 0.3-0.4% of their annual GDP to purchase oil.

Germany's military expenditures in 1938 were 18% of their GDP. Accumulation of oil would correspond to a very small fraction of Germany's military expenditures. The problem is that we don't have data on the costs of storing oil during the 30's.

Also, Germany developed a synthetic oil industry, with was ridiculously inefficient, since the price of synthetic oil was nearly several times higher, still, they managed to synthesize nearly 50 million barrels in 1943. Considering the price of synthetic oil, it would be cheaper to accumulate strategic oil stocks. A 500 million barrel oil stock would be more oil than the German armed forces consumed during WW2.
With greater supply of equipment and ammo, it would help to make the German forces stronger. To have stronger forces is always good.
But you want the Germans to spend money on oil. This cannot happen without weakening the military forces.
Actually, I said that assuming that Germany HAD their 1944 levels of military production in 1940 and 1941, they would stand a good change of winning the war. It quite a common argument.

However, I said after that if Germany wanted to get 1944 levels of war production in 1940, they would have to start mobilizing their industry for total war in 1935-36, so that their workers gained 4-5 years of experience and the entire industry learned to produce munitions to maximum efficiency by 1940. I didn't consider the political or foreign exchange rate problems associated with mobilizing for total war in 1935-36. But they are substantial.
Sure, that's also totally out of reason. Don't you think of the fucking Nazis of all people could have had FOUR TIMES as much ammo they would have done so?
They historically quadrupled their heavy ammo production between 1941 and 1944, from 27 million rounds to 108 million rounds in 1944. Source: The Review of Economic Studies, Vol. 13, No. 1 (1945-1946), pp. 33-52.

Also, note that in WW1 the Germans would have probably won as well if they had 1918 levels of production in 1915, with had tripled by 1918.
Did you miss how the Germans totally collapsed in WW1 because the German population basically starved to death because all the government did was make guns and ammo? The Nazis were intent to avoid that, and this is one place they did well. You want to start starving the German population in 1933... okay, they'll collapse by 1940 and end up speaking French.[/quote]

Military expenditures in Germany, both in WW1 and WW2, were still to low to make the private consumption to reach below subsistence levels. In WW2, by 1944, consumption was ~70% of 1938 level (as I pointed out before in this same tread). And Germany's 1938 level of consumption was around 10 times the minimum subsistence level.

The problem would be that a 1936 mobilization for total war in 1940 would imply in a peacetime reduction of per capita consumption, with is politically impossible. I never claimed that total mobilization in 1936 was the ideal strategic plan.
Increased production late in the war was the result of years upon years of steady increases in factory capacity, backed up by looting and starving occupied countries for labor and resources. You seem to think this can just happen earlier if the Nazis wish it. It cannot. The Nazis only took power in 1933 and by 1934 they already had enormous economic problems which ultimately forced them into war before they were ready. You want mass Nazi mobilization to an even more intensive degree, the most likely result is utter bankruptcy and war in 1936. Indeed the Germans only hung on until 1939 in large part because they stole all the Czech's gold after they seized everything in Germany.
You are wrong in your remarks. The major factor in the increase in war production between 1941 and 1944 was not looting of occupied territories (actually, the contribution of the occupied territories was much lower than their pre war industrial production levels), nor was the expansion of factory capacity, with did occur between 1938 and 1943, but was much smaller than the increase in total war production.

The major factor in the increase of war production between 1941 and 1944 was the natural process of industrial learning and adaptation from producing consumer goods to producing weapons and ammunition. The stock of industrial capital didn't increase significantly and neither the size of the industrial labor force, second to Wages of Destruction, page 442, Germany's industrial capital stock increased from 63 billion RM in 1941 to 68 billion in 1944. The size of the labor force employed in industry was constant at around 10-11 million, with the flux of recruits being compensated by the flux of foreign labor. While the labor force involved in production for the armed forces increased from 5.5 million in 1940 to 6.6 million in 1943. However, armament production increased 200% between mid 1941 and mid 1944.

