New car sales are on pace to exceed 15 million in the U.S. this year and as many as 85 million globally. A record 500 vehicle launches are expected by 2016.

"Everyone has parts shortages," said Carla Bailo, who heads Nissan Americas' research and development in Farmington Hills. "The supply chain is one of our biggest threats. Everyone cut back and is now ramping up. We can't get up to speed as quickly as in the past."

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