As the coronavirus crisis continues to disrupt the global economy, North American vehicle sales have dropped sharply, and production has come to a nearly complete stop. Given the complexity of automotive manufacturing, the tremendous capital required to restart production, and the industry’s deep global supply chains, resuming vehicle production in North America will be a complex undertaking that is likely to take place in stages. CAR researchers are tracking automaker announcements for the restart of production at the companies’ North American plants.

Restarting the automotive industry is more than just the issue of resuming production at each company’s plant, however. Automakers and suppliers need to address:

  • How does the automotive industry adjust its traditional business practices post-crisis?
  • How do companies manage and monitor workers’ health conditions?
  • Are changes needed to current inventory management?
  • How do companies evaluate and respond to supply chain risks and disruptions?
  • Does this crisis push the need for companies to reset the production process?
  • How do companies prepare to avoid another crisis impact on their business?

CAR addressed many of these issues in our recent Restart Playbook Webinar, which featured a conversation with Magna Executive Vice President and President Magna Asia, Jim Tobin, and Magna Executive Vice President and Chief Human Resources Officer Aaron McCarthy.

The following map series depicts automaker announced restart dates for each company’s assembly plants as of 17 April 2020. CAR researchers will continue to monitor automaker restart announcements throughout the production ramp-up and will update these maps regularly.

Assembly Plants in Production

The following table depicts confirmed assembly plants that have restarted production at their North American assembly plants.

Table 1: Confirmed Restart of N.A. Assembly Plants by Automakers, 2020

Source: Media announcements through 30 April 2020

Week of 3-9 May

Figure 1: Automaker North American Assembly Plant Restarts, Week of 3-9 May 2020

Source: Media announcements through 27 April 2020

BMW, FCA, Honda, Hyundai-Kia, Toyota, and Volkswagen announced restart dates for thirty-seven assembly plants during the week of 3 May 2020. The assembly operations scheduled to begin production during this week are BMW’s San Luis Potosi, Mexico and Spartanburg, South Carolina plants; FCA’s Toluca, Mexico, Belvidere, Illinois, Detroit and Sterling Heights, Michigan and Toledo, Ohio plants; Honda’s Alliston, Ontario, Celaya and El Salto, Mexico, East Liberty and Marysville, Ohio, Greensburg, Indiana, and Lincoln, Alabama; Hyundai-Kia’s Montgomery, Alabama and West Point, Georgia plants; Toyota’s Cambridge and Woodstock, Ontario, Celaya and Tijuana, Mexico, Princeton, Indiana, Georgetown, Kentucky, Tupelo, Mississippi, and San Antonio, Texas plants; and Volkswagen’s Chattanooga, Tennessee plant.

Table 2: Automaker North American Assembly Plant Restart Weekly Production Volumes for Restarts During the Week of 3-9 May 2020

Week of 10-16 May

Figure 2: Automaker North American Assembly Plant Restart Dates, Week of 10-16 May 2020

Source: Media announcements through 27 April 2020

Subaru and Volvo announced plans to restart production at two of their assembly plants during the week of 10 May 2020. Subaru’s Lafayette (#1 and #2) Assembly Plant in Lafayette, Indiana, is scheduled to begin production on 11 May at an estimated weekly production capacity of 10,017. Volvo also announced that its Ridgeville Assembly Plant, located in Ridgeville, South Carolina, will begin production during this week at a weekly production capacity of 902 units. 

Week of 17-23 May

Figure 3: Automaker North American Assembly Plant Restarts, Week of 17-23 May 2020

Source: Media announcements through 27 April 2020

FCA, Renault-Nissan, and Volkswagen announced restart dates for five assembly plants during the week of 17 May 2020. The assembly operations scheduled to begin production during this week are FCA’s Brampton and Windsor, Ontario plants, Renault-Nissan’s Canton, Mississippi, and Smyrna, Tennessee plants, and Volkswagen’s Puebla, Mexico plant.

According to numerous media sources, the Detroit Three (FCA, Ford, & GM) are tentatively aiming to restart some production at their U.S. facilities on May 18.

Table 3: Automaker N.A. Assembly Plant Restart Dates and Weekly Production Volumes, Week of May 17-23

Unknown Assembly Plant Restart Announcements

The following table depicts automakers who previously announced restart dates before the week of 3 May 2020 that have not publically confirmed the restart of their operations. This table also includes automakers who have not disclosed a specific date to restart their assembly plants.

Table 4: Unconfirmed N.A. Assembly Plant Restart Dates by Automaker, 2020

Source: Media announcements through 27 April 2020

CAR researchers are continuously monitoring automaker and supplier announcements regarding restarting North American production and the steps necessary to enable this undertaking. Because the announcements are updated and changed regularly, CAR will continue to provide updates on the CAR website as the situation unfolds.

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