Clearly, the main driver in the increase of war production was not the increase in the size of industrial labor force, nor the increase in capital stock, but it was the increase in total factor productivity, with is expected. For example, the average number of hours worked to make a single Me-109 frame decreased greatly, second to Wages of Destruction, page 583, from January 1940 to April 1944, the number of hours needed to make an me 109 airframe decreased from 5,500 hours to 2,000 hours.

This process of learning can begin earlier by mobilizing the industry before the start of the war. However, as I already said, it won't be politically possible, since it would imply in a reduction of consumption. However, the foreign exchange problem is not directly caused by war mobilization, but by political measures involving the maintenance of out of equilibrium exchange rates.

However, the expansion of military expenditures and the simultaneous expansion of domestic consumption would involve the more intensive utilization of existing factors of production and the existence of increasing deficits in the commercial balance (since domestic absorption would exceed domestic production), with would imply in tendency for deficits in the balance of payments. The correction of these deficits would involve the devaluation of the national currency, with would reduce national purchasing power in the international markets, would would imply in a reduction of national consumption. This wasn't politically possible.
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

The basic thesis of Overton in "Why the Allies Won" (at least with regards to industrial mobilization) is that Germany never whole-heartedly believed in truly "industrial" war production. They may have believed in total war, and they may have devoted huge funds to the war effort, but they never truly understood the importance of "War of Material" like the Americans did.

While a large portion of the German economy was co-opted to serve the military (and having more steel poduction than the Russians), it wasn't until the time of Speer that they began mass-producing weapons. Instead, the military tended to ask for limited batches of highly specialized and custom kit.

Thus, rather than relying on true factory production, the German military tended to rely more on "craftsmen" - much like a medieval Knight asking a favored smith to make a sword for him.

The result of this policy was massive waste and confused priorities. For instance, there were dozens of factories making airplanes for the Luftwaffe until Speer took over, at which point they went down to 7 main factories producing only several standardized types. At that point, airplane production soared, until the bombing began and wrecked German airplane production for good.

Similarly, massive factories like the Opel car plant were largely ignored and marginalized by the German military. Despite its potential to produce thousands of trucks or even tanks, the plant was designated to build only stoves for infantry soldiers, as the military was said to distrust any mass-produced warmachine built by a subsidiary of Ford.

In contrast, the American car factories built a mere 160 civilian cars during the war. In less than a year, they were converted from making cars to making guns, ammunition, and tanks. And that's just the existing plants - it doesn't yet count the triumphant feats of American production like Willow Run, which produced a four-engine bomber at the mind-bogging pace of one every 63 minutes, or the Liberty Ship Program which average one ship every two weeks.

In short, German war production never soared because they didn't believe that complex weapons like tanks or airplanes could be mass-produced. Instead, they poured skilled labor into making highly complex machines at a snail's pace. The Americans, by contrast, were so desperate to overwhelm the Germans that they were willing to have a 160K-part airplane produced via assembly lines that could churn them out at one every hour.
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Re: WWII: Germany starts total war mobilization earlier

Post by Vejut »

I'm no expert, but Alan Tooze (who generally seems to be well thought of around here by the people that are) disagrees with that--important points in "Wages of Destruction" are that the Nazis were very interested in mass production. According to Tooze, having enough internal market to make that possible was one of Hitlers main justifications for the war. I'd say a better guess would be less "don't like mass production" and more "don't actually have the steel", and "haven't fully grasped and converted over to the new style", as I'd suspect going from batch to assembly line style work takes more than just rearranging the machines in the factory. Also, assembly of the V2 rocket, IIRC, was mass production style, and would seem to refute your theory.
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

Hitler was very interested in mass production. He advocated building the Beetle after all as "The People's Car". Speer was Hitler's pointman with regards to converting German industry over to mass production. The V2 started coming online when Speer was already appointed, and he did succeed in opening mass-production lines for a lot of stuff (i.e. tanks and planes).

However, the German General Staff (Overy is very specific) did not agree with Hitler, which is also a reason why they pressed for the complicated Panther against Hitler's wishes for a T-34 close copy. It wasn't until Speer's arrival that they were brought to heel.

