The strategy, first employed in the mid-1980s, is called "Copy Exactly." And the Santa Clara, Calif.-based company means it.

Engineers strive to duplicate even the subtlest of manufacturing variables, from the color of a worker's gloves to the type of fluorescent lights in the building. Employees from around the world spend more than a year at a development lab in Oregon learning their small piece of the new recipe so they can bring it back to their home factory.

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