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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 Raptor or Corvette-powered Defender, which would you choose?

Autoblog may receive a share from purchases made via links on this page. Pricing and availability are subject to change. No donation or payment necessary to enter or win this sweepstakes. See official rules on Omaze.  Enter this sweepstakes today and get 150 bonus entries by signing up for the Autoblog Newsletter right here! Going around a track at breakneck speeds is exhilarating, but I much prefer leaving the asphalt behind and hitting the trail, which is why my dream garage is filled with vehicles like Land Cruisers, Broncos, Jeeps, Rams and even a lifted Subaru or two. Not to mention the two vehicles pictured above, the Ford F-150 Raptor and the Land Rover Defender. If either of these are in your dream garage, you’re in luck, because Omaze just happens to be giving away both, right now. All you have to do is enter here for the Raptor and here for the Defender. Win a Ford F-150 Raptor or a Himalaya Land Rover Defender - Enter Here Here is a side-by-side of the specs, according to Omaze: Vehicle: Himalaya Defender 110 Crew Cab / 2022 Ford F-150 Raptor 37 Maximum Seating: Four / Five Engine: 6.2-liter Corvette LS3 / 3.5L V6 EcoBoost Maximum Horsepower: 430 hp / 450 hp Maximum Torque: 425 lb-ft / 510 lb-ft Transmission: 6-speed automatic / 10-speed automatic Drivetrain: 4WD / 4WD Exterior Color: Satin Grey / Lead Foot Grey Interior Color: Jet Black / Rhapsody Blue Approximate Retail Value: $210,000 / $83,525 Defender special features: Black exterior roll bars and trim; Black 18” Sawtooth wheels with 35” tires; Wilwood brakes; 3" lift; Black diamond-stitched leather sport seats; MOMO Millenium steering wheel; front and rear matching consoles; Himalaya gauge cluster; Himalaya front and rear bumpers, bed-mounted tire carrier, and extended fender flares; Puma hood; LED lighting. F-150 Raptor special features: 0 to 60 mph in 5.1 seconds, 15 city / 18 highway miles per gallon fuel economy, Extended Range 36 Gallon Fuel Tank, 8,200-lb towing capacity, 17” beadlock-capable forged wheels, 37”x12.50 tires; Twin Panel Moonroof; Recaro Front-Seats; B&O Sound System; Fox Racing Shocks. Exterior Looks - Winner: Himalaya Land Rover Defender ThereÂ’s just something about the Defender. ItÂ’s rugged, yet handsome. ItÂ’s got classic appeal yet feels modern. It also has style while appearing to be as strong as a tank.

Hot-selling Ford Expedition, Lincoln Navigator get production boost

Ford is investing an additional $25 million in its Kentucky Truck Plant in Louisville to increase by 25 percent production of the hot-selling and all-new Lincoln Navigator and Ford Expedition SUVs. The investment adds to $900 million in previously announced spending at the plant, which also builds F-Series Super-Duty pickups and employs 8,400 workers. Assembly-line workers are putting in overtime and working voluntary weekend shifts to keep up with demand. The new investment will cover upgrades to the assembly line but does not involve further hiring, Ford spokeswoman Kelli Felker says. The popularity of the Ford Expedition and Lincoln Navigator is a bright spot as Ford stock has been battered by Wall Street amid concerns concerns about the automaker's future vision and slowness to detect trends. Ford says the investment is an example of its bid to improve "operational fitness," one of CEO Jim Hackett's common refrains. Ford says Navigator retail sales more than doubled in January, and Navigators are spending an average of just seven days on Lincoln dealership lots as customers trade in vehicles including Land Rovers and Mercedes-Benz. Nearly 85 percent of buyers are opting for high-end Black Label and Reserve trim packages, contributing to an average transaction price increase of more than $21,000 in January compared to a year ago. The 2018 Navigator won the North American Truck of the Year award and also topped a Detroit News poll of public favorites at last month's Detroit Auto Show. Sales of the Expedition, meanwhile, were up almost 57 percent last month as the full-size SUVs also spent an average of just a week on dealer lots. Platinum trim models represented 29 percent of sales, pushing transaction price increases up $7,800. Ford gave the 2018 Expedition an all-aluminum body to save mass in its first significant redesign since 2007. The plant last year got nearly 400 new robots, mainly in the body shop, to help increase line speed, and Ford added a robot lab where employees can test software tweaks or troubleshoot issues away from the factory floor. The Louisville plant also benefits from extensive new data analytics, with seven big-screen monitors providing minute-by-minute updates showing progress against hourly targets or alerting workers to pending parts shortages. A huge spare-parts "vending machine" lets workers more quickly locate needed parts and keep inventory at necessary levels.