Finally, Overy lists Soviet and Nazi steel production for 1941-43. While I don't have the book or recall the exact figures, the German production was much higher. So lack of steel wasn't the issue.
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Re: WWII: Germany starts total war mobilization earlier

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^Stas Bush already produced the numbers in an earlier thread:
Main Industrial Output Gauges:

1940, Coal:
Germany [pre-war borders] 233,7 million ton
Annexed Reich regions 34,0 million ton
European Axis (Nazi satellites and occupied nations) 96,9 million ton
Total for the European Axis, including imports 364,6 million ton

USSR 165 million ton

Reich [Germany+Austria] to USSR ratio, coal production, 1940: 1,62
European Axis to USSR ratio, coal production, 1940: 2,21

1941, Coal:
Germany [pre-war borders] 239,5 million ton
Annexed Reich regions 76,0 million ton
European Axis (Nazi satellites and occupied nations) 87,3 million ton
Total for the European Axis, including imports 404,3 million ton

USSR 151,4 million ton

Reich [Germany+Austria] to USSR ratio, coal production, 1940: 2,08
European Axis to USSR ratio, coal production, 1940: 2,67

(Addendum - in 1942 coal production in the USSR: 75,5 million ton)

Steel, 1940
Reich alone [Germany+Austria]: 31,8 million tons
USSR: 18,3 million tons

(in 1941-1942 production in the USSR plummeted to 8,5 million tons and steadily was around 8-11 million tons during following years, and until the very end of the war, the USSR did not overcome the Reich in steel production)

Electricity, 1940
Reich [Germany+Austria], 77 billion kwt-h
USSR: 48,3 billion kwt-h

In 1942, the USSR made 29,1 billion kwt-h, in 1942 - 32,3 billion, and in 1944 - 39 billion. Meanwhile Germany in pre-war borders produced 46,5 billion in 1942, 47,4 billion in 1943 and 49 billion in 1944 (approximately) before collapsing in late 1944-1945.

Pig Iron, 1941
Germany: 37,9 million ton
USSR: 14,9 million ton

Oil, 1940
USSR: 31 million ton (1941: 33 million)
Germany [w/imports and captured holds]: ~19,5 million tons
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

Highlighting steel:

Steel, 1940
Reich alone [Germany+Austria]: 31,8 million tons
USSR: 18,3 million tons

Yeah, the Nazis had about twice as much steel in 1940.
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Re: WWII: Germany starts total war mobilization earlier

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PainRack wrote:Are you suggesting that some of the late war exploits by Model, with regards to pocket defence was actually fundamentally flawed?
What exploits? The areas he commanded moved west just like everyone else's.
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Re: WWII: Germany starts total war mobilization earlier

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Zinegata wrote:Hitler was very interested in mass production. He advocated building the Beetle after all as "The People's Car". Speer was Hitler's pointman with regards to converting German industry over to mass production. The V2 started coming online when Speer was already appointed, and he did succeed in opening mass-production lines for a lot of stuff (i.e. tanks and planes). However, the German General Staff (Overy is very specific) did not agree with Hitler, which is also a reason why they pressed for the complicated Panther against Hitler's wishes for a T-34 close copy. It wasn't until Speer's arrival that they were brought to heel. Finally, Overy lists Soviet and Nazi steel production for 1941-43. While I don't have the book or recall the exact figures, the German production was much higher. So lack of steel wasn't the issue.
I think the problem is that people use the term "mass production" very loosely. Production runs through the following steps.

1) Individual Production. Each worker produces the finished item from start to completion, making all the components needed in turn.

2) Distributed Production. A given worker specializes in producing a specific part. These are then delivered to a central assembly area. The final assembly workers stand at a production line and each unit is brought to them. They then fit a specific part to the production item from a bucket of parts beside them. They try different parts, eventually finding one that fits best. At the end of teh day, all teh leftover parts are sent to a specialist workshop where as many of them as possible are assembled into working units (and lord help anybody who gets one). This was the kind of "mass production" used most places in WW2. Good example; magazines for automatic weapons. If a soldier wanted a new magazine, he would go to a pile of them, try them in his weapon until he found one that fitted or needed a minimum of filing down to fit. That's the real reason why the Garand and SKS had fixed magazines.

