Complete kit parts missing

[Malibu46pt]

I received my roadster kit last week. Checked off all the boxes I received then started the inventory of the contents box by box and identified all the parts missing on the inventory sheet for each box. This is in addition to the parts list shortage provided by FF When I started to assemble some of the parts it became clear that many more parts were missing and were not in the boxes and were not listed on the inventory sheets. In this case I don’t even know what parts are missing.
Has anyone else had this issue? How did you communicate this to Factory Five and how did you resolve it.
At this point there is no way for me to know what parts I am missing
Help!!!!

[Ted G]

I received my roadster kit last week. Checked off all the boxes I received then started the inventory of the contents box by box and identified all the parts missing on the inventory sheet for each box. This is in addition to the parts list shortage provided by FF When I started to assemble some of the parts it became clear that many more parts were missing and were not in the boxes and were not listed on the inventory sheets. In this case I don’t even know what parts are missing.
Has anyone else had this issue? How did you communicate this to Factory Five and how did you resolve it.
At this point there is no way for me to know what parts I am missing
Help!!!!

This is normal and you need to actually go through every box, every bag and document what is missing. You should have a full inventory list of what is in each box. Then, send your sales guy a list of missing parts. It is time consuming but you will know your kit much better after this experience. I received my kit on April 1st and I only have one item on my missing in kit list (door latches).

Good luck!

[Malibu46pt]

Thanks for your feedback. Unfortunately the inventory list sent with each box was incomplete. For example the was no accelerator pedal, head lights and many other items not listed on the inventory sheet for any box. These were also not on the missing parts list from FF. Since they are not on the inventory I have no is
Dear what is missing.
Any suggestions would be appreciated
Thanks

[egchewy79]

Huh. That’s interesting. Does anyone know if FFR updated their inventory list? I can’t imagine that they’d send out a complete kit without headlights on the inventory. I’d call or email them for clarity

[JJK]

I am awaiting my kit to arrive, but have been actively reading the forum the past few weeks in preparation. several folks have mentioned similar problems with parts not listed on the inventory sheet. steering wheel if I recall. I have also read that FFR is updating their inventory management system,so I suspect these are related.

[toadster]

yup - normal process, document each box and make sure FFR knows you have things missing outside their POL (Parts on Order List)
https://cobradreams.com/2020/03/10/5-more-boxes-arrived/

[racingandfishing]

Could be wrong and hoping it gets sorted out before I get my kit in January, but there seems to be a pattern here with the new inventory system vs. past experiences.

https://thefactoryfiveforum.com/showthread.php?43669-Needing-Inventory-Advice

[mmklaxer]

I had quite a few back and forth's with Dave Lindsey. He was very helpful.

I do think the new process has a few bugs to work out. For example - I was missing the steering wheel. Pretty obvious, cause I couldn't sit in the driver's seat and make the vroom vroom noises. Dave added it to my MIK list without issue. He also saw that the steering wheel was missing on his version of the inventory sheets, so no issue there.

On the pedal - did you get the coyote kit? If so, it doesn't come with the pedal; only the pedal mounting plate and associated hardware. The pedal comes with the Coyote Controls Pack when you buy that. (had the same issue). I jsut got my controls pack from Forte, and there it was right on top of the package. Ships direct from ford that way. I agree it's weird though.

The other stuff I found i was missing were the fasteners. nuts and bolts all over the place that weren't on the inventory sheets. For me they were all in box #1 in a box called "Fastener kit". felt like a bit of an idiot when i opened it and had that "aha" moment. WHen I inventoried box 1, i just checked it off and kept going. Didn't both to open it. I assumed I would open it when I got to the point of installing said "fastener kit" hahaha.

[Mike.Bray]

I had quite a few back and forth's with Dave Lindsey. He was very helpful.

I can't say I've had a problem with anyone at FFR, they've all been very nice. But my experience is Dave Lindsey is the guy that gets things done. He admittingly is always working, I've even received replies from him on Sundays. You should reach out directly to Dave.

[Jeff Kleiner]

…but there seems to be a pattern here with the new inventory system vs. past experiences.



Last I heard (from Dave S) the changeover to the new system has been delayed until September.

Jeff

[racingandfishing]

Last I heard (from Dave S) the changeover to the new system has been delayed until September.

Jeff

So rule that out!

Though I've been through quite a few system upgrades/new systems over the years and you typically have to make changes on the front to end before throwing the switch. Either way, seems like something has changed based on some of the posts. But just a newbie here so I am likely completely wrong!

[Tooth]

I'm in a similar situation. Thought I had done a thorough inventory, but have found a couple things I must have missed. They are sending them, but said I would have to order anything else from here on. My advice to anyone going forward is, don't trust the new system where things are bagged with associated hardware. That's where my missing stuff is adding up.

