For the last 3 months Toyota has been stockpiling parts and assisting tier 2 and tier 3 NA part suppliers in conjunction with financing alternate parts operations.
The Detroit 3: nothing ... waiting for the collapse. Delphi, the still Chapter 11 spin off of GM, is completely underwater even after recent GM money and TARP money. American Axle is also at the end of the road.
"Toyota stockpiles parts as a precaution" .
Autonews.com, April 27, 2009 - 12:01 am ET
Toyota Motor Corp.'s North American auto plants are warehousing key parts to safeguard against supply chain interruptions caused by supplier failures.
The company is ordering more parts than it needs in order to build reserves that would allow it to continue assembling vehicles in the event of an interruption.
It is also looking for duplicate sources of some parts in cases where it feels particularly vulnerable, said Steve St. Angelo, senior vice president of Toyota Motor Engineering & Manufacturing North America Inc. and president of the company's large assembly complex in Georgetown, Ky.
"Our biggest risk is our suppliers," St. Angelo said. "I can't ship a Camry or an Avalon if it's missing even one part."
Toyota is most concerned about the condition of Tier 2 and Tier 3 suppliers because it has less information about them, St. Angelo said. Toyota normally is reluctant to discuss problems in its supply chain.
But St. Angelo told Automotive News that the Georgetown vehicle assembly and engine plant complex is using warehouse space near the plant to house extra parts from critical suppliers.
The moves violate Toyota's vaunted "just in time" production philosophy, which views warehousing as a symbol of muda, or waste and inefficiency.
But Toyota now faces a worse problem than inefficiency: It fears that a bankruptcy by one of the Detroit 3 could set off a chain reaction of U.S. business failures that would shut down Toyota's own North American system.
Since opening its first U.S. assembly plant in 1984, Toyota has become deeply rooted in the U.S. landscape. Although it continues to do business with a cadre of Japanese parts companies in which it holds a small ownership stake, Toyota has expanded its supplier network.
More than half of Toyota's 500 U.S. parts suppliers also do business with General Motors, St. Angelo said. And some of them are struggling.
On March 11, Jim Lentz, president of Toyota Motor Sales U.S.A., said Toyota has "real concerns" about 20 to 30 of its U.S. suppliers for fear that they could shut down Toyota production.
War room
To monitor these suppliers, Toyota established a "war room" three months ago at its North American headquarters in Erlanger, Ky. Every Thursday morning, senior executives hold a one-hour meeting to monitor Toyota's suppliers.
Names of suppliers deemed to be in good shape for the week are marked with a circle. Suppliers marked with a triangle have experienced some trouble but are thought to be performing adequately, St. Angelo said.
Suppliers in immediate trouble are marked with an "X."
The weekly reviews are conducted by Toyota's Corporate Strategy Division, a high-level group consisting of Tetsuo Agata, president of the manufacturing company; Ray Tanguay, its executive vice president; St. Angelo, and Toyota's senior vice presidents.
St. Angelo also said that Toyota has dispatched people to help troubled suppliers improve their financial picture by cutting costs and improving performance[/i]