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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.

Honda poised for growth, Detroit to hold steady, Car Wars study says

The automotive industry is expected to keep booming in the US over the next several years, but the train might start running out of steam in the long term, according to 2015's Car Wars report from Bank of America Merrill Lynch analyst John Murphy. The forecast focuses on changes between the 2016 and 2019 model years, and the latest trends appear similar in some cases to the past predictions. Sales are expected to keep growing and reach a peak of 20 million in 2018, according to the Detroit Free Press. The expansion is projected to come from a quick pace of vehicle launches, with an average of 48 introductions a year – 26 percent more than in 1996. Crossovers are expected to make up a third of these, maintaining their strong popularity. However, Murphy predicts a decline, as well. By 2025, total sales could fall to around 15 million units. As of May 2015, the seasonally adjusted annual rate for this year stands at 17.71 million. Like last year, Honda is predicted to be a big winner in the future thanks to products like the next-gen Civic. "Honda should be the biggest market share gainer," Murphy said when presenting the report, according to Free Press. Meanwhile, in a situation similar to Car Wars from 2012, a lack of many new vehicles is expected to cause a drop for Hyundai, Kia, and Nissan. Based on this forecast, Ford, General Motors, and FCA US will all generally maintain market share for the coming years. The report does make some future product predictions, though. The next Chevrolet Silverado and GMC Sierra might come in 2019, which is earlier than expected. Also, Lincoln could get a Mustang-based coupe for 2017, a compact sedan for 2018 and an Explorer-based model in 2019, according to the Free Press. Related Video: News Source: The Detroit Free PressImage Credit: Nam Y. Huh / AP Photo Earnings/Financials Chrysler Fiat Ford GM Honda Lincoln Car Buying fca us

Expert: 54.5 mpg CAFE standard can be reached without many plug-ins

Johnson Controls executive Brian Kesseler isn't likely to get any holiday presents this year from Nissan chief Carlos Ghosn or Tesla Motors head Elon Musk, but lots of other folks might be happy with what he has to say about automakers' efforts to reach stricter fleetwide fuel-economy standards. Speaking at the Automotive News World Congress, Kesseler said automakers wouldn't need to sell an extensive number of plug-in vehicles in order to meet the 54.5 mile per gallon Corporate Average Fuel Economy (CAFE) standard the US government set in 2012 for 2025 model-year vehicles. In fact, he said, components such as stop-start engine technology, turbochargers and direct injection may actually do the trick. Already, things like smaller engine sizes and lighter cars are already playing major roles in spurring fuel-efficiency gains. Of course, Johnson Controls sells batteries specially built for stop-start systems, so Kesseler does have a bit of skin in this game. The 54.5-mpg CAFE standard equates to about a 40-mpg "real world" fuel-efficiency level. To put that into perspective, the Environmental Protection Agency (EPA) said in a report late last year that model-year 2013 average fuel economy was an even 24 mpg. That was up from 23.6 mpg for the 2012 model year and 22.4 mpg for 2011. News Source: Automotive NewsImage Credit: AP Government/Legal Green Ford Fuel Efficiency mpg CAFE standards ecoboost johnson controls