Ford

Challenging start-up experiences requiring a host of technical and people skills to achieve product from one Tier 1 (aluminum cast rear suspension components) and one Tier 2 (contractually supervised by the parent Tier 1, F-150 Series Ford Pick-up frames).

"Road warrior" requiring weeks of field work with continuous 100% travel within the Midwest (Bristol, IN and Bellevue, OH).

When selecting suitable Tier 1 suppliers, Ford must recognize that many of these companies languished in the post-recession business model. Senior employees chose to retire or were off-boarded to other industries. Hourly headcounts were constrained in many cases by single-shift operations. Ford underestimated the need to hire and train thousands of workers. This training required developing trainers and training programs, which impacted the volume ramp-up demanded by the 2014 MY sales goals and the large number of new model launches envisioned by the marketing team. The Tier 1 management teams needed to certify their facilities and products to conform to APQP.