Having worked for several European manufacturers, I can tell you the R&D division producing cars is small compared to the the aftermarket. A few of the challen

Having worked for several European manufacturers, I can tell you the R&D division producing cars is small compared to the the aftermarket. A few of the challenges: - which parts to produce and when - how many - how to ensure there is stock everywhere (shipping is not an option on a large market, as it is too costly) - how to make sure everybody knows how to mount the part - how to guarantee that your official spare parts are used Saying it is "hard to keep up with the demand" is a marketing way of saying "we are not good at manufacturing". Like software, it is easier to design the right car than fixing it after. But fixing defects or accidents is a necessity that no good design can prevent.