3) Mass production. The worker stands by the line and the item is brought to him. He has one (1) part for that assembly and when he installs it, the part fits. If it does not, the part is marked with a big red X and the assembly is rejected. Quality Control personnel then inspect both part and assembly and find out why they didn't fit. Whoever is responsible gets fired. Aftera while, the number of rejects falls to a very low level. Also, using the example above, any magazine designed for a specific type of weapon fits any weapon of that type. This is the kind of mass production used in American factories in WW2.

The above was very apparent when the T34 and M4 were run side-by-side. When they broke down, an M4 crew got the spare part, installed it (it would fit) and off they would go. The T34 crew would geta pile of parts, root through them until they found one that was almost right and file away at it until it fitted. Then, install it and off they would go.
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Re: WWII: Germany starts total war mobilization earlier

Post by Simon_Jester »

Thank you, Stuart. That explains much from my point of view, since I just had to do "file to fit" on a custom-made scientific instrument when one of the parts didn't fit without forcing. Imagining the same frustration on a continent-wide scale, with individual soldiers having to do this for submachine gun magazines...

Yes, now I think I understand why the Germans had so much trouble turning out weapons in mass quantities... and why the Soviets had trouble turning out such weapons at high quality, and in mass quantities.

[That said, it is to the credit of the machine shop responsible that everything else seems to fit together quite admirably]
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

Overy claims that the General Staff very much supported individual production ("craftmanship") over mass production ("assembly line"). Hitler preferred mass production, and it wasn't until Speer that he got his way.

Then the bombing began and ruined all of Speer's plans at rationalization.

Note though, that German individual production nonetheless produced weapons of extremely high quality. Overy claims a common theme in American and Soviet reports on enemy weapons is the astonishing level of quality and finish on the German weapons.
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Re: WWII: Germany starts total war mobilization earlier

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Zinegata wrote: Note though, that German individual production nonetheless produced weapons of extremely high quality. Overy claims a common theme in American and Soviet reports on enemy weapons is the astonishing level of quality and finish on the German weapons.
Oh, I can confirm that. I've got an 1895 Chilean Mauser that is a superb piece of engineering; its bolt and trigger are as smooth as silk and it groups so tightly it's hard to believe how many bullets hit the target. That's a weapon that is as good today as it was when it was made 115 years ago. Then they gave it to a rifleman whose average lifespan on a battlefield was seven minutes. . . . . . . . . .

The very high finish etc of German weaponry isn't a compliment. It's sad testimony to a nation that doesn't have its priorities right.
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

Yeah. Ironically, the most feared infantry weapon of the German military (The MG-42) was a child of the assembly line, as well as the German SMG.

That the rest of their stuff (especially their tanks) was assembled in a more archaic fashion helped doom them despite producing nearly twice as much steel as the Soviet Union.
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Re: WWII: Germany starts total war mobilization earlier

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Stuart wrote:
Zinegata wrote: Note though, that German individual production nonetheless produced weapons of extremely high quality. Overy claims a common theme in American and Soviet reports on enemy weapons is the astonishing level of quality and finish on the German weapons.
Oh, I can confirm that. I've got an 1895 Chilean Mauser that is a superb piece of engineering; its bolt and trigger are as smooth as silk and it groups so tightly it's hard to believe how many bullets hit the target. That's a weapon that is as good today as it was when it was made 115 years ago. Then they gave it to a rifleman whose average lifespan on a battlefield was seven minutes. . . . . . . . . .

The very high finish etc of German weaponry isn't a compliment. It's sad testimony to a nation that doesn't have its priorities right.
I am not really sure how much of that could be changed, even if there was enough willpower to do so. Especially considering that by the time Germany was free to rearm at will (I think the British kept a close watch before the start of the war on the armament industry) war was already happening, so they needed the open production lines.

