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World Development, Vol. 23, No. 1, pp.

9-28, 1995
Pergamon Copyright8 1995 Elsevier Science Ltd
Printedin GreatBritain. All rirdrtsreserved
0305-750x/95%9.50 + 0.00
0305-750x(94)00110-3

Small Shoemakers and Fordist Giants:


Tale of a Supercluster

HUBERT SCHMlTZ*
Institute of Development Studies, University of Sussex, U.K.

Summary. -This paperinvestigatesa success storyfrom a country in crisis:the shoe industryof the Sinos
Valley in Brazil. The main questionis to what extent the industrialdistrictmodel capturesthe realityof the
Sinos Valley. In many ways it does. The sectoraland geographicalconcentrationof shoe manufactumrsis
formidable.Even more strikingis the depthof the local economy which includes almost the entirerangeof
supply industriesand producerservices. Collective action has also been significantin the development of
the cluster but has changed over time; initially it was based on a common socioculturalidentity, then it
crumbledand its recentreturnis based on an economic rationale.Where model and reality differ most is in
the strong presence of large firms. Most of these large firms, however, were small two decades ago. The
inclusion of export agents is crucial to uuderstandthe radical transformationof this industrial cluster in a
span of two decades.Indeed, some of the most interesting conclusions emerge t?om tracing changes over

1. INTRODUCTION inputs for the industry, markets its output or renders


special services.
This paper investigates a success story from a coun-
try in crisis. For Brazil, the 1980s were a “lost decade”
and the 1990s are not proving much better. Stagnation *This is the revised version of a paper which was tirst
and decline has not, however, affected all sectors; one presented at a workshop “Intra-fhm and Inter&m
of the exceptions is the country’s leather shoe industry Reorganization in Third World Manufacturing Industry”
held at the Instituteof Development Studies, Sussex, April
which has grown rapidly, primarily by exporting.
14-16, 1993. I received many helpful comments from the
During 197&90, Brazil raised its share of world participantsof this workshop. I am particularlygrateful for
leather shoe exports from 0.5 to 12.3%. This made it insightful suggestions from John Humphrey,Mick Moore,
the third largest exporter after Italy and South Korea Khalid Nadvi and Hermine Weijland. Tessa Peasgood and
(UNIDO, 1992). The yearly growth rate of exports SarahDibb-Fullerprovidedvaluable researchassistance.
(pairs of leather shoes) during these 20 years was The researchis based on secondary sources and on inter-
24.1%, higher than that of South Korea or Taiwan. views catried out in Brazil in late 1992. My thanks go to the
Brazil has, however, been less successful in exporting shoe marmfacturers of the Sinos Valley who gave generously
sports footwear. of their time. A numberof people helped me to get a grip on
the shoe industryin the courseof extensive discussions. 1 am
Within Brazil, the fastest growing shoe industry has
particularly grateful to Enio Klein, Superintendent of
been that of the southernmost state, Rio Grande do FBNAC; Lawrence Geller, President of the Exporters
Sul, most of it concentrated in the Sinos Valley. This Association; Edvino Schaeffer, Director of the Business
paper focuses on that Valley and asks what lessons for Association of Novo Hamburgo; my colleagues Roberto
industrial organization can be drawn from this success Ruas, Valmiria Piccinini and Acyr Seleme of the Federal
story. The above is a very open-ended question and University of Rio Grandedo Sul and Nery dos Santos of the
them are various ways one could set about the investi- Science Policy Research Unit at the University of Sussex.
gation. This paper addresses questions which arise out My collaboratorLuiza Bazan has helped me to understand
of the recent industrial district debate, which seems the social foundations of industrial growth in the Sinos
Valley. Finally, I wish to thank the Te&nological Cents of
particularly relevant because it deals with sectoral and
the Shoe and &ather Industry(CTCCA)in Novo Hamburg0
geographical concentrations of local firms. The Sinos for providing me with a base from which to work. The
Valley is an impressive concentration of local firms. It research is funded with a grant from the Overseas Deve-
includes over 400 shoe firms, most of them specializ- lopment Administration to the Institute of Development
ing in women’s shoes. Around these shoe producers a Studies, but the responsibility for everything said in this
range of other firms has emerged which produces paperis mine alone.

9
10 WORLDDEVELOPMENT

This paper is a case study of this industry and pur- differ on how far-reaching this change is and what
sues two questions: form it takes. In principle one can distinguish between
- To what extent does the industrial district model a large-firm and a small-firm variant of flexible
capture the reality of the Sines Valley? specialization. The former exists where large firms
- If it does not, where do they differ and why? decentralize internally and adopt new organizational
What other model of industrial organization cap- techniques. In the small-firm variant, flexible
tures what has occurred over the last 25 years? specialization results from the clustering of firms and
In attempting to answer these questions I draw on deep interfirm division of labor (Rasmussen Schmitz
published sources and on interviews carried out in the and Van Dijk, 1992). This is where the industrial
Sines Valley during November/December 1992.’ This districts fit into the wider debate.
was a first round of fieldwork in an ongoing project. While this debate has so far been concerned mainly
with the advanced countries, it has also influenced the
research agenda on less-developed countries (LDCs)
2. WHY STUDY INDUSTRIAL DISTRICTS? (Humphrey, 1993; Kaplinsky, 1991; Murray, 1992;
Nadvi and Schmitz, 1994; Schmitz, 1990, Tendler,
In recent years, industrial districts have attracted 1987). The industrial district experience seems of par-
attention, particularly in Europe, because of their ticular relevance to LDCs, since most European suc-
apparent success in achieving international competi- cess stories:
tiveness and attaining high employment standards - come from sectors in which LDCs are thought
(pyke and Sengenberger, 1992). The term “industrial to have a comparative advantage;
districts” goes back to Alfred Marshall (1920), who - are based on local tirms, mainly of small and
stressed the economies which arise from the “concen- medium size;
tration of specialized industries in particular locali- - and have occurred in regions which were
ties” (heading of Chapter X of the Principles of rooted in small-scale agriculture and industrialized
Economics). The term was reintroduced into the relatively late.
recent debate by the Italian economist, Becattini; he The European debate does not, however, provide a
tried to make sense of the successful performance of clear guide for the researcher on how to proceed. The
local firms in Tuscany, Emilia Romagna and nearby debate is conceptually muddled and has large empiri-
regions in what has come to be called the “Third cal gaps. For example, there are disputes over what
Italy.” Becattini went beyond Marshall’s economic constitutes an industrial district, how significant they
analysis, however, and stressed the need for an inter- are and whether they can maintain their success. In
disciplinary approach. He defined the industrial dis- other words, the reference point for this paper is in
trict as a “sociotenitorial entity which is characterized itself problematic (see Schmitz, 1994). The empirical
by the presence of both a community of people and a questions concerning the European experience cannot
population of firms” and he adds that “in the district, be resolved in this paper, but conceptual and method-
unlike in other environments.. .community and firms oligical issues will be addressed. In fact, the t(r)opical
tend to merge” (1990, p. 38). tale from Brazil which unfolds in the subsequent sec-
In the ensuing international debate, the stylized tions, demands that they be addressed.
model of the Third Italy has become the main refer-
ence point. The main components of this model are:
- geographical and sectoral concentration of 3. THE SINOS VALLEY -A SUPERCLUSTER?
fill-IX
- predominance of small- and medium-sized The purpose of this section is to introduce the
fklS reader to the Sinos Valley. This is done by giving an
- vertical disintegration (at the firm level) initial overview of which elements of the industrial
- cooperative competition district model are present in the Valley. Subsequent
- a sociocultural identity which facilitates trust sections explore each of the elements in detail.
- active self-help organization. For there to be an industrial district, the two most
One of the main purposes of this paper is to exam- basic prerequisites are sectoral and geographical con-
me whether these elements are present in the Sinos centration. A group of producers making the same or
Valley. similar things in close vicinity to each other brings, in
It is worth recalling that the industrial district expe- itself, few benefits. It lays, however, a basis for a num-
rience feeds into a wider debate concerned with a shift ber of subsequent developments-which may or may
in industrial organization in advanced countries. The not occur: the division of labor and specialization
main theme is the relative decline of Fordist mass pro- among firms; the provision of their specialized prod-
duction and the growth of activities based on less rigid ucts and services at short notice and great speed; the
and more adaptable structures, often referred to as emergence of suppliers who provide raw materials
flexible specialization (Piore and Sabel, 1984). Views and components; the growth of suppliers who provide
TALE OF A SUPERCLUSTER 11

Table 1. The Sines Valley footwear cluster-number ofjbns and workers in 1991

Activity Fiis Direct Jobs


Footwear industry 480 70,ooo
Service rendering industries - workshops 710 18,000
Tarming industry 135 22,000
Leather and footwearmachines industry 3,6@3
Componentsindustry 2: 28,000
Rubber industry 26 1,900
Leather articles industry 52 4,900
Export and forwarding agents 70 2,ooo
Others 80 3,ooo

Total 1.821 153.4ot-l

Source: ABAEX (1992). Projections on information from PEE, AICSUL, ACI-NH, SINLXMAQ,
SINBORSUL, Municipal Government of Novo Hamburgo.