[Papa]

Not identifying missing parts on the inventory sheets and incomplete inventory sheets are two very different issues.

The first is the builder's responsibility. The second is FFR's responsibility. If the builder gets a set of inventory sheets that simply don't list parts that are supposed be included, how would the builder know what's missing?

[Otee453]

I had missing parts, not on the inventory sheets. Didn’t know what was missing, because it wasn’t in inventory. When I got to that part of the build, I drove myself nuts looking for the parts. It finally occurred to me that the parts weren’t there nor were they on the inventory sheet.

It was a bit of a helpless feeling…. Not knowing what else might be missing that I’d have no idea was actually missing.
An email to FFR had the parts shipped right away.

This was in 2020 during the summer of Covid.

[BradCraig]

Unless things have changed, everything that is part of the complete kit is on the inventory sheets delivered with your Roadster. The POL will tell you the subset that was not delivered and on backorder. SO important to open EVERY box an check off every part on the Inventory list as you do. FF does miss things and is extremely good about sending what is missing. What other parts have you identified as missing that are not on the Inventory sheet? The accelerator pedal and head lights you mentioned most definitely should be on the list. Good luck with your build!

[rthomas98]

As others have said very normal. I was missing some fasteners. I would also check anything that is supposed to be LH and RH to make sure you didn't get a double. I received 2 RH rear brake calipers in mine. FFR sent me a new one no issues. Also to be honest the 45 days that they state after receipt is more of a guideline. I had left turn signal that was messed up and they replaced no questions asked and that was a year and half after I received my kit. You are dealing with (in my opinion) one of the most reputable companies out there. They will fix anything needing to be fixed.

[Theshandman]

Ditto on Dave Lindsey- very helpful guy. My 'problem' was that when I inventoried the contents of all the boxes, I, as a relative newbie, didn't fully understand what I was looking at vs. what was described in the parts list, not all of which was very clear. Some stuff I thought I had I didn't and vice versa. And of course when it came to the part of the build where I needed some of the stuff I had marked as present, it actually wasn't and that was way past the 30 day inventory grace period. Dave L was very understanding and came to my rescue in all cases.

[haak60]

My front upper control arms, headlights, clutch cable missing and not listed anywhere.I had a couple of hey wait a minute moments after I did inventory realizing I was missing parts that weren’t even listed

[Malibu46pt]

I have asked FFR for a master inventory list. They say they don’t have such a list. How are we to know what is missing when their inventory sheet that comes with the delivery is incomplete.

[GT53]

I received my roadster kit last week. Checked off all the boxes I received then started the inventory of the contents box by box and identified all the parts missing on the inventory sheet for each box. This is in addition to the parts list shortage provided by FF When I started to assemble some of the parts it became clear that many more parts were missing and were not in the boxes and were not listed on the inventory sheets. In this case I don’t even know what parts are missing.
Has anyone else had this issue? How did you communicate this to Factory Five and how did you resolve it.
At this point there is no way for me to know what parts I am missing
Help!!!!

This is first time I have put a kit like this together and to put it mildly, there is indeed a “learning curve,” and the first part of this curve is inventory. Flatten the curve by doing a part by part inventory. I thought that I had done a pretty thorough inventory but when it came time to start putting things together I realized that should I ever do another build I would spend whatever time it took to identify EVERY SINGLE PART.

My suggestion, and please take this with a grain of salt from a new builder, is put in whatever time it takes to know what part is what, and bag and label said parts so that you’re not doing what I have been doing which is spend way more time than necessary looking for a damn nut or bolt.

As has been stated in other threads, sit down with the build manual and go through every box and every part and get in the manual to see where said part goes….Then bag it and label it. Jot down notes in the manual if it helps. I wish I had done that!!! I promise you that it may seem tedious, but the time you spend doing this now will save you a lot of time down the road.

With regard to the incomplete inventory list from FF, I would certainly make some calls to see what’s up with that.
In the meantime, here is a link to a previous thread (I don’t remember who posted it so I can’t credit it) that is a pretty complete spread sheet with what’s in each box etc. Things have likely changed but regardless of what box a part resides it’ll be a place to start.

http://http://docs.google.com/spreadsheets/d/1Uef9TQxjs7tWFECppbf3PGPJCVaLGfxL0MGpOWnnWBk/edit#gid=627606035

When I ran into problems my contact at FF was Sally Bean, and there was not a single time that she did not respond to my question / problem. She bailed me out more than once.
I haven’t talked to her in a few months so I can’t say for certain that she is still there and still in her position at Customer Service. (Sally@factoryfive.com)

Hope this helps.

