FoMoCo just like all the other manufacturers have tended to go towards JIT assembly lines. JIT == Just In Time, where the inventory needed for current production, a short period of time, is next to the line. Other parts are either in a staging area, quickly accessible to keep the line in productive mode(moving), or arriving at the loading dock. They likely do not keep 500 7-pin hitches next to the line, or maybe even in-house, but that's just one item.
Kanban or JIT requires the sub-assemblies to be readily available from suppliers. A seat manufacturer(forget the name) would actually co-ordinate with the plant to load the seats onto their truck in reverse order of the builds scheduled for that day. FILO, so the first out of the truck were the first needed when the line started moving. All other seats dribbled out of the trailer onto the conveyor/loader in the order needed to match the color of the vehicles in production. Engine/transmission assemblies are shipped in packaging, I've seen 12-packs, and so on, that fit onto a pallet/base that can be set and loaded directly. Do not know if they are 'synched' or one is just picked from the packing and placed onto the cradle.
Anyway, my take is there are problems in CVTe-2.5 land, something does not assemble well, or doesn't fit. I have not read of any problems in the transmission assembly plant, but figure the Hermosillo plant is not quite doing as well. Could be a training issue and they are doing the aseemble-grade-take-apart-repeat until they get it right the first time.
tom
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