IIRC retooling a line takes six months or so, which would mean the only time this could have been done was after the fall of france, but by then they were already building stockpiles for Barbarossa....
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Re: WWII: Germany starts total war mobilization earlier

Post by Stuart »

There is a lot the German Army could have discarded. For example, the kar98k is still a massively over engineered weapon. Production standards could be radically lowered and the weapon could be simplified without a complete reconstruction of the production line. Yet, for all that, it's still an example of distributed rather than true mass production. Simple example, if one needs a new magazine bottom plate, it's necessary to get one, file it until it fits and then get it blued. A "standard" bottom plate almost certainly will not fit first time. It's interesting to compare the late-war kar98k with a Japanese Type 99. The T99 started off absurdly over-complicated (the thing even has a built-in monopod and an anti-aircraft sight - no, I am not kidding) yet by the end of the war it had been dramatically simplified. So much so that there is a big question mark against the wisdom of firing it. After all, it was intended to be given to a Japanese soldier who would be dead very shortly anyway. A 1944 or 1945 kar98k is simplified certainly but to nowhere near the same extent. A little polishing and they're the same as a 1936 rifle.
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Re: WWII: Germany starts total war mobilization earlier

Post by Simon_Jester »

There would seem to be two separate problems here.

One is distributed production (which slows assembly, and is a problem on the user end because parts for the weapons are only almost interchangeable). The other is over-engineering, which I presume means that each weapon takes too many tool operations and too many time and labor-consuming steps to make.

Stuart, your contention would appear to be that German weapons were both over-engineered and subject to the drawbacks of distributed production. But solving the one problem would not necessarily solve the other, as far as I can tell: making Mauser 98k rifles on a true assembly line would not eliminate the problem of them being over-engineered, and simplifying the rifle's design (what form would that take?) would not eliminate the problem of having to file the magazines to fit.
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Re: WWII: Germany starts total war mobilization earlier

Post by erik_t »

I suspect there is some crossover.

Consider an access panel on a vehicle. A very simple approach might be to have a planar square hole covered by a planar square panel, with four identical screw holes. The panel might overlap the surrounding structure when closed, instead of being countersunk into it. Likewise the screws that will hold the panel to the structure will stand proud instead of being countersunk. Such a panel would have nine fine-tolerance dimensions (that is, those whose inaccuracy would lead to a nonfunctional part): four screw hole diameters (pretty easy to nail that one), three distances between one hole and the other three, and the two angles between these lines. The orientation of the screw-hole mapping onto the panel itself would only need to be approximately correct; likewise the size of the panel itself. The panel being 1/16" too wide, say, would not cause the panel to fail to fit the first time.

Consider the alternate extreme - counter-sunk, complex-curved, lots of fastener holes (also counter-sunk, and of varying sizes), complex projected shape. Defining the important tolerances of this panel would require an order of magnitude more work than the simple type, perhaps much more. It will require some similar increase in number of important forming and machining operations in order to physically impose these tolerances.

Which is the right design choice varies by application (the former might be suitable for a jeep but not for a high-mach interceptor). However, if we assume an approximately equal chance of serious error in any given operation, we might see that the square panels will tend to be interchangeable at a much higher rate than the complex ones, regardless of the organization of production. In fact it will probably be a stronger relation than this, as complex operations will tend to fail more often. Buildups of slight off-nominal dimensions will also be a more serious issue for longer chains of operations.
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Re: WWII: Germany starts total war mobilization earlier

Post by Stuart »

Simon_Jester wrote:There would seem to be two separate problems here. One is distributed production (which slows assembly, and is a problem on the user end because parts for the weapons are only almost interchangeable). The other is over-engineering, which I presume means that each weapon takes too many tool operations and too many time and labor-consuming steps to make.

Stuart, your contention would appear to be that German weapons were both over-engineered and subject to the drawbacks of distributed production. But solving the one problem would not necessarily solve the other, as far as I can tell: making Mauser 98k rifles on a true assembly line would not eliminate the problem of them being over-engineered, and simplifying the rifle's design (what form would that take?) would not eliminate the problem of having to file the magazines to fit.
To some extent this is true; over-engineering is a traditional German design characteristic. After all their engineers have a basic operating principle "never use one ton of large parts where 26 tons of small ones will do almost as good a job". German design art seems to rotate around complexity for the sake of complexity. In some areas (like machine tools) this actually works; in most others it does not. Take a P-38 and a Tokarev TT-33, dismantle them and pile the pieces up in front of you. It's awe-inspiring just how much simpler and better the Tokarev is. Do the same with an MP-40 and a PPSH and awe-inspiring becomes war-winning.