Greg

[racingandfishing]

I was trying to compare a base kit to a complete kit for a coupe. After multiple ambiguous responses and seemingly not wanting me to know, I asked for an inventory list for each so I could do my own comparison. I was told they don't have one. I asked how is that possible when every customer gets one with their kit. They said they only print one out for each individual order and every order is different so there is no standard list.

While I still find that hard to believe, now they can't even print a list with what is supposed to be on there when you get your kit?

X2 to Papa and others.

Yes, it's my job to do the inventory. It's their job to provide an accurate inventory list.

Old system, New system, Covid... This isn't rocket science.

I don't want to get months or a year into the build to find I am missing parts and be told I have to buy them (let alone the time and frustration till you figure out they aren't even on the list). I know folks with past experiences say don't worry they will take care of it, but it seems that things are changing.

[BradCraig]

I'm still hung up on the topic of not having major items on the box-by-box inventory list. Are you guys sure you have this? It's the actual pick list the FF packers use and has every part they have packed except the POL. In the pic, the left stack is every box and every component that was shipped and is the list you do your inventory from. The right is the POL. Often I had to run though the stack a few times to find the line I was looking for, but it was definitely there. 171363

[Papa]

I'm still hung up on the topic of not having major items on the box-by-box inventory list. Are you guys sure you have this? It's the actual pick list the FF packers use and has every part they have packed except the POL. In the pic, the left stack is every box and every component that was shipped and is the list you do your inventory from. The right is the POL. Often I had to run though the stack a few times to find the line I was looking for, but it was definitely there. 171363

It sounds like some recent kit deliveries are missing the complete inventory. I think it would be interesting to get an example list from a builder that has experienced this to see what is happening.

[Mike.Bray]

I was trying to compare a base kit to a complete kit for a coupe. After multiple ambiguous responses and seemingly not wanting me to know, I asked for an inventory list for each so I could do my own comparison. I was told they don't have one. I asked how is that possible when every customer gets one with their kit. They said they only print one out for each individual order and every order is different so there is no standard list.

I call BS on that one. When you order a kit the order confirmation they send you has several line items with part numbers such as 16799 Power Steering Components w/Complete Kit. So P/N 16799 is a sub-assembly of components that has a Bill of Material (BOM). I deal in this everyday in my job, a stroke of the keyboard and you've got the BOM. So the BOM's do exist as they have part numbers for everything they sell (as they should).

I ordered the pin drive front suspension which I tracked down the part number, 13242, from an old FFR order form I still had. It took my literally two months to get a BOM for this P/N, and once I did I realized FFR had added a couple of items on my order I did not need. To their credit they did take them off and give me a refund.

I've had discussions with Dave Lindsey about how nice it would be to get the BOMs/Inventory a month or two before shipment. With mine I have literally three or four boxes of brand new parts I'm not going to use like Mustang brakes, hubs, and Wilwood master cylinders. With the aftermarket for these cars there's just so many OEM parts that get replaced with parts from Breeze, Wilwood, or other suppliers. I told Dave conservatively I bet FFR is shipping over $100k/year of parts that aren't being used.

[Mike.Bray]

One thing I noticed with my kit is parts aren't always in the boxes they say they are. It wasn't a lot of parts but I did move a few items around to match the inventory lists.

[Barwickad]

I received my complete kit Thursday and finished inventory yesterday. Mark from Stewart gave me a list of the boxes shipped and delivered and an envelope of FFR paperwork. The FFR paperwork included an itemized breakdown of the contents of each box shipped and a POL. After carefully inventorying each box the parts received matched the itemized box inventory list with a couple of very minor discrepancies. The items identified as missing on the itemized box breakdown matched the POL. As I was putting everything away I realized I’m missing front upper control arm assemblies, mirrors, headlights, turn signals, no car show packet or any rivets. None of the paperwork provided mentions anything about any of these items. So yes. Very difficult to identity what else might be missing. I will reach out to FFR first thing tomorrow.

[racingandfishing]

I call BS on that one.

Agreed, but I have a dozen or more emails on the topic and they will not provide the inventory check lists. I was finally sent another persons checklist and it wasn't even for a coupe, it was for a roadster. I was told that was the best they could do. To date, they insist there are no such lists. Ultimately it makes me less confident about my decision to place an order.

[Ted G]

The only thing that was missing in my kit that wasn't on a sheet anywhere was the driveshaft (at least that's all I found this far 5 months into my build). They corrected that right away.

[BradCraig]

I received my complete kit Thursday and finished inventory yesterday. Mark from Stewart gave me a list of the boxes shipped and delivered and an envelope of FFR paperwork. The FFR paperwork included an itemized breakdown of the contents of each box shipped and a POL. After carefully inventorying each box the parts received matched the itemized box inventory list with a couple of very minor discrepancies. The items identified as missing on the itemized box breakdown matched the POL. As I was putting everything away I realized I’m missing front upper control arm assemblies, mirrors, headlights, turn signals, no car show packet or any rivets. None of the paperwork provided mentions anything about any of these items. So yes. Very difficult to identity what else might be missing. I will reach out to FFR first thing tomorrow.

