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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.

New autonomous testing ground in Michigan will help battle bad weather

If one of the big weaknesses of autonomous vehicles is their ability to navigate in the snow, consider this a trial by fire. The American Center for Mobility says it has opened its $110 million driverless car testing facility on the site of a former General Motors assembly plant in Michigan, with Toyota and auto supplier Visteon the first to begin testing this week. The ACM proving ground is a 500-acre site at historic Willow Run in Ypsilanti Township, near Ann Arbor. It's one of 10 sites designated by the U.S. Department of Transportation as pilot proving ground sites to test AV technologies. It features a variety of simulated environments to test driverless cars, including a 2.5-mile highway loop, two double overpasses, intersections, roundabouts and a 700-foot curved tunnel. It also opens just as the region experiences a series of snowstorms and the first frigid temperatures of the season. That ability to test autonomous vehicles in a wide variety of weather conditions is important, as autonomous vehicle sensors have struggled to handle cold, wet and snowy conditions. Google parent Alphabet in October said its Waymo division was expanding its winter testing operations to Michigan, making it the sixth state where it's testing its driverless car systems. In a Medium blog post, Waymo CEO John Krafcik wrote that "This type of testing will give us the opportunity to assess the way our sensors perform in wet, cold conditions. And it will also build on the advanced driving skills we've developed over the last eight years by teaching our cars how to handle things like skidding on icy, unplowed roads." Waymo also opened a development center in suburban Detroit in 2016, working with Fiat Chrysler to integrate its autonomous technology into Chrysler Pacifica hybrid minivans. Visteon began testing and validating its DriveCore autonomous driving platform to evaluate algorithms, vehicle-to-vehicle and vehicle-to-infrastructure technology and other systems. Toyota used the facility Wednesday to begin orientation and driver training. ACM has so far secured $110 million to construct the first two phases from founders Ford, Hyundai America Technical Center, Toyota and Visteon, and says it expects to announce more investment soon.

Honda Ridgeline, Ford Ecosport and Tesla profits | Autoblog Podcast #537

On this week's Autoblog Podcast, Editor-in-Chief Greg Migliore is joined by Green Editor John Beltz Snyder and Associate Editor Joel Stocksdale. We talk about driving the 2018 Ford Ecosport and Hyundai Accent. Joel tells us why he loves the naturally aspirated engine in our long-term Honda Ridgeline. We discuss Tesla's profitability claims, Johan de Nysschen leaving Cadillac and a possible date change for the Detroit Auto Show. As usual, we'll also spend a listener's money on a car. Autoblog Podcast #537 Get The Podcast iTunes – Subscribe to the Autoblog Podcast in iTunes RSS – Add the Autoblog Podcast feed to your RSS aggregator MP3 – Download the MP3 directly Rundown Driving the 2018 Ford Ecosport Driving the 2018 Hyundai Accent A love letter to the Honda Ridgeline's V6 Leadership change at Cadillac Will Tesla be profitable this year? Will NAIAS move to October? Spend my money Feedback Email – Podcast@Autoblog.com Review the show on iTunes Related Video: Earnings/Financials Green Podcasts Detroit Auto Show Cadillac Ford Honda Hyundai Tesla Used Car Buying Truck Crossover SUV Economy Cars Electric Sedan