Heres the process in a nutshell as they currently operate:
Why is the line stopped?
Theres a problem with ______
Well get the line moving, whatever you have to do
They dont bother fixing the problem because that takes too much time. They live and die by that almighty production number.
The other part of the problem is that most people in management have NO CLUE how these cars are built. I once heard a production manager (literally the guy running the whole plant at the time) ask if we could run with out front subframes because we were running low.
Just last week we had an issue where we got door panels that didnt match with the rest of the interior. Everything was correct on my end (numbers matched, color matched what was on the build sheet) but the rest of the interior was tan when it shouldnt have been. The guy who came and asked us about it didnt even know that the doors on door line arent the same from one side to the other, theyre offset by 11 (meaning my side of the line is 11 cars ahead from the other).
So ok yeah I guess its a failure in process after all....