new or second-hand machinery and spare parts; the tions. In addition, most of the machines to turn these
emergence of agents who sell to distant national and materials and components into shoes are made locally.
international markets; the growth of specialized pro- Roughly speaking, for every job in shoe manufactur-
ducer services in technical, financial and accounting ing them is a job in the local supply industry.
matters; and the formation of associations providing The extent and depth of this footwear cluster is
services and lobbying for its members. This is pre- underlined further by Table 2 which gives the number
cisely what occurred in the Sinos Valley. Table 1 of shoe producers and suppliers in all Brazilian states.
shows the dimensions and depth of the cluster. It shows that Rio Grande do Sul (where the Sinos
At the core of this district are close to 500 shoe Valley is located) has a high number of shoe producers
manufacturers. They farm out certain operations to and suppliers; in contrast to say Minas Gerais which
hundreds of small subcontractors whose exact number has a substantial shoe industry but a relatively weak
is hard to determine. But the outstanding feature of the local supply industry. The only other state which
Sinos Valley is that within a radius of 50 kilometers of comes close to Rio Grande do Sul (in having the whole
Novo Hamburgo, the economic center of the Valley, spectrum of local supply industries) is the state of S8o
most inputs are produced: uppers, soles, heels, insoles, Paul0 which specializes in men’s shoes (town of
insocks, shanks, glues, nails, eyelets, dyes, etc - all Franca) and children’s shoes (town of Birigtii). Here
of them made to many different technical specifica- one can make an initial connection between clustering

Table 2. Brazilian shoe manufacturers and suppliers, by state and subsector. 1991
State Shoe Tanning Machinery & Components Chemicals
industry industry Equipment
Amazonas 11 3 1
Bahia 56 17 1 3
Ceara 279 13 5
Espfrito Santo 55 3
Goias 203 25 10
Mato Grosso do Norm. 105 12 1
Mmas Gerais 1855 115 5 9 1
Paraiba 87 6 4
Parana 53 33 1 1 1
Pemambuco 40 15
Rio De Janeiro 217 12 2 11 5
Rio Grande do Norte 10 5
Rio Grande do Sul 1276 157 125 169 48
Santa Catarina 415 35 3 17 1
S%oPaul0 1070 135 45 148 46
Rest of Brazil (10 other state) 49 35

Total 5781 622 181 377 105

Source: CTCCA, Anubio da Indkstria National do Couro, Cal@os e Afins (Novo Hamburgo: CTCCA,
1991).
12 WORLD DEVELOPMENT

and competitiveness. Shoes are produced in many and 198Os, but in order to compete in the 1990s they
parts of Brazil (Table 2), but the capacity to export have had to reorganize their way of producing.
exists only in a few places, notably where the industry This industry can be used to tell many different sto-
has clustered and the cluster has depth. Rio Grande do ties of industrial organization depending on which
Sul accounts for about 30% of the total footwear pro- market segments are covered, which time periods are
duction of Brazil and over 80% of exports, Slo Paul0 included, and how many layers the researcher man-
accounting for most of the remaining exports ages to uncover. For example, behind the initial pic-
(ABAEX, 1992). ture of collective self-help (the above-mentioned asso-
The Sinos Valley also contains a wide range of spe- ciations are very active) there has been enormous
cialized producer services. Table 1 lists 70 export disunity in the industry, and if one digs further one
agents who fulfill more than a mere trading function. finds unexpected new signs of interfhm collaboration.
Examples of other producer services include: free- In short, there is no easy story to tell if it is to do jus-
lance designers, technical and financial consultants, tice to the entire Sines Valley. The organization of its
and specialized transport services. The industry is also shoe and allied industry does not fit neatly into the
served by two weekly papers (which specialize in the recent models. In many ways the Sinos Valley is a
shoe trade) and four bimonthly technical magazines supercluster, such is the depth of interfirm relation-
(of good quality and in competition with each other). ships and density of information flows. Simul-
These publications are for the shoe and leather trade taneously one finds Fordist mass production.
nationally but are produced in the Sinos Valley, The following two sections seek to explain how and
adding to the enormous concentration of specialized why this has occurred. Section 4 shows how a small
know-how. firm cluster became increasingly heterogeneous by
Thus, it is hardly surprising that the diffusion of tracing the changes in the size structure of the shoe
information and ideas in the Valley is rapid and dense. industry from the late 1960s to today. Section 5
Klein (1991) emphasizes that it occurs not only in explores why the industrial structure became rather
business transactions, but also at social gatherings of different from what the industrial district model would
friends, family, sports club, neighborhood or church. lead us to expect.
The diffusion reaches its peaks during the biannual
shoe fairs which are organized by FENAC (elaborated
below). None of this is to suggest that all infotmation 4. SIZE STRUCTUBE OF THE SHOE INDUSTRY
is shared, but clearly in such a cluster secrets are hard
to keep. While sometimes a problem for individual One of the key features of the industrial district
firms, it tends to benefit the collective performance. model is that the firms in it are of small or medium
To complete the picture, mention should be made size. In contrast, the shoe industry of the Valley com-
of the institutions which have emerged with this prises firms of all sizes, including very large ones. The
industry. There are three centers which provide spe-
cialized training and technical services for the shoe
Table 3. Size structure of the shoe industry of the Sinos
and leather industry; there are six specialized indus- Valley, 197143
trial associations and two professional associations.
All this suggests a sense of cooperation and a collec- Firm size according to No. of Fis
no. of workers 1971 1983
tive approach to common problems. Add to this the
fact that, in 1991, the Sinos Valley managed to export l-10 150 89
70% of its output in a highly competitive international 11-50 154 92
market, that is, almost 100 million pairs of shoes 51-100 82 65
exported or nearly US $900 million in foreign sales
101-500 64
(ABAEX, 1992).
101-600 138
It would not be difficult to piece together a picture
of an industrial district which outshines most of its 501- l,ooo 4
European counterparts. Since industrial districts are a 601 - 1.100 16
cornerstone of the paradigm of flexible specialization,
does the Sinos Valley experience point to the demise 1,001 + 1
of Fordist mass production? Far from it. In the midst 1,101 + 17
of this thriving Valley there are Fordist giants; these
are factories of over 2,000 workers (huge for an indus- Total 455 417
try in which scale economies are low2). These workers
Sources: ACI, Produpio de Calgados no Sul, Censo da
are organized along conveyors, engaged in highly Indtitria de Calpdos do Vale do Rio abs Sinos (NOVO
fragmented repetitive work, making large volumes of Hamburgo: Associac%o Comercial e Industrial, 1971). ACI,
standardized ,products. Such large factories account Censo do Calcaab, Thirteenth issue (NOVO Hamburgo:
for a good part of the growth in exports in the 1970s Associacao Comer&l e Industrial, 1983).
TALE OF A SUPERCLUSTER 13

Table 4. Size structure of the shoe industry of Rio Grande do Sul, 1991
Firm size according to No. of Firn~s No. of Firms No. of Fiis
no. of workers (Source 1) (Source2) (Source3)
l- 19 54
20- 99 155 N/A N/A
loo-499 150
5c0+ 15

Total 434 1.276 4,909

Sources: 1. Enterpriseregister of the Federation of Industries of the State of Rio Graude do Sul
(FIERGS).Quotedfrom Russ Piccinini and Seleme (1992).
2. Compiledfrom CTCCA,Anudrio da Indibria National do Couro, CalGados e Ajins (Novo
Hamburg0 (see Table 2).
3. Superintendhcia da Administra@o Tributhria, Divisao de Estudos Economico-Fiscais.

firms which are large now, however, were small 25 The reality is probably halfway between the two
years ago.3 higher figures.4 To conclude, in parallel with the large-
In order to elaborate on the size structure of the and medium-sized firms there continues to be a size-
industry it is useful to go back to the years before the able segment of small firms.
export boom. In the late 1960s a well-developed clus-
ter already existed in the Sinos Valley producing
almost entirely for the internal market. During the 5. INDUSTRIAL ORGANIZATION IS SHAPED
1950s and 1960s this cluster had been able to grow and BY THE MARKET
increase its share of the internal market at the expense
of shoe producers in other parts of Brazil (Reis, forth- This section explains the reasons for the structural
coming). A survey carried out in the four most impor- changes noted above. The main theme of the section is
tant municipalities (Novo Hamburgo, Campo Born, that the way the cluster has developed and the way
Sapiranga and Sgo Leopoldo) listed 454 firms in 1968 production is organized has been shaped - above all
(ACI, Censo 1969). According to a respondent who -by markets and the way traders operate. The story
codirected this survey at the time, virtually all these to be told is, however, neither linear nor are the causal
firms were small, most very small. chains unidirectional.
Since then the size composition of the industry has
changed dramatically. Consistent time series are not
available for the last 25 years but one can piece (a) From small firm cluster to large exporter
together an overview of the main changes. Table 3
compares the years 1971 and 1983. Note in particular How did the Sinos Valley manage the transition
the increase in the number of firms with more than 500 from producing only for the internal market to being a
workers: from five in 1971 to 33 in 1983. The impor- major exporter, and how did industrial organization
tance of small firms certainly declined in relative develop in the process?
terms, but there are doubts about whether their number In order to understand the export growth it is impor-
decreased in absolute terms as suggested in Table 3. tant to recall that by the end of the 1960s a cluster of
Unfortunately there are no comparable data for the over 400 shoe firms already existed in the valley pro-
early 1990s. Data for the state of Rio Grande do Sul ducing entirely for the intemal market. Due to a policy
are however available for 1991 and the Sinos Valley of import substitution, this market was protected from
accounts for the bulk of the state’s shoe industry. imports but there was internal competition. During the
Therefore, Table 4 gives a good approximation of the 1950s and 1960s the shoe industry of the Sinos Valley
number of large- and medium-sized enterprises. had been able to grow and increase its share of the
Particularly striking is the substantial increase in the internal market at the expense of shoe producers in
number of large firms (over 500 workers). The number other parts of Brazil.
of small firms (209 firms with up to 100 workers) how- The sectoral and geographical concentration laid
ever is underestimated by a wide margin. It is hard to the basis for the subsequent export boom in two ways.
tell by how much. Table 4 includes three estimates of First, US shoe importers were looking for new shoe
the total number of shoe firms in the state of Rio suppliers in low-wage countries, which they visited at
Grande do Sul, ranging from 434 to 1,276 to 4,909. the time (1969-70). The Sinos Valley manufacturers
The discrepancy between these three sources (all were able to land their lirst contracts because importers
referring to 1991) is almost entirely about small firms. recognized the advantages of buying from an estab-
14 WORLDDEVELOPMENT

