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GM laying off 500 workers to slow Chevy Sonic production

Due to slow sales of the Chevrolet Sonic and Buick Verano, General Motors is cutting a shift at the Orion Township plant that builds the pair. The move lays off about 500 workers, but most of them are expected to get offers to transfer to other factories, Automotive News reports. The move came just a day after GM announced adding 1,200 employees to the Detroit-Hamtramck plant. GM has been trying all year at the Orion Township factory to align production of the Sonic and Verano with their demand. The automaker first attempted idling the plant several times and eventually resorted to laying off about 100 workers. It also reduced the production rate there. With the huge rise in popularity of crossovers, demand for the plant's small cars is on the downturn. According to Automotive News, there's currently a 116-day supply of Sonics and 100 days of Veranos to sell. Delivers tell a similar tale because the Chevy is off 35.2 percent from January to September, and the Buick does little better with a 27.2 percent drop from the same period last year. While the situation at Orion Township might look rough now, big things are on the horizon. Soon, the new Chevy Bolt electric vehicle will be built there when it hits the market around 2017. Plus, the plant will also get a $245-million upgrade and 300 new jobs for another, unannounced vehicle.

Chevy Bolt EV's battery shows big improvements over Spark's

Plug-in vehicle battery technology moves fast, and all you need to do to see this in action is to take a look at the new 60-kWh lithium-ion pack inside the 2017 Chevy Bolt EV. Well, you need to do that and then compare it to the battery packs inside of GM's other plug-in vehicles. And you don't even to go as far back as the EV1 to see progress. Let's start with what we know about the new Bolt's pack. It is supposed to drive the Bolt EV over 200 miles on a full charge. It weighs 960 pounds and is made up of 288 cells. Chevy's other all-electric car, the limited-availability Spark EV, had a 19-kWh pack and offered 82 miles of range. It had 192 cells and weighed 474 pounds. So, in the few years since the Spark EV was released, GM engineers have figured out how to get three times the energy capacity and almost two-and-a-half times more range out of a pack that weighs only about twice as much. And that doesn't even get to the price drops. GM has figured out how to get 3x the energy capacity and almost 2.5 times more range out of a pack that weighs only twice as much. Speaking of those 288 cells, that number might sound familiar to regular readers because that's exactly how many are in the new Chevy Volt. But the packs in the Volt and the Bolt are entirely different beasts. For one thing, while the Volt cells are made by LG Chem in Holland, MI, LG Chem will make the Bolt's cells in South Korea. The cell chemistries are also different. We spoke with GM engineer Tim Grewe (again) and while he declined to answer some of our Bolt battery pack questions until more details are unveiled at the SAE World Congress in April, he was able to explain a few things. "The cell inside the Chevy Bolt EV was specifically designed for EV range so it's up on energy," he said. "That's a different cell chemistry than on the extended range Chevy Volt, which is a smaller pack, smaller energy but more power per cell. We work with all of those vehicle requirements and customer demands and we say how do we meet this and we change the chemistry to make it all work." Comparing the 60 kWh in the Bolt and the 18.4-kWh pack in the Volt is really one of those apples to oranges issues, he said. "If you look at the Volt battery pack, how it went from where it was and where it's up to, from 38 miles to 50 miles, that was basic, overall industry improvement. Now, the 18 [kWh] to the 60 [kWh] is extended range vs. EV.

Ford F-150, Chevy Silverado, Toyota Tundra flunk IIHS headlight test

The Insurance Institute for Highway Safety put pickup truck headlights to the test and found that the majority of them were equipped with subpar units. The 2017 Honda Ridgeline was the only truck to earn a rating of "good." The large pickup truck test was comprised of the: 2016 to 2017 GMC Sierra, 2017 Nissan Titan, 2016 Ram 1500, 2016 to 2017 Chevrolet Silverado, 2016 to 2017 Ford F-150, and 2016 to 2017 Toyota Tundra. The Sierra's headlights earned a rating of "acceptable," the headlights found on the Titan and Ram 1500 were found to be "marginal," and the ones on the Silverado, F-150, and Tundra were rated as "poor." IIHS claims the F-150 was the most disappointing out of the large pickup trucks as both its halogen and optional LED headlights failed to provide adequate visibility during testing. The Ridgeline (which earned a "good rating"), is usually considered a midsize or small truck, though IIHS included it in the field of large pickups. The headlights on the 2016 Chevrolet Colorado, 2016 GMC Canyon, 2016 Nissan Frontier, and 2016 to 2017 Toyota Tacoma, which made up the small pickup truck group, all earned a rating of "poor." The IIHS claimed the Colorado had the worst headlights of any truck that was tested, as the base vehicle's units were only able to illuminate up to 123 feet in front of the car. The Ridgeline's headlights, for reference, were able to illuminate up to 358 feet in front of the vehicle. To conduct its test, the IIHS utilizes a special tool to measure how far light is projected out of the headlights in different driving situations. The trucks' headlights were tested in a straight line and in corners, while vehicles with high-beam assist were given extra praise. The headlights on the pickup trucks also mimic the testing that was done on small SUVs and cars earlier this year. Next year, automakers will need to fit their vehicles with headlights that earn a rating of either good or acceptable to earn the IIHS Top Safety Pick+. Related Video: