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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 recalling 433k cars for engines that don't shut off

Ford Motor Company has announced an enormous recall affecting 433,000 vehicles built between April 2014 and June 2015. There's a problem with the body control module in the affected vehicles that can prevent them from turning off, even if the key is removed from the ignition or stop/start button has been pressed. Individual models include the Focus and C-Max, both built at the Michigan Assembly Plant. The defective Foci were built between June 17, 2014 and June 12, 2015, while the C-Maxes were built between April 22, 2014 and June 12, 2015. Also affected are model year 2015 Escape CUVs, built at the Louisville Assembly Plant in Kentucky, between April 1, 2014 and June 12, 2015. As is usually the case, the overwhelming majority of vehicles – 374,381 – are registered in the United States, while the 52,180 are in Canada and 5,135 are in Mexico. The Blue Oval is not aware of any injuries or accidents due to this defect. Individual consumers, meanwhile, will need to report into dealers to have the body control module's software updated. Scroll down for the brief press release from Ford. Related Video: FORD ISSUES SAFETY COMPLIANCE RECALL IN NORTH AMERICA DEARBORN, Mich., July 2, 2015 – Ford Motor Company is issuing a safety compliance recall for approximately 433,000 vehicles in North America, including certain 2015 Focus, C-MAX and Escape vehicles, for an issue with the body control module. In these vehicles, it could be possible for the engine to continue to run after turning the ignition key to the "off" position and removing the key, or after pressing the Engine Start/Stop button. This is a compliance issue with FMVSS 114 regarding theft protection and rollaway prevention. Ford is not aware of any accidents or injuries associated with this issue. Affected vehicles include certain 2015 Focus vehicles built at Michigan Assembly Plant from June 17, 2014, through June 12, 2015; certain 2015 C-MAX vehicles built at Michigan Assembly Plant from April 22, 2014, through June 12, 2015; and certain 2015 Escape vehicles built at Louisville Assembly Plant from April 1, 2014, through June 12, 2015. There are 432,096 vehicles in North America, including 374,781 in the United States and federalized territories, 52,180 in Canada and 5,135 in Mexico. Dealers will update the body control module software at no cost to the customer.

Ford Model e losing billions as it says EV unit should be seen as startup

DETROIT — Ford Motor Co.'s electric vehicle business has lost $3 billion before taxes during the past two years and will lose a similar amount this year as the company invests heavily in the new technology. The figures were released Thursday as Ford rolled out a new way of reporting financial results. The new business structure separates electric vehicles, the profitable internal combustion and commercial vehicle operations into three operating units. Company officials said the electric vehicle unit, called “Ford Model e,” will be profitable before taxes by late 2026 with an 8% pretax profit margin. But they wouldn't say exactly when it's expected to start making money. Chief Financial Officer John Lawler said Model e should be viewed as a startup company within Ford. “As everyone knows, EV startups lose money while they invest in capability, develop knowledge, build (sales) volume and gain (market) share,” he said. Model e, he said, is working on second- and even third-generation electric vehicles. It currently offers three EVs for sale in the U.S.: the Mustang Mach E SUV, the F-150 Lightning pickup and an electric Transit commercial van. The new corporate reporting system, Lawler said, is designed to give investors more transparency than the old system of reporting results by geographic regions. The automaker calculated earnings for each of the three units during the past two calendar years. Model e had pretax losses of $900 million in 2021 and $2.1 billion last year, and it is expected to lose $3 billion this year. In the past two years Ford has announced it would build four new battery factories and a new vehicle assembly plant as well as spending heavily to acquire raw materials to build electric vehicles. By the end of this year, the company based in Dearborn, Michigan, expects to be building electric vehicles at a rate of 600,000 per year, reaching a rate of 2 million per year by the end of 2026. Ford Blue, the unit that sells internal combustion and gas-electric hybrid vehicles, made just over $10 billion before taxes during the last two years. Ford Pro, the commercial vehicle unit, made $5.9 billion during those years, the company said. For this year, Ford expects Ford Blue to post a $7 billion pretax profit, modestly better than last year. Ford Pro is expected to earn $6 billion before taxes, nearly double its earnings last year, Lawler said. Ford was to present the new structure, announced last March, to analysts and investors on Thursday.