"Everything about Tesla is supposed to be fast, the car, the development process, the launch process," said John Shook, an auto industry veteran who got his start at NUMMI, in a
recent podcast. Shook summarized Tesla's approach as "let's start to build the thing before we've actually finished designing it. Because what we're building even for cash-paying customers is actually betas."
"The idea is we can go fast by leaving out steps, and we'll just iterate our way to something really good. But what we can see is that actually creates a lot of problems."
This kind of rapid iteration works well in the software industry because a programmer can change one line of code and then re-build the entire project with the click of a button. But physical manufacturing isn't like that. Car design decisions have to be translated into physical tooling that takes months to build and fine-tune.
And rapid iteration is a nightmare for suppliers, Shook added.
"I talked to a supplier and asked 'who's your worst customer'" Shook said. "The answer was Tesla. How can you be a good supplier when you don't know when you're supposed to deliver?"
"I was giving a talk at a tooling group," said David Cole, an analyst at the Center for Automotive Research. Veteran toolmakers there told Cole that most automakers do prototype tooling when they're designing a vehicle. "They make some vehicles so they can test them and find out if the tooling is good. They said that that was standard procedure at every auto company except for Tesla."
At Tesla, he said, "they take their prototype into production."
"I think what we're seeing is a lack of basic manufacturing experience," Cole added.