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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 doubling 1.0L EcoBoost engine production

Ford's 1.0-liter EcoBoost three-cylinder engine hasn't been around that long, but it sounds like the engine is getting to be fairly popular in the automaker's global car lineup. The Detroit News is reporting that Ford has add a second shift that will allow its German engine plant to double daily output from 500 engines to 1,000.
The increased capacity is part of a plan to sell more than 300,000 vehicles a year with this engine in Europe by 2015. Europe is currently the only market where the smallest of the EcoBoost engines is offered (including in the Focus pictured above), but US-spec Fiesta models will be getting this mill for 2014.
Three-cylinder engines are expected to continue to grow in popularity in coming years with the report indicating that global production of these engines will double by 2018 to 9.8 million units. General Motors, BMW and Mitsubishi are all expected to introduce three-cylinder engines in the near term, as well.

Former Ford CEO Alan Mulally lands on Google board

Former Ford CEO Alan Mulally often referred to the Blue Oval as a technology company when he led the automaker. Now he'll be offering guidance to a different kind of technology firm: Google.
Mulally was appointed to Google's board of directors July 9, and late Tuesday, it was announced that he will serve on the company's audit committee. The veteran executive led Ford from September 2006 until he retired in June, succeeded by Mark Fields.
While Mulally will act as a board member - rather than in a managerial role - his presence adds credibility to Google's recently announced plans to produce an autonomous car. The ambitious program calls for 100 prototypes to begin testing later this summer. Production of the car is rumored to be in collaboration with a Detroit area performance company, Roush.