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Ford adding second supplier for F-150 frames

Metalsa, the company that builds steel frames for the aluminum-bodied Ford F-150, is still having trouble providing enough frames to supply the two factories that build the pickup. The snafu is preventing Ford from selling as many of the country's best-selling truck as it could, and eating into profits - even though the bottom line is still breaking company records. According to The Wall Street Journal, Ford has picked Michigan company Tower International as a second frame supplier and expects to have inventory up to a proper level at the beginning of Q4 of this year. Neither Ford nor Tower would confirm the development - Automotive News got comments from a source and pieced together bits of info from Tower's financial statements and local press reports. Tower currently builds body structures for several vehicles, including the F-series, and the Bellevue, Ohio factory that will build F-150 frames previously manufactured frames for the Ranger and Econoline. According to a story in the local Sandusky Register, Tower will add one production line at the end of next month to begin shipping frames in October, and another line in April 2016. Something like 138 full-time workers and 364 robots are expected to carry out the work. Tower's most recent financial statement said that capital investment will be necessary to get everything set up, but the contract will be worth $140 million in yearly revenue.

2015 Ford Edge First Drive [w/videos]

We're routinely told that it's not easy being the middle child. The oldest sibling will always outshine the rest, while the youngest is routinely doted upon. The middle child, meanwhile, is seemingly never able to measure up. You know the drill: Marcia, Marcia, Marcia! But that hasn't really been the case for Ford's mid-kid crossover, the Edge. Sandwiched between its highly successful big brother, the Explorer, and the stylish younger brother, the Escape, the Edge has had plenty of its own bragging rights over the years. It's where the Blue Oval chose to first launch MyFord Touch in 2011, and was one of the company's first applications of an EcoBoost engine in a CUV. For 2015, Ford has given the Edge a brand-new outfit, complete with stand-out sheetmetal and a revamped 2.0-liter four-cylinder engine fitted with a twin-scroll turbocharger and direct-injection. The result is a vehicle that truly stands out from its compact and fullsize siblings while promising to retain Ford's edge in the midsize CUV market. Where many of Ford's cars have opted for a slim, Aston Martin-like grille, the new Edge's face is big and bold. It's around back, however, where the Edge really comes up with its own personality. The slimmer D-pillar forms the edges of a more aggressively raked rear window. It's difficult to spot in pictures, but the result is a decidedly more assertive profile than the outgoing CUV. Beyond that, the rear is home to Fusion-inspired taillights, although unlike Ford's popular midsize sedan, they're joined together by a vehicle-spanning lighting element that prominently features a Ford badge at its center. Ford's work on the Edge's interior is less progressive, though. The owner of a 2014 model wouldn't feel the least bit out of place climbing behind the wheel of a 2015, as it features Ford's same reconfigurable instrument cluster, and a center stack that's been crowned by the latest (and final) edition of MyFord Touch. Meanwhile, more JD Power Initial Quality Study-friendly buttons have replaced the obstinate and unintuitive touch-capacitive controls. The conservative take on the interior design belies the big improvements in material quality. The leather inserts in the doors are more heavily padded and the plastics are far softer. It's a similar story throughout the cabin, where owners will notice softer dash plastics and generally richer materials.

Malcolm Gladwell reflects on engineering, recalls, and compromise

Journalist Malcolm Gladwell has made a career taking on big, complicated topics and humanizing them to make the unwieldy understandable. He has already done this in bestsellers like The Tipping Point and Outliers, and now he has brought the same approach to automotive recalls in a long piece for The New Yorker. The article titled The Engineer's Lament is framed around an interview with the former head of Ford's recall office about the famous Ford Pinto campaign where the position of the compact's fuel tank could cause it to explode in rear-end collisions. Plus, there are detours into Toyota's unintended acceleration cases and the General Motors ignition switch problem. While all the history is illuminating, the heart of the story comes from an examination at the thought process of engineers, and how their thinking differs from other professions. Gladwell comes off as sympathetic to auto engineers in this piece. While he admits that they often approach problems in a sterile way, the writer doesn't try point that out as a failing. It's merely a fact to be understood. The story itself is quite lengthy, but well worth a read if you have the time for an insiders view into how these recalls are assessed on the inside.