lished cluster which included some specialized local American market and the local producers came to be
input suppliers (interview with one of the first carried out by offices which the US retail chains set up
importers).5 Second, the local manufacturers did not in the Valley. Other intermediaries were independent
just passively wait for importers to come; they took agents; initially most of them were foreign, especially
collective action (discussed further in section 8). The American, but increasingly Brazilians were included.
national shoe fair, held in Novo Hamburgo, was pro- These export agents were not just buyers. In addi-
moted overseas: foreign buyers were invited to visit it; tion to negotiating with the US retail chains on the one
foreign journalists were invited - airfares paid - so hand and the Brazilian producers on the other they
that they could report on the fair and on the local shoe carried out the following functions: they studied the
industry. Advertisements to promote Brazilian shoes market which necessitated visiting shoe shops in the
were placed in foreign papers. Moreover, most impor- United States and Europe as well as international shoe
tant, a consortium of producers took their products to fairs. They developed models which required setting
the United States and Europe in search of export up model shops in the Valley to produce samples.
orders (Klein, 1991 and interview with the author). They inspected product quality and production sched-
All this was aided by export incentives newly intro- ules on site; they provided technical assistance; they
duced by the Brazilian government in 1969-70 organized the transport and payment arrangements.
(Lticke, 1990), but it was through collective action All this required building up substantial technical
that the local producers were among the first to avail departments for which they initially recruited experi-
themselves of the export incentives. In summary, enced personnel from the United States and Europe
clustering helped to build the economic and institu- but then pirated skilled workers from the local manu-
tional platform on which the subsequent export boom facturers.
was based. In spite of their developmental function the export
The local initiatives and central government incen- agents are controversial figures in the Valley. This is
tives led to quick results because export agents were for two reasons: first, it is widely known that a shoe
very effective in connecting the Brazilian producers with a factory gate price of, say, $10 sells for $40 in
with the US market. In that market a major change was the United States (price to the consumer). This gives
underway. In a nutshell, whereas in 1960 imports rise to a sentiment that profits in manufacturing are
accounted for 20% of US consumption, this rose to hard earned and profits in trading arc easy and exag-
80% in 1990 (Klein, 1991). This rise in imports geratedly high. In practice the agents earn a commis-
occurred in a relatively silent way because the US sion of about 10% (of factory gate price) from which
manufacturers themselves became importers. Their they have to pay their sales people and technical staff
detailed knowledge of the market and connections in the United States and Brazil (interviews with export
with the retailers facilitated the rapid rise in Brazilian agents). Second, before placing an order the export
exports. The retailers themselves were indifferent to agents often hold what amounts to an auction system:
where the shoes came from. a model of the shoe that they have managed to sell to
Thus, in a matter of a few years, a cluster of local the US retailer is given to various manufacturers who
producers, most of them small, was plugged into a dis- are invited to make a bid. Several manufacturers we
tant mass market. Without their collective strength spoke to complained that in awarding contracts agents
this connection would not have occurred. Once made, do not always reward quality and punctuality in previ-
it meant that a number of local producers evolved into ous contracts and care little about continuity. price is
mass producers. The effects on the cluster were two- all that matters. The response of the export agents was
fold. In an economic sense it was strengthened that they prefer to work with a small number of manu-
because the export growth increased the demand for facturers on a regular basis but are often forced to
local inputs and machinery, thus contributing to fur- invite bids from other producers because they them-
ther specialization and deepening of the cluster. In a selves face the jibes of the US shoe buyer: “If you as
political sense it was weakened: collective action my agent cannot obtain the goods for the price I expect
became more difficult because the sector became more then there are other agents who can. And if not from
differentiated, the sheer speed of growth weakened Brazil at my price, then from any of the other shoe
social ties among local producers (explained in sec- exporting countries” (interview).
tions 8 and 9) and because the initiative moved from Under this system the industry expanded rapidly
them to the new figure of the export agent. during the 1970s and the first half of the 1980s.
Product development and marketing was taken care of
by the export agents; they also enforced adherence to
(b) The role of export agents basic quality and delivery standards. Export manufac-
turers concentrated on increasing scale and competing
As stated above, initially the traders were ex-manu- on price. The factories expanded so fast that workers
facturers from the United States. This did not last. In had to be bussed in from outlying regions. Several
some cases, the role of intermediary between the manufacturers relocated their factories closer to where
TALEOFASUPERCLUSTER 15

the workers lived. Production was organized along starts with, say, 10,000 and then follows this up with
conveyors, work was fragmented, training times could additional orders of say 6,000 at a time. With luck the
be kept short and wages low (Ruas, 1989). Profits producer may wind up with the same sum total of
were reinvested for capacity expansion rather than 60,000. This is merely an example and in many cases
innovation. Fordism seemed to reign supreme in the the numbers of pairs per order are much smaller.
Valley. The fast growth of exports from the Sinos Thus Brazilian manufacturers have to adjust to
Valley during the 1970s and first half of the 1980s is three changes in the market: smaller orders, shorter
reflected in Figure 1. delivery times and higher quality requirements. The
consequences have been two-fold: first, a number of
large firms have gone out of business. According to
(c) The impact of recent changes in the market dos Santos (1992, p. 134), 12 of the 100 largest shoe
producers closed down during 1987-92. Second, large
Rapid export growth came to an abrupt end in the firms which continued production shifted their empha-
second half of the 1980~.~ The reason was increased sis from growth to internal reorganization. Production
competition from other countries with even lower departments the size of football fields are being broken
wages. The main threat came from China. Chinese down into mini-factories: most of these continue to be
exports to the United States squeezed Brazil out of the organized around conveyors but cellular manufactur-
American market for low-priced leather shoes (Ruas ing is beginning to be applied. The hiring and firing of
Piccinini and Seleme, 1992). labor is beginning to make way for investment in
As a result, Brazilian manufacturers are forced to human resources and reducing labor turnover. Wages,
move up market. This is not easy because in addition however, remain low (Piccinini, 1991a; Antunes and
to the threat from China and other exporting countries, Russ, 1992; and own interviews with manufacturers).
changes have occurred in the US market. Competition In parallel with such changes in production some
among American retailers concentrates increasingly large firms are also trying to modify their marketing.
on reducing the cost of inventory. This is beginning to The objective is to diversify and sell directly to the
have implications for the way shoe production is orga- European retailers. Some manufacturers do so suc-
nized in the Valley. cessfully, but most exports continue to be for the US
In the past Brazilian shoe exporters used to have market and are channelled through the export agents.
3-6 months of orders in hand, this is now reduced to In principle, the changes in the market, particularly
typically l-l.5 months (interview with export agents, in the smaller orders and shorter delivery times,
confirmed by manufacturers). In order to reduce the increase the viability of small firms. A survey of 50
cost of inventory the retailers buy little by little instead small firms, which I conducted in 1992-93, showed
of placing one bulk order. The trend is to buy closer to that a number had managed to secure export orders:
the point of sale. Take the example of 60,000 pairs per 25% of these firms were exporting 50-100% of their
model: in the past retailers used to place an order of output.
40,000 and then perhaps buy a further 20,000 over the The bulk of the small firms, however, continue to
season. Now the retailer may still want 60,000 but produce primarily for the internal market. There are
some large firms producing for the internal market
who do so quite successfully by establishing their own
retail stores and promoting their own brands. Unlike
the United States and several European countries,
however, Brazil has a very diffuse retail system; most
stores are independent and place their generally small
orders with an army of travelling salesmen who then
feed them back to the shoe manufacturers, most of
whom are small. The way the internal market operates
is relatively little understood but it seems safe to say
that the very diffuse marketing of shoes is essential to
understand the continuing existence of the large num-
ber of small shoe manufacturers. It is worth adding
1968 1970 1972 1974 1976 1978 W&l 1982 1984 I986
that the Brazilian retailers themselves are trying to
reduce the cost of inventory. Thus, in the internal
market there has also been a trend toward shorter
delivery times and smaller orders.
The Sinos Valley has gone through three phases: up
to the end of the 1960s it was a cluster of primarily
Figure 1. Sitw Valley: Shoes producedfor internal and
small firms, most still at an artisan stage. Then there
cvttwal mar-kets. 1968-87.
was a period of expansion, much of which occurred on
16 WORLD DEVELOPMENT

