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Why U.S. Auto Factories Are Struggling to Stay Productive

Challenges Facing the U.S. Automotive Industry

Automotive factories across the United States and around the world are struggling to produce enough vehicles to remain profitable. Several factors are contributing to this downturn in productivity, but two major issues stand out.

First, new car demand has not fully recovered to pre-pandemic levels. In 2016, the U.S. automotive market reached a record high of 17.5 million cars sold, according to forecasting firm GlobalData. By 2019, that number had decreased to about 17 million. However, during the pandemic, sales plummeted, reaching a low of 13.8 million in 2022. Sales have only partially rebounded, with expectations for 2024 being just under 16 million units. High vehicle prices are deterring many customers, who are turning to the used car market instead.

The second major factor is the industry’s transition to electric vehicles (EVs). Despite expectations for rapid growth in the EV market during the 2020s, the demand has not materialized as quickly as anticipated. Many factories are equipped to produce hundreds of thousands of electric vehicles, but consumer demand has lagged behind these production capacities.

This leaves automakers facing an unprecedented challenge: designing vehicles, supply chains, and factories to accommodate both traditional gasoline-powered vehicles and electric powertrains. For over a century, nearly all vehicles ran on gasoline, and manufacturers had hoped for a smooth transition to a future dominated by electric cars. However, the shift to electrification has been more complicated than expected, creating uncertainty in the industry’s direction.

The U.S. automotive sector finds itself in a period of significant change, with many variables still in play that could dramatically alter its future trajectory.


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