You sure the items aren't on the inventory sheet? My upper control arms are listed on "Box 1H-Primary Chassis Components". Headlights and turn Signals on "Box 3A - Body Finish Components". As I stated before, unless FF has changed inventory sheets then they should be there. Any way you could scan your inv sheets to PDF? Some guys have done this with OCR so they can search.

[Barwickad]

You sure the items aren't on the inventory sheet? My upper control arms are listed on "Box 1H-Primary Chassis Components". Headlights and turn Signals on "Box 3A - Body Finish Components". As I stated before, unless FF has changed inventory sheets then they should be there. Any way you could scan your inv sheets to PDF? Some guys have done this with OCR so they can search.

Hi Brad. My “Box 1” inventory is completely different than the photo of Box 1H you posted. Ditto on my box 3 which is Koni shock assemblies (which are on my POL). I’ve reviewed every line item on all my paperwork, no mention anywhere of the parts that were not included. I can’t post pictures yet or I’d include a screenshot of how different they are.

[BradCraig]

Hi Brad. My “Box 1” inventory is completely different than the photo of Box 1H you posted. Ditto on my box 3 which is Koni shock assemblies (which are on my POL). I’ve reviewed every line item on all my paperwork, no mention anywhere of the parts that were not included. I can’t post pictures yet or I’d include a screenshot of how different they are.

Wow, they must have switched up the inventory sheets then. Good luck, hope you get it worked out.

[Papa]

Keep in mind that every inventory will likely be somewhat different. I just looked at mine again, and my complete kit inventory and POL are printed on 40 pages. I scanned them and the PDF is just over 11MB; not easy to share. I would be very interested in anyone that believes they have a "short" inventory that is willing to share to reach out. I'd like to see what you are seeing.

For reference, here is what my Box 1H contained:

https://thefactoryfiveforum.com/attachment.php?attachmentid=171366&d=1661108969

[Malibu46pt]

FFR has a serious inventory system issue. I don’t understand why each kit does not have a complete BOM. How does anyone at FFR pull stock to fill the orders. Parts can be in random boxes with their individual inventory sheets but this has to be checked against a master list to generate to POL. I think anyone who received a recent delivery for a kit using the new inventory system should receive a master itemized parts list for their build. Otherwise we will not know we are missing a part until we get to that part of our build and find out we don’t have that part, leading to more delays and frustration

[Namrups]

I received my coupe a couple of months ago. I did not have a 1H inventory sheet. I had a 1i sheet. Don't know it that's because it's a coupe or not. I had 1 and 1/2 pages of POL items that matched the items on the inventory sheets that were listed as missing. I did have a handful of MIS items that I notified FF on. I also had 1 item that was not on my inventory or POL sheets. That was the IRS diff! That was easy to figure out. If there is anything else that is missing and not on the inventory/POL sheets I will never know.

[BradCraig]

FFR has a serious inventory system issue. I don’t understand why each kit does not have a complete BOM. How does anyone at FFR pull stock to fill the orders. Parts can be in random boxes with their individual inventory sheets but this has to be checked against a master list to generate to POL. I think anyone who received a recent delivery for a kit using the new inventory system should receive a master itemized parts list for their build. Otherwise we will not know we are missing a part until we get to that part of our build and find out we don’t have that part, leading to more delays and frustration

They do. Every delivery does come with "your" BOM which is custom to every order. The FF packers use that list to pack the boxes and check off every single part they pack. Parts not available on that list at time of packing will be on the POL. Now if they in fact have moved to the new system they may have some bugs they are working out, they will fix it and any parts missing will be delivered with no questions asked. That's how FF works.

[Barwickad]

Here is a copy of my box 1. Quite a bit different than others have posted. Just to be clear, I have no concerns about FFR sorting this out as soon as they can. Just allot of extra work for folks on both ends.

171376171377

[Papa]

Thanks for sharing. Obviously using a different system, but it looks like the detail is still there. It would be interesting to see a complete set of inventory sheets to try to compare to the old system.

[sasteel43]

Here is a copy of my box 1. Quite a bit different than others have posted. Just to be clear, I have no concerns about FFR sorting this out as soon as they can. Just allot of extra work for folks on both ends.

171376171377

That is the newest inventory system with bar codes. I spoke with Dave Smith yesterday and he mentioned this would be launching soon.

[Namrups]

I'm sure the new inventory system will be much better after all the bugs are worked out but going back to the original post, if an item is not listed on the inventory sheet nor on the POL list a first time builder won't know its missing. We don't know what we don't know!