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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.

Huge, pricey trucks haul jobs and profits for the Detroit Three

DECATUR, Texas — Mickey McMaster is on his 12th pickup truck. The 61-year old farm equipment dealer in Decatur, Texas, two weeks ago treated himself to a 2019 GMC Denali for around $69,000 — a reward for long hours at work. "For me this is the Cadillac of trucks, it's a real luxury vehicle," McMaster said. "I've worked my way up to afford a truck like this and it shows that I've earned it." McMaster is the kind of customer General Motors Co is banking on as it plans to add 1,000 jobs at a plant in Flint, Michigan that will build a new generation of its largest pickups. Demand from Texas and other heartland states for big pick-ups is providing a lifeline to many workers the No. 1 U.S. automaker is laying off at plants elsewhere. The Detroit Three automakers and thousands of their U.S. workers are counting on customers like McMaster to keep buying bigger and more luxurious pickup trucks even if overall U.S. vehicle demand weakens this year, as most analysts predict. At Flint, GM will build a new generation of its heavy-duty Chevrolet Silverado and GMC Sierras, including luxury models that are some of the most profitable vehicles on the planet. GM, Ford Motor Co and Fiat Chrysler Automobiles NV's Ram division own the segment and are each doubling down with new or redesigned models launching this year. Sales of heavy-duty pickups in the United States have grown to more than 600,000 vehicles a year, up more than 20 percent since 2013, according to industry data. Prices for luxury models can easily top $70,000. GM on Tuesday celebrated the launch of a new generation of heavy-duty GMC and Chevrolet pickups at the assembly plant in Flint, Michigan, that is now building all such trucks for the company. At the same time that GM is laying off thousands of U.S. workers and planning to shutter five North American factories, Flint is hiring. The plant runs on three daily shifts, six days a week. As the new model's assembly system ramps up, the plant's capacity will increase by more than 25 percent, plant manager Mike Perez told Reuters. The Flint plant plans to add 1,000 workers, more than half of the 1,500 factory workers who have asked to transfer from plants GM has targeted for shutdown as part of CEO Mary Barra's restructuring plan. "We're bringing in 50 to 100 people every week," said Perez. Workers last week were still finishing the job of retooling the Flint factory to build the new heavy-duty trucks as part of a $1.5 billion investment project.

‘American Auto’ fires on most cylinders

If you like cars or you enjoyed “Superstore” then “American Auto” is worth your time. NBC previewed the punchy sitcom last night ahead of the series premiere Jan. 4, and it offers a humorous take on the U.S. auto industry as seen through the team at fictional Payne Motors. Overseen by Justin Spitzer, the creator of “Superstore” and a producer on “The Office,” the two episodes that dropped Monday show Payne executives trying to navigate the challenges of the modern auto business.  “Saturday Night Live” alum Ana Gasteyer stars as a pharmaceutical exec turned Payne CEO. The cast also includes Harriet Dyer as stressed-out PR boss, Sadie; Tye White as Jack, a factory worker who gets promoted to the C-suite; and former “Superstore” cast member Jon Barinholtz as the company scion, Wesley, who has no job responsibilities and is employed because of his name. The cast also includes X Mayo, Michael Benjamin Washington and Humphrey Ker as executives. This content is hosted by a third party. To view it, please update your privacy preferences. Manage Settings. Autoblog -- thatÂ’s us -- gets name-checked early in the second episode (2:37 into the show) for "our" critical take on GasteyerÂ’s introduction of the Payne Ponderosa, a car the company scrambled to build in time for its auto show reveal.  GasteyerÂ’s CEO character walks in on a meeting between Sadie and Jack -- their budding romance appears to be part of the story arc -- and blurts out “Autoblog says hasty HastingsÂ’ premature launch,” apparently a reference to a headline that pans the Ponderosa. Looking at the cartoonish wagon-like thing, itÂ’s well-earned criticism. Perhaps the writers know of us -- weÂ’ve been around for nearly 18 years and are read by millions each month -- or thought ‘AutoblogÂ’ sounded like a good name for a car website. Either way. The pilot is centered on the Ponderosa and its troubled development (the first version of the car ran over people). Episode 2 features a Ponderosa Magellan van being used by a serial killer in a police chase. Titled “White Van,” the episode is obviously reminiscent of O.J. SimpsonÂ’s 1994 chase in a white Ford Bronco. ThereÂ’s also some Michigan references, which help to set the scene. One character has a Wayne State degree on the wall and the Magellan flees on Interstate 94, which runs through the state.