Fordist lines, sustained by exports of large volumes of changes in the market mentioned above, particularly
standardized low-priced shoes. More recently there smaller orders and faster responses.
has been a reorientation toward smaller production This scepticism is shared by Prochnik (1992) and
runs combined with shorter delivery times and more Ruas, Piccinini and Seleme (1992). Perhaps the clear-
emphasis on quality prompted by changes in both the est assessment comes from one of our respondents
external and internal market. The influence of these who was for many years an accountant in large shoe
changes will surface again in the course of the next firms and is now a small shoe manufacturer himself.
section which deals with the relationships between He stressed thatthe verticalization in the Sinos Valley
manufacturers and suppliers. is limited to about half a dozen very large firms. While
acknowledging that problems with the supply of
inputs had arisen, he felt that the main reason for their
6. VERTICAL DISINTEGRATION verticalization lay elsewhere: during the years of easy
growth their profits increased so fast that they did not
A key feature of the industrial district model is that know where to apply them, so some of the reinvest-
most firms specialize in particular stages of a produc- ment resulted in backward integration. He felt
tion process, hence the term “stage firms” (Brusco, strongly that vertical integration was not a dominant
1990). The purpose of this section is to explore tendency. This is confirmed by our discussions with
whether such vertical disintegration (at the firm level) other manufacturers.
is also prevalent in the Sinos Valley. Section 3, which The vast majority of shoe firms are not vertically
mentioned the many specialized input suppliers and integrated. Table 1 tends to confirm this high degree of
subcontractors seems to give an affirmative answer. interfirm division of labor. Note in particular the exis-
Then section 4 showed the emergence of very large tence of over 200 firms producing components for the
shoe manufacturers. Does this mean that these firms shoe industry. A comparable table is not available for
orchestrate the division of labor in this sector? The earlier decades but if one pieces together the informa-
short answer is as follows: some very large firms have tion from various oral and written sources (Klein,
integrated vertically in spite of a relatively well-devel- 1991; Carneiro, 1986) it becomes clear that the Sinos
oped supplier network. Thus, while still located in the Valley has been an agglomeration of specialists for
cluster they no longer need it, or certainly much less so several decades. If anything, the specialization and
than when they were smaller. The rest of the industry, inter&m division of labor have increased - notwith-
however, relies very much on complementarity for standing the vertical integration strategy pursued by a
buying components and services. Recently there have small number of very large firms.’ There are, however,
even been signs of a move toward further vertical dis- signs that the relationship between input suppliers and
integration and further deepening of interlirm division shoe manufacturers is beginning to change. Whereas
of labor. The remainder of this section explains these in the past conilict resulted in blame and the switching
trends in more detail. to different suppliers/customers there are now some
According to a study by Prochnik (1992) there has attempts to explore problems jointly. However timid,
been a tendency toward vertical integration. This con- they are steps toward collaborative manufacture and
clusion is based on interviews in large Brazilian shoe learning by interaction8
firms, most of which were located in the Sinos Valley. This section has focused so far on the supply of raw
In some cases these shoe manufacturers had added to materials and components from which shoes are
their operation a section which carried out the final made. Shoe production goes through various stages
processing of the leather. In other cases entire tanner- and the remainder of this section is concerned with
ies were acquired. Expansion into production of rub- these stages: to what extent are they carried out “in-
ber and plastic components also took place (confirmed house”; to what extent are they put out to specialized
in ongoing research by Nery dos Santos). “stage firms”; and, what kind of relationships exist
The reasons for this vertical integration are not between the “final firms” and “stage firms” (to use
entirely clear. There is mention of the need to have a Brusco’s, 1990 terms). Pursuing these questions
reliable supply of good quality inputs for large scale means taking a difficult path because many of the
production (Pro&n&, 1992). Elsewhere (Schmidt, stage firms are homeworkers whose numbers are hard
1989) the stress is more on the shoe manufacturers’ to quantify. A specialized study of this segment of the
need for leather with varied specifications and the industry is being undertaken by Azevedo (1993), but
inflexibility of large tanneries to supply them. Without for the time being our work has to rest on piecing
doubt difficulties with input supplies are real; they together information from a variety of sources. The
were mentioned to us by various shoe manufacturers following sets out what kinds of processes are
and frequently feature in reports and interviews in externalized, how common this practice is and what
technical magazines such as Tecnicouro or tendencies can be detected.
Laqamentos. One needs, however, to question the Shoe production consists of a number of discrete
wisdom of such vertical integration in view of the stages which, from a technical point of view, need not
TALE OF A SUPERCLUSTER 17

Finishing
Lasting
lnrole lining
Stamping
Heel covering
Sole lining
Sole cuuing
Upper stitching
Hand stitching
Weaving upper
Tresss
Uppcr plaiting
Uppcr cutting
Pattern grading
Pauem cutting

Percentage of respondents

Source: A rurvsy of 50 small fimu. conducted by Hubert Schmitz and Acy Sclomc

Figure 2. Externalization ofproduction tasks byfirms (percentage)

be caked out under one roof. Few shoe firms in the Firm-level observations confirm the extensive use
Sinos Valley carry out all stages in-house. Operations of subcontracting. It seems to be particularly common
which are farmed out fall into two categories: among small firms (according to my survey of small-
(a) Operations which require highly specialized scale shoe manufacturers, see Figure 2), but less so
equipment and/or skilled labor. Examples are the among the very large firms (according to ongoing
production of lasts, the creation of new models, or research by dos Santos). It should, however, be
the grading of patterns. The reason for externalizing pointed out that variations among enterprises are
such operations lies in the efficiency advantage of great, partly because they specialize in different types
the supplier; these are mostly but not always small of shoes and partly because they give different
firms. In some cases small shoe manufacturers buy emphases to control and flexibility. The former is
in the services provided by large firms, for example, easier in internal production, the latter is enhanced
for making lasts or insole printing. by subcontracting.
(b) Operations which are relatively simple and As regards trends, they cannot be established on the
labor intensive. Examples are the stitching of basis of available data, but some likely future changes
uppers, hand-weaving of uppers or the preparation can be mapped out: first, subcontracting will probably
of bottoms. By externalizing such work, shoe man- increase. We noted earlier that the size of orders and
ufacturers save on premises, sometimes on equip- the response times are shrinking, and the number and
ment and particularly on labor costs. The saving on types of models is increasing. This puts a premium on
labor costs is in the region of 20 to 30% (according flexibility and is likely to contribute to an increase in
to interviews with manufacturers). Piccinini subcontracting. Indeed, Prochnik (1992) concludes
(199lb) also emphasizes the flexibility advantage from his interviews in large firms that the practice of
of outwork. Virtually all such work is carried out by subcontracting will increase. My interviews with
small firms. When the work is entirely manual it is small manufacturers pointed in the same direction.
usually distributed to “self-employed,” mostly Second, the increase in quality requirements,
women working from their homes (for descriptions referred to earlier, could potentially pull practices in
see Azevedo, 1988; Costa, 1988; Ruas, 1993). the opposite direction9 Product quality is difficult to
It is hard to assess the quantitative significance of maintain or improve when several operations are con-
such contracting out, but some rough estimates can be tracted out. This is why some manufacturers are
made, taking the above categories (a) and (b) together. beginning to change their relationships with their sub-
One way of estimating the percentage of subcon- contractors from casual to more regular ones. This
tracted work is to return to Table 1 which lists 7 10 sub- emerges from case studies in firms which are of a
contractors employing 18,000 people, compared to the medium to large size and which are particularly con-
70,000 internal workers (same table). This gives a cerned with product quality due to the markets in
total of 88,000 workers engaged in shoe production, of which they operate .I0They provide training to their
which 20.5% are accounted for by the subcontracted subcontractors, they give advance notice if orders
workforce, based on 1991 data. A similar computation decline and seek to achieve reliable quality from their
on 1988 data (in ABAEX, 1989) would give 18.6%. subcontractors by investing in the relationship with
18 WORLD DEVELOPMENT

