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How Ford switched gears for the all-new F-150

Editor's Note: This story is authored by Julia Halewicz, a senior editor with AOL's Custom Solutions Group. She holds a Masters in Journalism from NYU and has spent her career as an editor of various newspapers, magazines and digital outlets. Last year on the Friday before Labor Day, the 2014 Ford F-150 pickup truck came off the Dearborn assembly line for the last time. After the last seam was welded, the F-150 that had been so beloved by American consumers would begin the transition from traditional steel manufacturing to an aluminum body, and the second phase of Ford's 2007 blueprint for sustainability would begin. Jobs would be created, and Ford would deliver a stronger product to its consumers. It was a moment Ford would call the biggest in the company's 111-year history. Breaking The Mold For some, the change was almost unfathomable. How could a truck be made with aluminum, and why change what clearly was working very well for the company? "We have a saying at Ford that leaders lead," said Doug Scott, the company's truck group marketing manager. "This was an ideal product to make with aluminum-alloy, because lightweighting made so much sense for a truck, because the extent to which you could take weight out of a truck, you could add more value to the customer in terms of more towing, more payload, more durability, more efficiency – so again all this required us to be out in front further out in front that we normally would be to make sure that we would deliver on all those expectations." Ford began the planning process about five years before the first aluminum F-150 would come to market. The company had a lot of questions. What was customer acceptance of aluminum, could they build the truck, and could the truck be repaired out in the field? Finally, Ford needed to determine if there were enough materials available to support the demand for the F-Series. Aluminum vehicles aren't unusual, but had never been built on the scale of the F-150 – approximately one every minute. Ford created two prototypes to determine if the product would meet and exceed consumer expectations. Any change to the vehicle had to be justified in performance, safety and economy. An aluminum truck needed to be safer, lighter, have increased payload, haul more, and have improved fuel efficiency. After driving the prototypes, Ford knew it was ready to move forward. Once the aluminum truck was ready to build, the next challenge was quickly transforming the plant.

Ford highlights new F-650 and F-750 with full-size Tonka show truck [w/videos]

Who among us hasn't been tempted by the prospect of buying a big yellow truck and painting the name Tonka along the side? Well apparently there were some folks over at Ford who were just as tempted, only they actually had the means to make that childhood fantasy a reality in the form of the truck you see here. Revealed at the NTEA Work Truck Show this week in Indianapolis, this Tonka show truck stands nearly 10 feet tall. It's painted bright yellow, just like the one you played with in the sand box (and probably still would given the opportunity and maybe no one else looking) and has a blacked-out nose treatment and special graphics. As you can see, it's also equipped with a working dump bed, and has a truly staggering 33,000-pound gross vehicle weight rating, built to showcase the Blue Oval's new line of medium duty trucks. Of course "medium duty" is a relative term, and the new F-750 is clearly a heavier piece of machinery than the company's own Super Duty pickups, but they're lighter-duty than a proper big rig. The new 2016 Ford F-650 and F-750 are just as tough as the models they replace, but they're now quieter and more comfortable to use. In fact, Ford says its 6.7-liter Power Stroke V8 diesel is now 25-percent quieter inside the cabin at highway speeds, 45-percent quieter at idle and 35-percent quieter standing outside in front of the grille. Ford notes that it's the only medium-duty truck manufacturer that makes its own engines and transmissions. That Power Stroke diesel comes with 270 horsepower and 675 pound-feet of torque as standard, but can be upgraded to 300 hp and 700 lb-ft or all the way up to 330 hp and 725 lb-ft. Commercial buyers will also be able to choose between Regular, Super and Crew Cab models with a straight-frame, dock-height or tractor-towing frames, meaning that whatever it is you've got to haul, chances are high that the new Ford F-650 and F-750 can be set up to get the job done.

Ford worker files for UAW dues refund, stirs right-to-work debate

Let's start with some history: Ford's Dearborn truck plant, part of the company's massive River Rouge complex, was the center of a strike in 1941 that led to Ford signing the first "closed shop" agreement in the industry. The agreement obliged every worker at the plant to be a dues-paying member of the United Auto Workers. In December 2012, however, Michigan Governor Rick Snyder signed legislation making Michigan a right-to-work state, which outlawed closed shops. The new law gave workers the right to opt out of union membership and stop paying dues even if they were still covered by union activities like collective bargaining. For employees at the Dearborn plant, the right-to-work clauses take effect at the end of their current contract in 2015.
As a tool-and-die maker at Ford's Dearborn plant for 16 years, Todd Lemire pays dues to the UAW - about two hours' salary per month. However, he's been unhappy with the UAW's support of the Democratic party, and not wanting to wait until next year to be out of the UAW entirely he invoked his Beck Rights, which state that a non-member of a union does not have to pay dues to support non-core activities, such as political spending. But Lemire wasn't happy that Ford still subtracted the total amount of dues, with the UAW reimbursing the difference, so he filed suit with the National Labor Relations Board, feeling that the workaround violates his rights.
Lemire's case is just a week old, so it could be a while before a resolution. Yet, as September 15, 2015 draws near and the right-to-work laws take full effect for Michigan workers - and others wonder whether it could help revitalize the state's manufacturing base - a case like this adds more fuel to the discussion.