[jcommin]

The title of this post is: How did a single part made by a single supplier screw the world's biggest automaker?

The answer is: it didn't. Toyota did.

There are plenty of Tier 1, 2 and 3 suppliers that supply parts to one or many of the automotive manufacturers. They all have criteria that must be met to be awarded the business. Toyota has a very good process for approving vendors. Their criteria to meet there requirements are very detailed, better than most. As demanding as they are, they are fair and reasonable. Any supplier cannot change the process, location or substitute materials w/o the approval of Toyota. Parts are submitted for testing and approval. In the event of a material change, testing occurs not only in the lab but in the field. A supplier can lose business if they make a change w/o approval. No one will do that because there is business to lose. All suppliers are graded and when incidents occur, a corrective action plan and remediation must take place.

Making quality parts doesn't compensate for bad design, or designs that cost cut. Or demanding suppliers to cut cost 5% per year every year during the contact.

Toyota got sloppy; they are no different than Ford, GM, et all. Cost cutting, market share, profit is the name of the game. They deserve to pay or are they to big to fail?