them. To be sure, there. is still a long way to go for this second-hand machinery in the Valley. Indeed, my sur-
practice to become mom common but the first indica- vey shows that most of the equipment in small firms is
tions of a qualitative change are visible. second (or third or fourth!) hand. Borrowing machin-
ery from other manufacturers is also frequent-a sign
of cooperation.
7. LOCAL RIVALRY To conclude, intense competition is an important
element of the industrial district model even though
The previous two sections dealt with vertical rela- the analysis of competition is overshadowed often by
tionships, that is from the shoe manufacturers forward the attention given to cooperation among producers.
to the buyers and backward to the suppliers. This and In the Sinos Valley, competition is fierce even though
the next section deal with horizontal relationships, that some market segmentation exists. There is intense
is among the shoe manufacturers. In the industrial dis- local rivalry which is likely to continue since entry
trict model the clustering enterprises both compete barriers am low and setting up a shoe business contin-
and cooperate, hence the notion of cooperative com- ues to be one of the main venues for pursuing status
petition. It means that competition does not exclude and income ambitions.
joint action for solving specific problems, for exam- Recently one of the main criticisms from within
ple, in precompetitive areas such as the provision of and outside the industry has been that too much effort
infrastructure, services or training. It is the coopera- goes into competition within the Valley and that not
tion element which has attracted most attention, that is enough attention is given to competition from abroad
associations, consortia and other self-help initiatives. (see, for example, Ruas Piccinini and Seleme 1992).
Their relevance in the growth of the Sinos Valley is The argument is that this requires collective action.
discussed in the next section. This section is con- This issue is pursued in the context of our next section
cerned with competition. which deals with self-help institutions.
The question of competition is easy to deal with.
There is no controversy about its existence; all our
interviews brought out that competition is fierce. 8. SELF-HELP INSTITUTIONS
Klein (1991) emphasizes that rivalry among local pro-
ducers has been one of the main reasons for the suc- As mentioned before, much of the industrial district
cess of the Sinos Valley. In making this argument he discussion has focused on cooperation among firms
follows Porter (1990) who suggests that what propels (see, for example, the title of Pyke Becattini and
firms into becoming competitive is not just competi- Sengenberger, 1990, Industrial Districts and Interfirm
tion per se but local rivalry. This point is illustrated Cooperation in Italy). Cooperation can take various
with the following story: an export agent invited bids forms and can have different degrees of intensity.
for a shoe to be produced for the US market. Frustrated Various distinctions can be made, a simple one would
that none of the bids was below $7 per shoe he pointed be between individual firms cooperating (lending each
out that Taiwanese producers could make it for $6. other equipment, sharing an order) and collective
The local manufacturers showed no reaction and the action. Both are considered important to the success
negotiations got stuck. When he mentioned that of clusters but the former is harder to trace. This sec-
another local producer was willing to make the shoe tion focuses on the latter, more precisely, on collective
for $6 a pair, however, the other local manufacturers action which is institutionalized in associations, ser-
became keenly interested and reentered the negotia- vice centers and the like.
tions. Self-help institutions have played a major role in
In the course of this competition, some enterprises the development of the Sinos Valley, but there is no
grow and others decline. Time series on birth or death simple tale to tell. A brief historical account is perhaps
rates of shoe enterprises in the Valley would be hard to the best way of cutting through contradictory develop-
construct but several respondents, with long experi- ments. As mentioned in previous sections, the 1970s
ence in the shoe trade, mentioned that there has always and first half of the 1980s were the years of fastest
been pressure from below: the stream of people trying growth primarily due to the increase in exports (see
to set up new enterprises has never dried up. Table 5). A number of factors contributed to this
Moreover, my survey on small firms shows that there growth, we mentioned the importance of (initially
are a significant number of new entrants into the sec- mainly foreign) export agents and government export
tor: 35% of firms in this representative sample are up incentives. What is rarely mentioned, except in Klein
to three years old. Clustering facilitates the setting up (1991), is that a number of local institutions were set
of new enterprises because as Marshall (1920) put it, up prior to this boom:
“the mysteries of the trade become no mysteries; but 1963 -The shoe fair organization FENAC.
are as it were in the air” (p. 225). Equally important, 1965 - The SENAI Tannery School.
the machinery required to start up production is rela- 1966 -The Technical School Liberato Salzano
tively easy to find. I counted more than 20 dealers of for chemistry and mechanics.
TALE OF A SURERCLUSTER 19

1968 -The SENAI School for Shoe Design and producing for the internal market. As a result, a num-
Manufacturing. ber of new associations were formed: the association
1972 - The Technological Centre for the Leather, of the tanning industries (AICSUL), the association of
Shoe and Related Industries - CTCCA. component producers (ASSINTECAL), the associa-
The setting up of these schools and centers in the tion of machinery suppliers for the leather and shoe
Sinos Valley owes much to collective campaigning industry (ABRAMEQ, initially SINDIMAQ/ABI-
and pressure from local producersrr The private sec- MAC), the association of export agents (ABAEX),
tor also played a major role in financing some of these and, above all, the association of shoe manufacturers
centers and in defining what they offer. In spite of var- (ABICALCADOS, initially ADICAL) which is
ious shortcomings, together they constitute a formida- essentially the club of the big shoe producers and
ble capacity to tram, research and advise. Establishing concerned primarily with enhancing their exports.
a direct connection between the work of these schools Membership of these associations is not restricted to
and the increase of exports would be difficult, but firms of the Sinos Valley (in some cases it extends to
there can be little doubt that together they enhanced the whole of Rio Grande do Sul or the entire country)
the capacity of local industry to respond to the new but all these associations have their seat in Novo
export opportunities. Hamburg0 and most members are local firm~.~~
A more direct connection between export growth Such splitting up into separate associations is a
and local institutions, especially self-help institutions, common occurrence (Moore and Hamalai, 1993) and
can be made when we turn our attention to FENAC. a “natural” outcome of differentiation in the economy.
The main purpose of this organization is to hold shoe The problems is that there ceased to be a political
fairs as well as components and machinery for the voice for industry of the Sinos Valley as a whole. The
shoe and leather complex. The initiative for this shoe associations were more concerned with defending the
fair came from the manufacturers; the municipality interests of their subsectors than with common prob-
provided the site and is today the main shareholder. In lems. This occurred partly because conflicts among
addition to holding fairs, FENAC played a major role the subsectors were real (particularly in the short run)
in the late 196Os/early 1970s in bringing foreign and partly because each association sought to project
buyers to the Sinos Valley and taking local manufac- itself.13
turers to fairs abroad, mentioned also in section 5(a). The lack of common purpose can be illustrated with
This was done in conjunction with the Business the fate of the shoe census. In 1969 the Business
Association of Novo Hamburg0 (ACI). The ability of Association of Novo Hamburg0 carried out a compre-
local producers to avail themselves of the federal hensive survey on production and sales of local shoe
export incentives was enhanced by the fact that firms. Subsequently this developed into an annual
FENAC and the Association had good access to the census of the shoe industry which was carried out
federal government in Bra&a; for some years their throughout the 1970s and most of the 1980s. It
officials occupied public office in the federal govem- included data on size of firms, raw materials used,
ment. In summary, self-help institutions played an types of shoes produced, main markets, employment,
important role in the early export success. etc, all made available at a relatively disaggregated
It is, however, important to note that the five insti- level. Since data collection and processing was an
tutions listed above would not have emerged without expensive operation and the information was of prac-
participation of the public sector. The sequence of tical value to shoe producers, suppliers and buyers, the
involvement, the organizational arrangements, the Business Association of Novo Hamburg0 sought to
contributions to installation and running costs of the share the costs with other new associations, but they
public and private sectors varied between the institu- refused. As a result, the production of the census
tions and over time. The critical point is that there was ground to a halt in 1987.r4This database which was a
a local developmental coalition across the public/ valuable resource for all, individual and collective
private sector divide, particularly in the transforming actors, collapsed. Today there is not even a reliable
period of the 1960s and early 1970s. register of enterprises.
This early phase of significant collective action and Since late 1991, there have been signs of new coop-
its institutionalization was followed by a phase of eration among the institutions. The six industry asso-
comparative disintegration and disunity from the mid- ciations and the Centre for Technology (CTCCA)
1970s to the late 1980s. Until the mid 1970s the formed a working group to discuss what key common
Business Association of Novo Hamburg0 (ACT) problems had emerged, what studies should be com-
embraced and represented the interests of all enter- missioned to understand them better, and how to coor-
prises in the Sines Valley. With the rise in shoe dinate lobbying.r5 Joint projects also include a data-
exports conflicts of interest also rose, shoe manufac- bank and the creation of a permanent forum in which
turers wanted easier access to inputs and equipment these institutions can work together. Even though
from abroad, while local suppliers were against it; and progress remains slow it signals new awareness of the
the needs of large shoe exporters differed from those need to cooperate.
20 WORLD DEVELOPMENT

Table 5. Membership and use of self-help imtitutiom according to size of&n (in 96)
Size of Firm Member of Contact with Contact with
Association(s) Technical Schools of Technology Centre
SENAI CTCCA
Less than 10 workers 0 7% 0
Between 10 and 50 workers 38% 10% 30%
Between 51 and 100 workers 67% 47% 42%
More than 100 workers 61% 100% 94%

Source: Survey of 50 firms with up to 100 workers conducted by Hubert Schmitz and Acyr Seleme in 1992/3.
Survey of 18 firms with more than 100 workersconductedby Roberto Ruas and Elaine Antunes in 1993.

