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Single points of production failure

Each entry is a single entity whose failure can stop a material operation. Stated as a business condition — the dependency graph is available on request from the exposure view.

Ostrander Brake — 83K-1088 (Shock tower D)

Single-source supplier · confidence Moderate

What will be affected
Synthetic SC Assembly — Line SC-1 (body), Synthetic X-Program SX-1
Estimated time to impact
16.8h of verified tolerance
Existing protection
16.8h of usable inventory
Missing protection
No alternate source and no cross-plant transfer agreement
Recommended mitigation
Qualify a second source, or hold the approved 72h buffer

Solvay Polymers Group — 13C-1184 (Bracket, seat rear E)

Single-source supplier · confidence Low

What will be affected
Synthetic SC Assembly — Line SC-1 (body), Synthetic X-Program SX-1
Estimated time to impact
16.9h of verified tolerance
Existing protection
16.9h of usable inventory
Missing protection
No alternate source and no cross-plant transfer agreement
Recommended mitigation
Qualify a second source, or hold the approved 72h buffer

Solvay Polymers Group — 28E-1134 (Coolant manifold E)

Single-source supplier · confidence Low

What will be affected
Synthetic SC Assembly — Line SC-2 (final assembly), Synthetic X-Program SX-1
Estimated time to impact
17h of verified tolerance
Existing protection
17h of usable inventory
Missing protection
No alternate source and no cross-plant transfer agreement
Recommended mitigation
Qualify a second source, or hold the approved 72h buffer

Halbrecht Drivetrain — 18B-1001 (Floor pan reinforcement B)

Single-source supplier · confidence Low

What will be affected
Synthetic SC Assembly — Line SC-2 (final assembly), Synthetic X-Program SX-1
Estimated time to impact
17.5h of verified tolerance
Existing protection
17.5h of usable inventory
Missing protection
No alternate source and no cross-plant transfer agreement
Recommended mitigation
Qualify a second source, or hold the approved 72h buffer

Ostrander Brake — Ostrander Brake — Nagoya Plant 1, Nagoya (Japan)

Single supplier site · confidence Moderate

What will be affected
3 critical part number(s) across the production network
Estimated time to impact
Governed by the shortest part tolerance at the receiving plants
Existing protection
Supplier recovery capability recorded as tested; evidence partial
Missing protection
No second manufacturing site for these part numbers
Recommended mitigation
Require a second manufacturing location or hold dedicated buffer for these part numbers

PO replication (OEM SAP S/4HANA → Meridian ERP (SAP ECC))

Single ERP or system interface · confidence High

What will be affected
Supplier order management; Materials planning
Estimated time to impact
24h recovery objective for the receiving system
Existing protection
None recorded for this interface
Missing protection
No tested manual fallback for this message flow
Recommended mitigation
Create and test a manual processing procedure with a stated daily capacity

Sequenced pull signal (OEM SAP S/4HANA → SC Assembly MES)

Single ERP or system interface · confidence High

What will be affected
Line sequencing; Materials planning
Estimated time to impact
2h recovery objective for the receiving system
Existing protection
None recorded for this interface
Missing protection
No tested manual fallback for this message flow
Recommended mitigation
Create and test a manual processing procedure with a stated daily capacity

Sequenced pull signal (Saltillo) (OEM SAP S/4HANA → Synthetic Saltillo MES)

Single ERP or system interface · confidence High

What will be affected
Line sequencing; Materials planning
Estimated time to impact
2h recovery objective for the receiving system
Existing protection
None recorded for this interface
Missing protection
No tested manual fallback for this message flow
Recommended mitigation
Create and test a manual processing procedure with a stated daily capacity

OT work order push (SC Assembly MES → SC Assembly Body Shop PLC Network)

Single ERP or system interface · confidence High

What will be affected
Body welding; Line sequencing
Estimated time to impact
2h recovery objective for the receiving system
Existing protection
None recorded for this interface
Missing protection
No tested manual fallback for this message flow
Recommended mitigation
Create and test a manual processing procedure with a stated daily capacity

SC Assembly body shop bank build-ahead

Untested manual process · confidence Low

What will be affected
PLT-1 stamping shortage
Estimated time to impact
Plan states a 24h recovery objective
Existing protection
Run banked bodies, resequence Line SC-2 to the SX-2 mix (180 units/day claimed)
Missing protection
Never tested — capacity is a claim, not a demonstrated capability
Recommended mitigation
Exercise the plan and record the demonstrated capacity

Meridian Stamping — Meridian ERP (SAP ECC), Meridian EDI Gateway, Meridian Shipping WMS

Shared technology provider across multiple plants · confidence Moderate

What will be affected
3 plants depend on this provider
Estimated time to impact
Governed by the shortest recovery objective of the affected systems
Existing protection
Recovery capability recorded as tested; notification commitment 4h
Missing protection
Concentration is not reduced and there is no independent fallback provider
Recommended mitigation
Reduce concentration or contract an independent fallback for the shared function

Silverline Logistics — Global TMS, Milk-run Scheduler

Shared technology provider across multiple plants · confidence Low

What will be affected
3 plants depend on this provider
Estimated time to impact
Governed by the shortest recovery objective of the affected systems
Existing protection
Recovery capability recorded as unknown; notification commitment 24h
Missing protection
Concentration is not reduced and there is no independent fallback provider
Recommended mitigation
Reduce concentration or contract an independent fallback for the shared function

M. Delgado, Plant Ops is the sole recorded owner of 4 critical systems

Recovery dependency controlled by one individual · confidence High

What will be affected
SC Assembly MES, Synthetic Saltillo MES, SC Assembly Body Shop PLC Network, Saltillo Paint OT Segment
Estimated time to impact
Immediate on any recovery that requires this owner
Existing protection
Named owner recorded
Missing protection
No named deputy recorded for these systems
Recommended mitigation
Record and exercise a deputy for each critical system