AI monitors 2,400 tier-2 suppliers and predicts disruptions before they cascade
A single missing bracket from a tier-3 supplier in Thailand shut down their Alabama assembly line for 4 days. Cost: $6.2M in lost production. The irony? The supplier had posted on LinkedIn about 'capacity challenges' two weeks before the shortage hit. Nobody at the automaker saw it.
This Irvine-headquartered automaker's North American operations depended on 2,400 tier-2 and tier-3 suppliers across 18 countries. Their supply chain visibility extended to tier-1 only. When a disruption hit deeper in the chain, they typically learned about it when parts stopped arriving. By then, the only options were expensive: air freight, production line changes, or shutdowns.
We built a supply chain intelligence system that monitors the entire supplier network — not just tier-1. NLP models scan supplier communications, news feeds, social media, financial filings, and logistics data for early warning signals. A risk scoring model predicts which suppliers are most likely to disrupt in the next 30-60 days. Our data team updates risk assessments overnight as Asian and European markets report.
We caught a flooding event in Malaysia affecting our tier-3 sensor supplier 19 days before it would have hit our line. We'd already qualified an alternate by the time the shortage was official.— VP of Procurement, North America
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