The main reason for this change seems to be to disunity in the Sinos Valley and a neglect of com-
increased international competition. In particular the mon problems.
pressure to raise quality has forced the issue of co- - Small firms (of less than 50 workers) seem least
operation among suppliers, shoe manufacturers and to contribute to and least to draw on local self-help
export agents on the agenda. This is reinforced by the institutions.
federal government’s new “Quality and Productivity - The role of interfirm cooperation and local insti-
Programme” in which all the above-mentioned sec- tutions has changed over time. Collective action
toral and local institutions are expected to play a major played an important role prior and during the first
role (PBQP, 1991). years of export growth. Subsequently collective
In drawing conclusions on the role of local institu- action (for the Valley as a whole) declined. More
tions, it was shown that one needs to differentiate recently it has increased again in the face of stiffen-
between three different time periods. If one digs ing international competition.
deeper, one would also need to differentiate between Inter&m cooperation is also influenced by socio-
size of enterprise. Data for the most recent period cultural factors which are examined in the section that
show that support for and use of self-help institutions follows.
varies according to size of firm (see Table 5).
One would expect that self-help institutions are of
particular importance to small firms, yet the data show 9. SOCIOCULTURAL. IDENTITY AND TRUST
that membership in or contact with or use of these
organizations increases with firm size. It seems that A further element of the industrial district model is
firms of less than 50 workers contribute little and draw that the ties between actors are not purely economic:
little on local self-help institutions. The benefits which there exists a sociocultural identity which facilitates
they derive from clustering arise more from the prox- trust relations between firms and between employers
imity of specialized input suppliers and rarely result and workers.16 The economic importance of such ties
from joining collective efforts. It was probably differ- is easy to envisage; the industrial district is a system of
ent prior and during the first years of export growth production which consists of a multitude of formally
when size differentiation was limited and when most independent actors with a high density of transactions
of today’s large enterprises were still small. among them. For these to function smoothly and result
To conclude, self-help organizations are an impor- in cumulative (not merely one-off) gain, trust and
tant part of the industrial district model. The role such reciprocity are of great importance. They are also
institutions play in the Sinos Valley can be summed up essential for collective action.
as follows: In the Sinos Valley, there used to be a strong socio-
- The shoe manufacturers and supply industries cultural basis for such reciprocity. Most of the popula-
have given rise to an impressive range of local insti- tion was of German origin, descendants of people who
tutions: six industry associations, two professional emigrated during last century from a very poor region
associations, an organization which holds regular in Germany, the Hunsrtick, most had led a peasant
fairs and four centers which provide training and existence in Germany and continued to be peasants in
technical services (with varying combinations of Brazil. There was little entrepreneurial tradition in this
public and private sector finance). community but the life mode in the Sinos Valley was
- Duplication and overlap in the range of services one of self-employment rather than selling labor to
provided by these institutions are not necessarily a others (such as the owners of large cattle herds in other
problem. On the contrary, they induce competition parts of Rio Grande do Sul). Presumably this con-
and give local producers a choice of where to turn. pibuted to the strong sense of wanting to own one’s
- The differentiation of the industry and prolifer- own business which prevails in the Valley until today.
ation of collective actors has, however, contributed This drive for economic independence did not, how-
TALE OF A SUPERCLUSTER 21

ever, develop at the expense of communal ties. On the outside the factory and within the factory antagonism
contrary, a strong community spirit developed in the seemed to increase.l* More. recently however, some
region based on the common German heritage. employers began to see the importance of a more col-
Korzeniewicz (1990) links this so&cultural iden- laborative approach. The reason is economic. In order
tity to the economic success of the region.” According to achieve the increasingly high quality standards and
to one of his respondents: tight delivery schedules industrial relations need to
change. Not all employers recognize this and even
There is in the region a competitive spirit that is very fewer have changed their practices. But if one hears
healthy but at the same a gregarious spirit of unity and production managers in some firms say (with convic-
collaboration, perhaps because of the German &scent. tion) that labor is their greatest resource then - at
Community action is impressive,you can easily manage least in Brazil - this signals a qualitative change.
to get the participationand the supportof peoplefor com- To conclude, in the stylized model of the industrial
mon activities (Korzeniewicz,1990,p. 131). district, the cluster of firms and the local community
are inseparable. In addition, a common social identity
Such issues of the sociocultural foundation of eco- is thought to favor codes of behavior which induce
nomic competitiveness are hard to research. A collab- trust and cooperation. We found that in the Sines
orator, Luiza Bazan, is focusing on this very issue in a Valley such a so&cultural identity did indeed exist
case study of one of the municipalities of the Sinos and contributed to the emergence of the cluster. The
Valley. While this work is still to be written up, a speed of the export growth in the 1970s and 198Os,
review of the interview material permits some initial however, undermined the previously existing social
indications. In the Sines Valley non-economic ties fabric. The influence of so&cultural ties lessened.
between actors do seem to play a major role. Some Greed and the ambition to get rich fast squeezed out
have to do with ethnicity (being of German descent); community values. More recently there has been a
others with geography (being local) or kinship. The return to more cooperative relationships, but this has
existence of such ties exerts pressure to keep commit- little to do with sociocultural ties among actors. The
ments and to cooperate but their importance has new quality and delivery standards induce shoe manu-
changed over time. It seems useful to distinguish facturers to invest in their relationships with suppliers
between three phases: and workers. This investment is expected to engender
- First, the reciprocity and trust based on socio- commitment and trust.
cultural identity seemed to work well until the early
1970s. It underpinned the collective action which
led to the setting up of the shoe fair organization 10. IMPLICATIONS FOR LABOR
FENAC and the training and technology centers,
- Second, in subsequent years (most of the 1970s European industrial districts came to prominence in
and 1980s) so&cultural ties weakened and had less the 1980s for two reasons: the attainment of intema-
inRuence on inter&m relationships. This seems to tional competitiveness and of high labor standards
have been a result of the speed at which growth and (bke and Sengenberger, 1992). As regards the Sines
differentiation occurred and of the key role of out- Valley, there is little doubt about the competitiveness
siders, the export agents, in this growth process. of its shoe industry. But what has its economic growth
- Third, most recently there has been a return to a meant for labor? The record has been mized: employ-
greater spirit of cooperation, not because of socio- ment has increased but wages have remained low.
cultural ties but because of the economic cost of not According to the industrial census, employment in
cooperating. As mentioned earlier, there are indica- the shoe industry of the state of Rio Grande do Sul
tions of a qualitative change in the relationship increased from 27,000 in 1970 to 76,000 in 1980, an
between shoe manufacturers and their suppliers and increase of 280%. The results of the 1990 census are
new signs of collective action. not yet available, but data from the Federation of
The above refers to relationships between entre- Industries of Rio Grande do Sul indicate that employ-
preneurs. A similar phasing can be used to map the ment growth continued in the 1980s - even though at
changes in relationships between employers and a slower pace: approximately 80% over the decade.
workers. Until the early 1970s they belonged to and Some of this job growth took place outside the Sinos
felt part of the same community which induced coop- Valley, but it is within the Valley that indirect job cre-
eration in the workplace. These communities began to ation (in supplier industries and producer services) is
disintegrate with the fast growth of the industry, most highest. Even though there are problems with the
visibly so in Novo Hamburg0 but increasingly also in reliability of data and the comparability of different
the smaller towns of the Valley. Sociocultural ties sources, the increase in employment has been impres-
have not entirely disappeared, but even where they sive.
continue to exist a more stratified society has emerged. One might have expected that such substantial
Increasingly, class differences asserted themselves growth in the number of jobs would be accompanied
22 WORLD DEVELOPMENT

by rising wages. It was not. During 1970-80 average tutes the major difference to European experiences
wages in the shoe industry of Rio Grande do Sul from which the industrial district model was derived.
remained roughly at the same level (based on compu- It is the main reason for the high wages in the
tation of Industrial Census data). During 1980-90 European clusters and the low wages in this Brazilian
average wages seem to have fallen. Computation cluster.
based on data of the Federation of Industries Have these low wages helped the cluster to grow?
(FIERGS) suggests a decrease in the order of 40% for No doubt, low wages were essential when the industry
the state’s shoe industry (compared to a decrease for began to export. Whether the cluster benefited from
the state’s industry as a whole in the order of 25%). A stagnant or falling wages in subsequent years is more
computation based on data of the local shoe census questionable. One could argue that slowly rising
(ACI, various years) shows the same ttends for the two wages would have induced entrepreneurs to try earlier
decades: by 1980, the real average wage was at and harder to engage in the “new competition” (Best,
roughly the same level as in 1972; and by 1987 it was 1990), by adopting new organizational principles,
about 38% below that of 1980.19Firm-specific exam- investing in technology and in product development.23
ples suggest that the decrease was less, nearer 24% This is not a hypothesis which can be tested. It can be
during 1980-90.20 Tracing the evolution of real wages said, however, that for most of the 1970s and 1980s
over time is difficult when intlation is high and defla- there was mainly quantitative growth, that is, expan-
tors vary; the margins of error can be high. But for the sion of capacity to make low-priced, wage-sensitive
purposes of this paper a rough indication of trends is shoes. The cluster only changed gear and moved into
sufficient and the various sources consulted point qualitative growth when it was pushed from the out-
toward a decline in real wages over the 1980sz1 To side to do so.
give an idea of the absolute wage level: the bulk of the
workforce (approximately 80%) earns between one
and three minimum wages (based on management 11. CONCLUSIONS AND ISSUES FOR
interviews), that is between US $53 and $159 per FURTHER RESEARCH
month.22
Wages in the shoe industry are lower than those in The industrial district model was used as the main
most other industries in the state of Rio Grande do Sul reference point in this paper, but the wider debate on
(Piccinini, 1990). But family incomes in the Sinos flexible specialization was also addressed. This final
Valley are probably not quite so low. Frequently two section seeks to draw together the main conclusions
or more members of the family work in the shoe indus- for these debates and to highlight some issues for fur-
try which employs all age groups and both sexes. ther research.
According to the shoe census of 1987, 47% of the
workforce are women, and direct observation suggests
that the industry employs many teenagers. In addition (a) TheJexible specialization debate
there is a significant amount of domestic outwork,
which tends to be a source of complementary income. One of the main conclusions of this paper is that in
All this suggests that - at the family level -multiple many ways the Sinos Valley is a highly developed
sources of income are common and helps to explain industrial district. Yet it would be wrong to deduce
why poverty is not quite as stark, widespread and from this that the Sinos Valley is a show-case of flexi-
visible as the low wages would suggest. ble specialization. This twist in the story is hard to
Nevertheless, two and a half decades of extraordi- handle because industrial districts gained prominence
nary growth has been combined with falling real in the recent international debate as one of the main
wages. The immediate reason lies in the erosion of real variants of flexible specialization. As shown in the
wages by accelerating inflation. When inllation rates course of this paper, some Sinos Valley firms devel-
reach up to 30% per month, delays in raising the nom- oped into Fordist giants and integrated vertically. The
inal wage have a cumulative eroding effect on the real emergence of this unexpected hybrid gives rise to a
wage. The underlying reason for stagnant or falling more fundamental question. How useful is the juxta-
real wages lies in the labor surplus. In the early years position of flexible specialization and Fordist mass
of the export boom the shoe industry attracted production, which is the starting point of much of the
migrants from other parts of the state. In later years, recent debate on industrial organization? Should we
expansion took place mainly outside Novo dismiss it altogether?
Hamburgo, in municipalities of the Valley where If we take the longer view one can distinguish three
labor was more abundant. There were short periods phases: until the 1960s most of the Sinos Valley was a
when labor was scarce, particularly in the boom year cluster of craftsmen, with the exception of a few facto-
of 1984, but these were exceptions. The degree of ries. The main feature of the 1970s and 1980s was the
abundance/scarcity also varied with the occupational rise of Fordism even though small-scale production of
category. Overall, however, the labor surplus consti- varied products for regional markets in Brazil contin-
TALE OF A SUPERCLUSTER 23

