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Zacks Investment Research thinks the worst of the supply disruptions for the auto industry have yet to come. Dealers in the U.S. are questioning what models and colors will likely be available for customers in the coming months, while others are wondering just how quickly suppliers can get back up running.

Reports are even starting to break about automakers asking dealers to limit the colors they’re ordering as some paints are available through the Japanese plants and suppliers.

While by and large, most automaker plants did not see massive damage in Japan, these facilities are still taking stock and the officials are still trying to get a grasp on the fallout from the quake, subsequent waves and nuclear disasters. Suppliers are still taking assessment it appears, and even when their facilities were not as hard hit, they are still dealing with rolling blackouts and the like.

Via its Zacks Analyst Blog, one firm analyst offered some interesting insight:

Japan

Toyota Motor Corp. has suspended vehicle production at its 11 plants in Japan since March 14. As a result, it has lost production of about 140,000 vehicles to date. However, it has started producing auto parts at seven domestic plants from March 17, according to Zacks.

The automaker now plans to resume production of its highly sought after Prius hybrid and two other Lexus hybrids, HS 250h and CT 200h, from March 28. The company decided to suspend production at nine other plants until Saturday, the analysts continued.

Honda Motor Co. ceased production at six plants in Japan soon after the earthquake. It has extended production suspension to March 27 from March 23 at all the plants except two. The automaker has extended closures at those two car-assembling plants in Saitama and Suzuka until April 3. On the other hand, it will start producing motorcycles from March 28, Zacks reported.

The firm went on to say, “Honda has been considered the most affected automaker from the twin disaster. It has 110 suppliers who are located in the earthquake zone itself. Among them, 10 suppliers are still in the dark about restarting their operations. Due to these reasons, Honda decided to suspend orders for May from U.S. recently for vehicles manufactured in Japan.”

Continuing on, Zacks reported Nissan Motor Co. suspended production at six plants until March 20. The automaker has resumed production of its popular Leaf electric cars, which are manufactured entirely in Japan at its Oppama plant. Before the earthquake, the company has managed to ship 600 Leafs to the U.S. on March 10. Nissan has also started operations at its Zama battery plant, officials continued.

Nissan revealed that production at the plants will largely depend on the frequency of power shortages. It has conceived the idea of shipping six-cylinder engines from its Decherd, Tenn., plant in the U.S. to its home country in order to compensate for the lost production at its Iwaki engine plant, according to the analyst firm.

North America

Among the Japanese automakers, Nissan, Honda, Mazda and Mitsubishi asserted that they have no plans to disturb their production levels, according to the companies. However, Toyota has suspended overtime shifts and production on Saturday at its 13 plants in the region. Meanwhile, Subaru froze overtime shifts at its Lafayette plant in Indiana.

“Among the U.S. automakers, General Motors Co. is the only one to be affected by the calamity so far. It halted production at an engine plant in Buffalo, N.Y., and has temporarily laid off 59 of its 623 workers,” the firm indicated.

The Buffalo facility supplies engines for compact pickups, Chevrolet Colorado and GMC Canyon, assembled in Shreveport, La. The Shreveport facility was shut down last week and GM transferred the electronic parts from the same to its Kansas City plant, where it assembles the highly profitable lineups, Chevrolet Malibu and Buick LaCrosse sedans, Zacks discovered.

Europe

Authorities in Europe are apparently worried about production returning to normal levels as it may take months and cost the industry billions of Euros.
According to Lars Holmqvist, head of the region’s Clepa auto suppliers association, European automakers are yet to feel the storm until the next few weeks as local supplies of vital auto parts such as semiconductors and infotainment systems dries up, Zacks reported.

“The situation has become unnerving to such an extent that German automakers have begun inquiring about government support that laborers can access if they halt assembly lines in the absence of vital components that are sourced from Japan. Nuremberg-based Federal Labor Agency has already started seeing shorter workweeks as the backlash of the earthquake,” the firm stressed.

Volkswagen, Europe’s largest automaker, has already reduced work shifts at its main plant in Wolfsburg. On the other hand, production of Peugeot and Citroen models by the second largest automaker, PSA Peugeot Citroen, is expected to fall by as much as 60 percent due to a shortage of diesel engines. Both the automakers are likely to halt production in coming weeks due to a shortage of parts.

“These apart, Bayerische Motoren Werke AG and Daimler AG have been struggling with tight availability of parts as they operate plants at high capacity levels to meet orders on time,” the firm discovered.

Among the U.S. automakers, GM has idled two compact car plants and its Opel division called off shifts at plants in Germany and Spain due to the lack of an electronic component.

On the other hand, Ford Motor Co.’s unit in Cologne, Germany has been contemplating on applying for shortened hours at its plant, Zacks said.

Finally, among the auto parts manufacturers, both Robert Bosch GmbH and Continental AG and Volvo cars (owned by China’s Zhejiang Geely Holding Group Co.) are likely to face supply shortfalls in the coming weeks.

Volvo sources about 10 percent of components from as many as 30 suppliers in Japan.