However, shifting to a true mass production base has subtle effects that are felt far beyond the interchangeability of parts. Once one accepts that if a part is not made properly, it will be thrown back at the maker with considerable force, quality control becomes much easier. To work the "part will fit - or else" methodology, the components have to be made with very tight tolerances. If manufacturing tolerances are too large, then we return to the "find a part that nearly fits and then file to match" principle. So, true mass production means very tight tolerances. Now, this also means that more complex designs can be accepted and produced. Here we have the Garand being issued across the board in the US Army in WW2, something no other army managed to do.

So, true mass production was something that affected both the kind of product that was being produced and the quality of the product (for example Packard actually got better tolerances on their Merlin engines using unskilled labor than Rolls Royce did using highly skilled traditional craftsmen). This is something traditionalists never got (and still don't). Properly done, true mass production improves quality, not lowers it.

True mass production doesn't eliminate the over-engineering problem. Any poor sap who's bought a BMW, Mercedes or Audi can confirm that. So, the comment about the finish of German weapons really isn't relevent. All it meant was that the weapon made a much better souvenir when pulled out from under the body of its previous owner. However, true mass production is much more beneficial when applied to well-engineered designs.
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Re: WWII: Germany starts total war mobilization earlier

Post by erik_t »

My QC experience (turbine engine parts), somewhat to the contrary*, was that a straight go/no-go checksheet was beneficial in that workers had no real compunction about tossing a part aside if it didn't make the grade. Waste-not-want-not is a fine attitude to have if you slightly boogered up your last 2x4 and you don't want to swing by Home Depot to pick up another, but it's inefficient from a man-hours point of view in production. And you get an inferior product. Accepting some loss of material up front definitely pays dividends.


* I certainly never got a "omg tolerances are tight so we have to make all the parts perfectly or the supervisor is going to beat us!!!1" feeling on the production floor. I am not sure to what degree, if at all, this is what you meant.
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Re: WWII: Germany starts total war mobilization earlier

Post by Simon_Jester »

erik_t wrote:I suspect there is some crossover.

Consider an access panel on a vehicle. A very simple approach might be to have a planar square hole covered by a planar square panel, with four identical screw holes. The panel might overlap the surrounding structure when closed, instead of being countersunk into it. Likewise the screws that will hold the panel to the structure will stand proud instead of being countersunk...

Consider the alternate extreme - counter-sunk, complex-curved, lots of fastener holes (also counter-sunk, and of varying sizes), complex projected shape. Defining the important tolerances of this panel would require an order of magnitude more work than the simple type, perhaps much more. It will require some similar increase in number of important forming and machining operations in order to physically impose these tolerances.
This is more or less what I was getting at with:

"The other is over-engineering, which I presume means that each weapon takes too many tool operations and too many time and labor-consuming steps to make."

That's the obvious flaw with using an elaborately countersunk access panel on a jeep (though not on a high-mach interceptor). It's also the obvious problem with using twenty-six tons of little fiddly parts in your tanks. You increase the number of machine operations required to fabricate all the parts for one unit. That also creates a secondary problem if you are using distributed production: you're outsourcing some percentage of those operations (one "file to fit" stage per fiddly little part) to the end user, who may be trying to do all this in the middle of a battle and cursing your name while he does the filing.

The same logic applies to Stuart's comparison between the MP-40 and the PPsh. Ivan the PPsh gunner and Hans the MP-40 gunner are both filing parts to fit; the difference is that Hans is doing more filing, on more parts, because his gun has more parts to begin with.

But that end-user difference is just the end-user's share of an increased labor burden all along the line; Hans spends twice as much time filing bits of his Schmeisser (actually not designed by Schmeisser) as Ivan spends on his PPsh... because the guys at the factory spent twice as much time making it as the guys who made Ivan's gun.

Whereas Roland the Thompson gunner spends no time filing to fit, because he's got the advantage of fully interchangeable parts for a gun made on a true assembly line. However, that doesn't mean the production burden of the M1928A1 that Roland uses is low (like the PPsh). Indeed, the high tolerances may actually make the number of man-hours (or tool-hours) needed to make the gun worse, as far as I can tell.