ued. The 1990s promise to be the decade of flexible is a highly developed industrial district.
specialization in both its small and large-lirm variant. Some features, however, do not fit into this model.
Large firms are beginning to decentralize internally The remainder of this section examines these differ-
into mini plants, throwing out their conveyors, intro- ences. It also suggests that one needs to go beyond this
ducing cellular manufacturing and internal just-in- model to understand how and why a cluster of local
time, trying to stabilize their workforce, investing small shoemakers has become an internationally com-
more in training, and building more cooperative rela- petitive industrial complex. Thus, what follows con-
tionships with their suppliersU The improved quality tains both conclusions and suggestions for further
and delivery standards of suppliers also help the small research.
firms which are sometimes comparable in output to
the mini plants of large firms but tend to be more de- (i) Methodological and conceptual issues
verticalized. The scope for such small-firm production This paper proceeded by contrasting the industrial
is increasing in the 1990s due to smaller order size and district model with reality. There is an inherent danger
shorter delivery schedules. One can argue over the in this approach in that it can give rise to a static
advantages and disadvantages of the small and large- perspective. We sought to avoid this by tracing the
firm variant but few would deny that the market changes over time. This proved essential in that the fit
requites a change of industrial organization toward between elements of the industrial district model and
flexible specialization. This is far from being the reality in the Sinos Valley varied over time.
achieved, but first steps have been taken. Overall, it seems that the industrial district model was
In summary, a distinction between three phases, helpful in that it guided us to critical factors which
which are predominantly craft (up to the late 196Os), need to be investigated to explain the growth of the
Fordist (the 1970s and 1980s) and flexible specializa- shoe industry: the combination of competition and
tion (the 199Os), is plausible and has its uses if one is cooperation, collective action, social embeddedness,
confined to using a broad brush. The problem is that etc. Disaggregating the model into its components
some of the most interesting features of the Sinos provided a useful framework for organizing the
Valley escape a broad brush. To give just two exam- empirical investigation. Since this is a case study of a
ples: first, the large firms which are adopting new rapidly growing industry, however, two shortcomings
methods in order to become more flexible and raise of this model are also apparent: it emphasizes special-
quality do so only selectively.25 Second, Fordist ization, i.e. differentiation by product/process, but
expansion contributed significantly to the growth of ignores (negates?) differentiation by size; it is strong
the local supply industry and the proximity of the sup- on linkages internal to the cluster but weak on external
pliers enhances the prospects for flexible specializa- linkages.26
tion, particularly in its small-firm variant. This case Before elaborating, it is useful to recall that the
study suggests that more important than the bound- industrial district model is not an analytical model but
aries are the connections between Fordism and flexi- an ideal type or, less flatteringly, a list of stylized facts.
ble specialization. Why then has it attracted so much attention over
This is why the industrial district model was used as recent years? As indicated above, the reason is that
the main reference point. While feeding into the local industrial systems with such characteristics had a
debate on flexible specialization, in itself it is not favorable growth and employment record in the 1970s
based on a juxtaposition to Fordist mass production. and 1980s; at least this is what case studies from Italy,
Germany, Denmark, Spain and various other countries
suggested (Pyke and Sengenberger, 1992). Some of
(b) The industrial district debate these European success stories, however, seem to be
running into trouble. There is even a recent article
The primary question addressed in this paper con- entitled “Requiem on the Third Italy” (Bianchi, 1993)
cerned the extent to which the industrial district model but such judgement may well be premature.”
captures the reality of the Sinos Valley. In many ways Whatever the outcome, the case for examining
it does. The sectoral and geographical concentration industrial districts in LDCs cannot rest merely on how
of shoe manufacturers is formidable. Even more strik- they perform in Europe. It has to rest on an analytical
ing is the depth of the local economy which includes argument that this form of industrial organization
almost the entire range of supply industries and pro- offers a competitive advantage. The first to develop
ducer services. Such depth and density has given rise such an argument was Alfred Marshall. As mentioned
to the notion of the “supercluster.” Collective action in section 2, he stressed the economies which “can
has also been significant in the development of the often be secured by the concentration of many small
cluster but has changed over time; initially it was businesses of a similar character in particular locali-
based on a common so&cultural identity, then it ties” (1920, p. 221). He called them “external
crumbled and its recent return is based more on an economies” which arise incidentally with the increas-
economic rationale. In many respects the Sinos Valley ing division of labor between firms. The Sinos Valley
24 WORLD DEVELOPMENT

experience shows the importance of such external tends to bring about both differentiation in
economies, but also stresses the need to go beyond product/processes and in size. Equally, within clusters
Marshallian economics. In addition to the incidental there tend to be leaders and followers. An explicit
external economies it is necessary to capture the com- emphasis in further research on the leading firms may
petitive gains which arise from purposeful learning by contribute to an understanding how clusters develop
interaction (for example, between producer and user over time.
of components) and from collective action. In order to
bring out the various gains which am opened up by (iii) Internal and external linkages
clustering and which individual producers can ramly Once the analysis shifts from the static to the
attain, I have introduced elsewhere the concept of col- dynamic, it becomes necessary to include external
lective efficiency (Schmitz, 1992). But this was linkages. This needs emphasizing because the indus-
merely the first step in a conceptual struggle. The rea- trial district debate is primarily about linkages internal
son for raising such issues here is to indicate that the to the cluster (e.g. proximity between producers and
tools of analysis brought up in the industrial district users of components, cooperation between local firms,
debate remain blunt. In order to sharpen them it will the social embeddedness of economic transactions)
probably be useful to draw on other bodies of research and indeed has helped to focus on these in a fresh light.
such as theories of collective action, social network Understanding the internal organization of the cluster,
analysis or innovation studies which focus on learning however, does not suffice to understand its trajectory.
by interaction. The Sinos Valley experience shows this in a stark way.
One of the clearest lessons from this case study is that
(ii) Size differentiation traders need to be included in the research in order to
Where the industrial district model and reality dif- understand the manner and pace at which clusters
fered most was in the strong presence of large firms. develop.28
Indeed, the title of this paper seeks to capture the The paper showed that export agents played an
cohabitation of small shoemakers and Fordist giants. important role in enabling the cluster to export. There
As stressed above, however, the size structure is a tradition of viewing such intermediaries as
changed over time. The Valley used to have a predom- exploiters who accumulate at the expense of local pro-
inantly small firm economy and the subsequent rise of ducers. No doubt, export agencies in the Sinos Valley
large firms has passed its peak. Recent market changes were a lucrative business but interestingly they pro-
seem to favor small firms, but judging the outcome is vided not only a trading link but acted as development
not straightfotward and requites further research. In agents also. This was not an act of generosity but one
examining the differential impact of market changes of necessity. In order to sell Brazilian shoes abroad
on firm size it would probably be useful to distinguish they had to bring in new designs and assist firms in
between: reaching international quality and delivery stan-
- The ability to react: smaller batches and shorter dardsz9 The Sinos Valley, however, being now a
delivery times tend to favor small firms. Large firms relatively mature cluster, also shows the dangers of
need not become ailing dinosaurs, they can respond relying too much on export agents. Ongoing research
to these external changes by restructuring inter- by Nery dos Santos suggests that the manufacturers
nally, but small firms may well have an agility accommodated themselves to this division of labor
advantage. with the export agents and invested little in product
- The ability to be proactive: here the large firms development and marketing. This is probably one of
seem to have an advantage. A proactive strategy the main reasons why the Sinos Valley remains heav-
aimed at improvements in quality and innovation ily tied to the US market which still accounts for about
includes collaboration with suppliers. The problem 70% of exports, and inroads into the higher quality
of the small firm is that it has no clout vis-li-vissup- European market have increased only slowly. This
pliers and can rarely, if ever, initiate changes along gives rise to the more general question of whether
the value-added chain. The benefits from the efforts there can be sustained product and process innovation
made by large firms, however, in raising the quality within the cluster without somehow reducing this
and punctuality of their suppliers will - with time functional divide between manufacturers and export
- be reaped by the small shoe firms. agents.
While it is hard to predict the outcome of research Exploring such issues as the role of traders and their
which pursues these questions, it is probably safe to developmental impact at different stages of clustering
say that the Valley will not change back into a cluster ultimately requires comparative research. Fortunately,
of small firms, i.e. it will not become like the textbook there are case studies on the footwear industry in Italy,
model of industrial districts. The “problem” here lies Mexico (Rabellotti, 1993, and in this issue) and India
with the model rather than reality. The emphasis on (Knorringa, 1993) which - partly by design, partly
smallness of firms turns the model into a strait-jacket by accident - also focus on clustering. Like this
when one examines clusters which grow. Growth research, however, they are studies in progress and the
TALE OF A SUEERCLUSTER 25

