So, to quote "My Cousin Vinny", my theory holds water? They can stockpile more chips due to a sheer lack of volume compared to Ford.
I don't think that makes much sense for a few reasons:
(1.) It's not just "chips" there are all kinds of shortages of every conceivable thing (e.g., Mercedes is not making V8s this year) -
supply chain experts have warning auto makers about this problem for over a decade. It was simply a matter of time before it happened - this isn't a one-off, it's due to a systemic auto maker supply chain design problem.
(2.) BMW's factory was built as an inland port directly connected to shipping & rail lines with its own airport so it's got a ton of flexibility on how to get supplies
(3.) American suppliers use stupid supplier leveraging; that is, rather than contract for a specific numbers of parts they make their suppliers guess thus shifting the risk to them (
but risking a supply constraint!). Suppliers use consulting firms (IHS Markit) to try to guess a manufacturer's needs. In this case, IHS Markit used low 2020 sales volumes which were way down due to covid and extrapolated to 2021, and then a demand spike happened, so it was a double whammy: low production combined with a demand spike.
(4.) American manufacturers use 20-year-old 200mm wafer chips which everyone else stopped using in the early 2000s in favor of 300mm+ chips. Since nobody wants to build a new factory for make old parts there's a global limit on supply and demand has wavered over the last 15 years making production spotty.
(5.) "American" excludes Tesla who both contracts for numbers AND employs engineers who can rewrite the code for whatever chips they can get. This is why Tesla had the highest 2021 production plant of any auto make anywhere in the world.
In short all American auto manufacturers except Tesla are inflexible and use extremely outdated engineering & supply modes.
The general idea of Blue Oval City is to fix this problem amongst others.
Said simply,
had Ford contracted for X million of chips in 2021 they would've hit the same production records Tesla did, but they use the old "profit from core and outsource everything else" model and it bit them in the arse hard.
In short, Ford engineers, supplies, & builds cars the old dumb way, and they know they have to fix that, and they are - but in the meantime parts are still being held up due to production limits, demand spikes, and transport holdups.
This isn't a one-off: chips were simply the first of many ICE parts shortages to come ...