Yes, what Stuart says is true:
However, shifting to a true mass production base has subtle effects that are felt far beyond the interchangeability of parts. Once one accepts that if a part is not made properly, it will be thrown back at the maker with considerable force, quality control becomes much easier.
But that's only possible because of a virtuous-cycle phenomenon: your industry is capable of very high-tolerance work, therefore you do more of it, therefore you can produce fully interchangeable parts and do the final assembly on an assembly line, rather than using distributed production.

So he may be confusing cause and effect: you get higher tolerances on assembly line designs because it would be impossible to make the product on an assembly line if you didn't already have the capability for such high tolerances.

Thus, assuming for the sake of argument that Soviet factories used distributed production, for instance, I suspect that Stalin ordering them to go to mass assembly line production would NOT have helped. Because while the end products might have been made to higher tolerances that way, and while Ivan the PPsh gunner might no longer need to file his magazines to fit, the amount of extra labor required to attain those high tolerances would reduce the total supply of parts. They'd wind up losing the advantage they gained by having a simple design.
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Re: WWII: Germany starts total war mobilization earlier

Post by erik_t »

Well, not quite. Some percentage of any given part is going to interchange onto some percentage of end units, regardless of the complexity of the part. Less complexity, and less manufacturing operations, improves those percentages somewhat. That's what I mean by "some crossover".
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Re: WWII: Germany starts total war mobilization earlier

Post by Simon_Jester »

[reviews]

Ah, I see. OK, that makes sense. If each step in the machining process leaves the part out of "fully interchangeable" tolerance 1% of the time, and there are nine steps, your parts will be fully interchangeable 91% of the time- not stellar, but good enough that you will hardly ever be so unlucky as to find two or three spares in a row that don't fit.

If there are, say, thirty steps, full interchangeability only happens 74% of the time... not so good; at that point you're getting two or three non-interchangeable parts in a row often enough to become a real nuisance.
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Re: WWII: Germany starts total war mobilization earlier

Post by Zinegata »

Here's the thing though: The Soviet Union was able to simply their tank production despite the massive disruptions by the Nazi invasion. Overy cites that the T-34 needed about 30% less parts (figure may be wrong, I'm going from memory and the book is in the library) after about a year after moving to the Urals.

America likewise went from making automobiles to war planes and tanks in less than a year.

And on top of all that, Speer's appointment was almost immediately followed by a huge boost in production within a year.

Could the Germans have re-adjusted their production before Speers arrival to produce tanks in the tens of thousands as opposed to mere thousands? I suspect that they actually can - the will to convert was simply lacking.

Also, I suspect that while retooling does take a while, the later surge in output more than makes up for the time lost while retooling.
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Re: WWII: Germany starts total war mobilization earlier

Post by PeZook »

Zinegata wrote: Also, I suspect that while retooling does take a while, the later surge in output more than makes up for the time lost while retooling.
Not always. Some things you need a steady supply of, and disrupting production for six months means death. Are you going to tell Hans, who has to shoot at stubborn Frenchmen, "You will get that ammunition you need. In six months."?

In that context, delaying Barbarossa for six months may very well mean the difference between "We hit a partially deployed enemy army in the middle of a reorganization" and "We run straight into deployed and reorganized units ready for a fight."
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Re: WWII: Germany starts total war mobilization earlier

Post by Thanas »

PeZook wrote:In that context, delaying Barbarossa for six months may very well mean the difference between "We hit a partially deployed enemy army in the middle of a reorganization" and "We run straight into deployed and reorganized units ready for a fight."

You cannot delay Barbarossa for six months, because by then the weather will have made any advance impossible. So by the time your forces can move again, it will be close to a year.
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Re: WWII: Germany starts total war mobilization earlier

Post by Thanas »

Stuart wrote:You don;t understand what that means do you? This actually tells you something very different from what you expect. We know that the rail network behind the German lines in Russia was strained to its maximum. Any reputable book on logistics will tell you that.


Would taking Leningrad alleviate the problem? Because it seems to me that with the baltic ports in German hands, they would have an easier time supplying their forces, at least in the northern sector. Seems to me that this is the only way the Germans could somewhat influence their supply concerns.
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