comparative work remains to be done. the existence of self-help institutions. Would the
export growth have occurred without incentives?
(iv) The cupaciQ to respond Probably yes, but more s10wly.~
The main theme in these conclusions is that the fit The export incentives were gradually dismantled in
between the industrial district model and the reality of the early 198Os, seemingly without much negative
the Sinos Valley varied over time. The cluster changed effect on the industry’s competitive position in the
in response to the changes in the market. Indeed, this world. The difficulties in the second half of the 1980s
capacity to respond to opportunity and crisis is one of had more to do with the competition from China and
the most interesting features of this experience. To with the anti-intlation policy of the government. The
highlight this further it is worth adding a ,brief com- latter is the second set of macro policy interventions
ment on how this cluster responded to changes in which made its mark on the industry. In the course of
macroeconomic policy. various packages to control hyperinflation, the gov-
Elsewhere we have pointed out that the European ernment froze the exchange rate (or delayed devalua-
industrial district debate has little, if anything, to say tion) which drove exporters to despair (Klein, 1991).
on the role of the macro policy environment (Schmitz The differential effect of these stabilization policies
and Musyck, 1994). In Brazil, it would be foolish to (which failed in the end) on the various actors in the
ignore the effects of how federal government deter- Sinos Valley is a matter for further research. Overall,
mines the incentive structure of the economy. In the what is astounding is how comparatively well this
case of the Sinos Valley two sets of government inter- cluster has escaped the (continuing) macroeconomic
ventions stand out, one which favored export growth crisis.3r
and one which was detrimental. The paper mentioned This experience confirms an earlier hypothesis
the introduction of export incentives in the late 1960s. (Schmitz, 1990) that clustering increases the capacity
No doubt these contributed to export growth. But it to adapt, but the why and how require further study.
was also pointed out that the supply response of the Indeed, this is a priority issue for further research,
shoe manufacturers was greatly enhanced by cluster- because high uncertainty seems to be only certainty
ing. A comparative study of the performance of labor- for industry in the rest of the 199Os, not just in Brazil
intensive industries in Brazil tends to confirm this. but worldwide. High uncertainty means high risk. A
Liicke (1990) stresses that the footwear industry’s better understanding of how clustering helps local
exceptional response to export incentives and to exter- firms to cope with uncertainty and take risks would be
nal demand was due to favorable supply conditions in an important advance. 32For policy purposes, it would
the Sinos Valley. Most of the supply factors listed by be particularly important to know how local mstitu-
Lticke can be seen to result from clustering, notably tions influence perceptions of risk and investment
the concentration skills, the proximity of suppliers and decisions.

NOTES

1. The fieldwork includes a survey of 50 small tirms, car- 5. Local production of machinery for the shoe industry
ried out in conjunction with Acyr Seleme. The data have not only took off in the 197Os,but maintenance and repair work-
yet been fully analyzed but the impressions gamed during shops already existed. Most machinery firms started as main-
visits to these ftrms inform this paper. I also had the opportu- tenance workshops.
nity to visit medium- and large-sized firms and interview
managers or owners, but much of what is said in this paper 6. Data comparable to that used for Figure 1 are not avail-
about such firms is based on secondary sources. able. The “Shoe Census” ceased to be produced in 1987. For
details see section 8.
2. Some firms have over 3,000 workers but distributed over
several plants. 7. Their verticalixation never extended to all inputs and
their net effect has probably been one of increasing the inter-
3. In discussing the size structure and its changes over firm division of labor by increasing the demand for inputs
time the following terms are used: “very small” = firms up to and thus encouraging specialization., It is also worth men-
10 workers, “small” = 11-100 workers, “medium” = tioning that the Sinos Valley today is a net exporter of inputs
101-500 workers, “large” = 501-1,000, “very large” = more for the shoe industry-exporting to other parts of Brazil, but
than 1,000 workers. as yet little abroad.

4. The highest estimate is based on statistics provided by 8. Ongoing research by Nery dos Santos suggests that
the state’s treasury, which overestimate the real number of shoe firms pursue this especially with new suppliers special-
firms because those that go out of business are deleted with a izing in the finishing of leather and less so with old large tan-
lag whereas new start-up firms are included immediately. neries. A large shoe firm, which Luixa Baxan and I investi-
gated in some depth, had embarked on a collaborative
26 WORLD DEVELOPMENT

strategy with 60 suppliers of raw materials and components; 21. IamgrstefultoLuizaBazanforworkingoutdttailed


the case material shows that progress is uneven and that time series on employment and wages, based on various
many obstacles.must be overcome, but there is a definite sources. This section only provides a rough summary of this
qualitative change in relationships with suppliers. A number Work.
of other shoe manufacturers had started similar initiatives.
22. Calculated at the black market rate of exchange (“u..uI
9. Indeed, ongoing research by Rosane Cruz reports a puralelo”). For a mote detailed analysis of wages and wage
case in which rising quality requirements and tighter delivery differentials in different fypes of tirms and for different occu-
schedules led a firm to phase out the use of subcontracting. pational categories, see Piccinini (1990).
Such a response, however, seems to be an exception.
23. This line of reasoning linds support in a statistical
10. Based on case study carried out in conjunction with analysis of the growth determinants of the 100 largest enter-
Luiza Bazan. prises of 1987, based on the sboe census of 1981-87. DOS
Santos (1992. pp. 132-134) found that fast growth was not
11. Vocational training centers of SENAI exist throughout associated with rising labor,productivity and mentions low
Brazil but few, if any, regions/sectors have such a concentra- wages as the reason for the lack of process innovation.
tion of speciahzed schools and technology centers.
24. This came out clearly in interviews with managers of
12. These associations are independent. membership is innovating lirms, but due to space limitations the evidence of
voluntary, and they are not part of the govermnent-control1ed intratirm change could not be included in the text. For inter-
sindicaro system. national examples of what can be achieved by adopting new
organizational principles in shoe manufacturing, see Mody,
13. Based on interviews with representatives of several of Suri and Saunders (1992).
the above associations and with industrialists.
25. FIeury and Humphrey (1993) and Posthuma (1992)
14. Based on interview with official who was in charge of have noted the same in other Brazilian industries. Indeed,
producing the census at the time. industries such as metal working and engineering are more
advanced than the shoe industry in the use of new production
15. Based on interviews with representatives of some of methods.
these institutions and an internal working paper of this group
to which we were given access. 26. I am grateful to Hermine Weijland for helping me to
recognize these problems more clearly.
16. As mentioned earlier, Becattini (1990) stresses that
local community and local economy cannot be separated if 27. Germany’s success region, Baden-Wtlrttemberg, is
one wants to understand the growth potential of industrial also under duress. See Cooke, Morgan and Price (1993) for a
districts. These concerns feed into a wider literature on the recent assessment.
so&cultural foundations of competitiveness; see, for exam-
ple, Dore (1983) and Granovetter (1985). 28. Export traders were also important in the footwear
indushy of Taiwan (Levy, 1990) and, to some extent, India
17. This is only one of many factors analyzed by (Knorringa, 1993).
Korzeniewicz. Indeed, any attempts to explain the success of
regions such as the Sinos Valley purely in sociocultural or 29. There are similarities with the impannarore who
ethnic terms need to be countered with examples of other according to Beccatini (1990) and Piore and Sahel (1984)
communities of German descent in South America which played a key role in the growth of the industrial district of
remain underdeveloped and poor. Prato in Italy. Evidence of a different kind comes from a
study by Weijland (1992). Her comparative statistical analy-
18. Bazan’s interviews show, however, that among work- sis of small firm clusters in Indonesia shows that growth was
ers a divide emerged between locals and migrants. associated with the presence of marketing agents, comirming
the importance. of middlemen particularly at an early stage.
19. Comparable wage data - based on the shoe census -
could only be calculated for 1972-87. The average real wage 30. Slower growth would have had its advantages. As men-
was calculated by dividing the total wage bill by the total tioned earlier, the speed of growth contributed to the break-
number of workers and by deflating the result with the down of cooperative spirit.
General Price In&x (IGP) of the Ftmda@o Gettllio Vargas.
The same procedure was used for the computations of the 3 1. Conlirmed in a special report on the Sinos Valley in the
Industtial Census and Industrial Fe&ration data. Brazilian weekly Veja, “0 Vale Resiste - Como a inddstria
cal9adista do Vale dos Sines encontra caminhos para
20. Based on primary data for three occupational cate- enfrentar a crise” (January 1992).
gories (operator in cutting, in sewing and auxiliary worker).
Nominal wages were translated into multiples of minimum 32. Even for theEuropean industrial districts there is little
wages. Since the real minimum wage changed over the empirical evidence on this issue. There are, however, useful
decade, the multiples were deflated with the minimum wage reflections on the possible connections between clustering
index of DIEESE. and uncertainty or risk of technical innovation. See, for
example, Camagni (1991) and Dei Gttati (1991).
TALE OF A SUPERCLUSTER 27

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