Vehicle Semiconductor Chips 101

[ocbucks1]

The boards are all part of the electrical assemblies. They are assembled outside MAP in another plant. If you ever have a chance to do a tour it will make more sense. The entire dash assemblies , seats, computers and harnesses are literally being unloaded from trucks as the vehicles are coming down the line. They will install the entire dashboard as a complete module, seats the same, engines the same, harnesses and computers the same. They are not installing “soldering” chips into boards in assembly.

It could be any of these modules that have shortages or a combination.

Below is an idea but even more modules with 4WD controls.

Those are the modules and what the chips control like the seats, etc. But the boards can be installed separately from what module it controls after the build. Plug in of course not solder. They don’t leave out the seats if the chips are missing that control the seat.

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[22OBX]

Those are the modules and what the chips control like the seats, etc. But the boards can be installed separately from what module it controls after the build. Plug in of course not solder. They don’t leave out the seats if the chips are missing that control the seat.

Of course not they just plug in the module that is missing. And the chip that controls the seat is usually under the seat in a separate module. Just the motors are attached to the seat itself. Occasionally one my be attached to the seat but most times not.

 

[North7]

Those are the modules and what the chips control like the seats, etc. But the boards can be installed separately from what module it controls after the build. Plug in of course not solder. They don’t leave out the seats if the chips are missing that control the seat.

Untrained personal do not install circuit cards, first reason is ESD static damage. Second reason, only complete electronic devices/module/unit/assemblies are shipped, AFTER the full unit has gone through specialized testing, at the unit manufacturer, only then is the final unit shipped to Ford,, the seat manufacturer, etc..

Here is an example of an F-150 module being replaced. Ford ICE Mountain workers are doing nothing more than plugging in full assemblies, similar to this.

 

[Okstate1010]

Are they expecting to have these “chips” when production starts back on the 21st? Or are they just building more to move to the mountain?

 

[22OBX]

Untrained personal do not install circuit cards, first reason is ESD static damage. Second reason, only complete electronic devices/module/unit/assemblies are shipped, AFTER the full unit has gone through specialized testing, at the unit manufacturer, only then is the final unit shipped to Ford,, the seat manufacturer, etc..

Here is an example of an F-150 module being replaced. Ford ICE Mountain workers are doing nothing more than plugging in full assemblies, similar to this.

Yes. 100% agree. That PCM as well as all other major assemblies, electrical components, etc are shipped in from other plants using JIT (just in time) inventory. If shipments get behind or don’t come at all things come to a screeching halt.

 

[North7]

Yes. 100% agree

Now, can we get rid of the "it's missing chips" misnomer!

 

[ocbucks1]

Are they expecting to have these “chips” when production starts back on the 21st? Or are they just building more to move to the mountain?

Good question. I don’t think it’s known but the chips are really installed before final assembly in specific modules. It’s certainly is better not to install after for them. So I’m guessing they have gotten some orders. Doesn’t make sense they would keep producing without.

 

[ocbucks1]

Now, can we get rid of the "it's missing chips" misnomer!

True but it was the chips that forced the module to be incomplete.

 

[22OBX]

True but it was the chips that forced the module to be incomplete.

Yeah, but some folks think they are installing chips at the plant and they are not. The chips are not short at MAP, it’s a module shortage or shortages since there are numerous modules. The chip shortage is at the electrical assembly plants. What we have at MAP is a module shortage. We just don’t know which ones. It could be the PCM or the BCM or half dozen other modules that all have chips in them. Basically anything in the Canbus network has chips. We know they were building some and they were stacking up in the yard so I feel like those will be direct plugs ins. A pcm can take as little as 5 minutes to install and plug in. Some of the others could take longer depending on module. I know Ford wiring and schematics thoroughly.

 

[coreymd]

Great thread. Seems like Ford's best option was to keep the assembly line running and wait for the missing modules. That creates an inventory issue for them, and they obviously can't continue that trend indefinitely. But installing the modules on otherwise finished vehicles surely means we get our Broncos faster, compared to Ford starting the entire production process only after those modules become available.

 

[mcinfantry]

I would assume, assume…
You run the production line for a lot of reasons

1) if you shut it down you get backlogged very badly with parts and I think there’s some labor contracts that become involved

2) you build as many vehicles with a-y modules waiting for the z module. This should keep the people employed, the lines running and keeping stock moving instead of having tons of car parts stacking up

3) you build a-z (complete vehicles ) as the modules come in, and as you get excess z then you go and complete those. No reason to go get an incomplete widget then send another unfinished widget to the same spot. Inefficiency I would assume.

that’s how I assume people get completed vehicles built well after partially completed ones stopped being finished

just my thoughts

 

[ocbucks1]

I would assume, assume…
You run the production line for a lot of reasons

1) if you shut it down you get backlogged very badly with parts and I think there’s some labor contracts that become involved

2) you build as many vehicles with a-y modules waiting for the z module. This should keep the people employed, the lines running and keeping stock moving instead of having tons of car parts stacking up

3) you build a-z (complete vehicles ) as the modules come in, and as you get excess z then you go and complete those. No reason to go get an incomplete widget then send another unfinished widget to the same spot. Inefficiency I would assume.

that’s how I assume people get completed vehicles built well after partially completed ones stopped being finished

just my thoughts

Agree you would think. It would be interesting to see the plan but we don’t know as usual. One thing is the incomplete vehicles represent cash flow that they need. So they are definitely juggling to maximum deliveries. I think they will be able to organize a assembly line like operation to complete. Since this impacts many lines not just bronco they should be efficient. Hoping this translates to shorter than the 3 months. That’s too long.

 

[mcinfantry]

Agree you would think. It would be interesting to see the plan but we don’t know as usual. One thing is the incomplete vehicles represent cash flow that they need. So they are definitely juggling to maximum deliveries. I think they will be able to organize a assembly line like operation to complete. Since this impacts many lines not just bronco they should be efficient. Hoping this translates to shorter than the 3 months. That’s too long.

I would be upset if I was an employee that you sent home for weeks waiting on parts when I could make almost complete

I can’t stand going to work with stuff stacked up. Couldn’t imagine a backlog of infinite cars

 

[JohnnyX]

Untrained personal do not install circuit cards, first reason is ESD static damage. Second reason, only complete electronic devices/module/unit/assemblies are shipped, AFTER the full unit has gone through specialized testing, at the unit manufacturer, only then is the final unit shipped to Ford,, the seat manufacturer, etc..

Here is an example of an F-150 module being replaced. Ford ICE Mountain workers are doing nothing more than plugging in full assemblies, similar to this.

There are probably 30-50 'chips' in that PCM... maybe 10-25 unique types..

 

[DogHauler]

Why is there a shortage?

Purchasing doesn't care about anything but cost. They will source anywhere to save a tenth of a cent.

Like they say, we get what we deserve.

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