Optimizing Supply Chain Resilience in Automotive Manufacturing: A Case Study of Ford

Thesis Abstract

The resilience of supply chains is increasingly recognized as a critical determinant of operational continuity and competitive advantage in the automotive manufacturing industry, particularly amidst global disruptions such as geopolitical tensions, pandemics, and technological shifts. This study investigates strategies to optimize supply chain resilience within Ford Motor Company, aiming to identify effective interventions that enhance robustness, agility, and recovery capabilities. The primary objectives include evaluating current supply chain resilience practices at Ford, examining the influence of supply chain flexibility and risk management on resilience, and proposing an integrated framework for resilience enhancement tailored to automotive manufacturing contexts. Employing a mixed-methods research design, the study integrates qualitative and quantitative approaches to provide a comprehensive understanding of supply chain resilience. The qualitative phase involves semi-structured interviews with 15 supply chain managers and key logistics personnel at Ford’s North American manufacturing facilities, complemented by a thematic analysis to uncover perceptions, practices, and challenges related to resilience. Concurrently, the quantitative phase involves administering a structured survey to 150 supply chain professionals within Ford’s supply network, employing stratified random sampling to ensure representativeness. The survey instrument, developed based on a literature-derived resilience framework, measures constructs such as supply chain flexibility, risk mitigation strategies, and resilience outcomes. Data collected are subjected to descriptive statistics, correlation analysis, and multiple regression analysis using SPSS, with regression models tested for significance at a 0.05 level. Furthermore, the study applies the Dynamic Capabilities Theory and the Supply Chain Resilience Framework to interpret findings, enabling the assessment of how organizational capabilities and strategic practices influence resilience outcomes. The anticipated results suggest that flexible sourcing, diversified supplier networks, real-time data integration, and proactive risk management significantly contribute to supply chain resilience at Ford. Regression analysis is expected to reveal that supply chain flexibility and strategic risk mitigation collectively explain a substantial proportion of variance in resilience performance, thereby affirming their pivotal roles. This research contributes to existing knowledge by developing an empirically validated, context-specific resilience model for automotive manufacturing firms, highlighting practical interventions and strategic priorities. It advances the understanding of how organizational capabilities interplay with external disruptions in shaping resilient supply networks. The findings will equip industry practitioners and policymakers with tailored recommendations to bolster supply chain robustness, including the adoption of digital monitoring tools, supplier diversification, and resilience-oriented training programs. The study concludes that enhancing supply chain resilience necessitates an integrated approach combining strategic flexibility, risk mitigation, and technological investments. It recommends that Ford and similar organizations implement resilience-focused frameworks, continuously monitor supply chain risks, and foster collaborative supplier relationships. Future research may explore longitudinal impacts of resilience strategies over time, incorporate emerging digital technologies such as blockchain and IoT, and extend analysis across different geographic markets and car segments to enhance generalizability. Overall, this study underscores the imperative for automotive manufacturers to embed resilience as a core strategic competency, ensuring sustained operational excellence in an increasingly volatile global environment.