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The biggest single biggest cost is setting up the production line and this is roughly the same whether the car is a Cadillac or a Yugo. Variation kick in do to different costs in different countries (Thus Cadillacs factories in the US cost more then Yugo factories cost in the former Yugoslavia), but once you get away from that factor the remaining costs difference are quite low (Labor is about the same, no matter what car is being made, they is less material used in smaller cars, but the material cost are minor compared to the cost to form that material into a car part).
Prior to the 1960s, GM had a policy of making sure the better parts went into its better cars, but then the cost of such items dropped and GM found people were willing to spend more for them even in Chevrolets, thus by the late 1960s Chevrolets had the same suspension, frame and body as a Cadillac (and often came out of the same Assembly line). You could get higher end options on the Cadillac, but as for rideability the two cars have had the same ride quality since the 1960s (If you compare large size Chevrolets with large size Cadillacs as opposed to Chevrolets Vegas vs Cadillacs).
The prime reason US small cars were so bad was the big three profits came from the sale of Compact, Mid-Size and Large Cars NOT the Subcompacts. In fact the Big Three really only entered the sub-compact market do to the gas crisis of the 1960s AND to meet their Corporate Fleet Average. In affect the Sub-compacts were subsidized by the profits off the larger cars and later SUVs. Given the low profit on sub-compacts and the fact it was the most price sensitive section of the market, the big three put the minimal amount of expense into that market, including minimal design, care and priority when it came to the latest machines to improve the quality cars.
Now the Japanese were very good at sub-Compact cars, for that was the main car in use in Japan. Japan would produce them for a few years in Japan, find out all the bugs, and then export them to the US. This meant the Japanese cars of the 1970s had less problems then the American Sub-Compacts of the same time period (Including the addition of galvanized steel in areas where cars tended to rust out, something Detroit would NOT start to do till the early 1980s). Once entrenched in the Sub-Compact market the Japanese then started to bring in their larger cars, also first produced and driven in Japan and then to the US. These were what we in the US call Compact Cars and the Japanese started to dominate that market. The US still dominated the Mid-size and Large car markets, even as the SUV craze hit the US in the 1990s. The Japanese never really entered the large car market, through some of its compacts started to move into the mid-size market in the 1990s (and again with cars driven in Japan for a few years before the cars were offered in the US). Now the SUV craze the Japanese were caught flat footed, in the 1990s the Japanese finally had to US drop it restriction on importation of trucks (The US had restrictions in imports of trucks for decades, do to a concern such trucks may be needed for national Defense), just as the SUV boom started. The Japanese were slow to get into the market, but once their realized their larger pickups (Small to American eyes) could be made into very comfortable SUVs, the Japanese went into that market WITHOUT selling the cars in Japan first (No market for such large cars in Japan, through the small trucks the SUVs were based on were common in Japan).
I go into the above to point out that while US sub-compacts were inferior to Japanese Sub-compacts and why), once you move into mid-size cars, large Cars and SUVs the Japanese quality advantage quickly dropped (Compact cars was the main area of contention when in came to cars between the big three and the Japanese, but the big three liked the higher profits on their other cars so slowly conceded the compact car market to Japan, through would come up with a decent design when needed, see the Chevrolet Cobalt and Ford Focus for example. Since the 1980s American Made Compact cars have slowly improved, with each new version better then its predecessor, but in a market dominated by the Japanese. Part of this is the history of the Compact in the US (Take a look at a 1960s and 1970s Chevrolet Nova with a 350 or 400 cc engine and realized that was an American compact car, the Nova internal room is less then the Cobalt which is half its size, weight and engine, thus the Nova was a Compact car do to its interior room).
Notice if you are use to looking at compact cars from Japan, how can you even think that the Nova was a Compact car? Once Americans came to view compact cars like the rest of the world, the US firms had to meet those expectations and at a price people would be willing to pay. Furthermore the big three profit centers were its mid-size and large cars, cars that with the end of the Nova and its V-8 engines no longer had much in common with the Compacts being made by the big three. At the same time the Japanese could use the engines from their sub-compacts in their compacts. It was a better overall fit and the Big Three found it self in a dilemma, it could NOT use its profitable cars engines in the compacts of the 1980s and 1990s and thus could NOT cuts its cost of producing such cars by having them share components with the more profitable cars, but at the same time had to sell them to meet the corporate fuel average requirement. High Cost and low profit meant efforts to control costs became more important then quality of the cars being produced. Now Given the competition from Japan the quality could NOT go down to far (and actually increased) the big three were always in a losing position (one caused by their own lobbying, the big three prefer Corporate Fleet average to improve US fuel economy as opposed to the solution that worked in Europe, Japan and over the last few years in the US, high gasoline prices).
Just comments, that the quality difference is more a factor of WHAT GM was making a profit on AND what the Japanese were making a profit on as oppose to any real cost difference in producing a Sub-compact, Compact, Mid-Size or Large Car. The big difference in quality is NOT the price of the car being sold, but the price the maker is willing to put into the car. In the 1970s the Japanese were willing to put more into a small car then the big three were. In more recent years, with CAD becoming the preferred way to design cars replacing the old wooden models that the engineers would work up, the cost to design any car has dropped, thus the Cobalt the Cruze being much better design then the Cavalier the Cobalt replaced. Compact cars are no longer the forgotten step child of Big Three design and except for a long history of neglect which the American cars must over come, equal to anything the Japanese put out today IN THE SAME CLASS OF CAR.
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