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Ford running short of F-150 frames

Like most any automaker, Ford is eager to build as many F-150 pickups as it can sell. And considering that the truck has long stood as the top selling vehicle in the United States, that means building (and selling) a lot of them. Further, Ford reports that its factories are finally fully up to speed and ready to build as many F-150s as dealers can sell. Unfortunately another factor is reportedly preventing the new aluminum-bodied pickup from reaching its potential. According to Automotive News and as we've heard before, the Blue Oval automaker has had trouble getting its hands on as many frames as it needs. Though Ford would not confirm the shortage itself, AN cites union sources in reporting that the Metalsa plant in Kentucky, which produces the new F-150's frame for Ford, has been unable to meet the demand for more such frames. "Whenever you have launches, you have issues that you have to deal with in the supply base," is all Ford CFO Bob Shanks would admit. "We're always working closely with suppliers if there's an issue to sort it out. If that were the case, that's what we'd be doing." The reported supply shortage could be why plans for overtime production are reportedly being canceled at both the plants in Kansas City and Dearborn where the F-150s are assembled, despite reaching or nearing full capacity. The shortage could also help explain why, according to AN, sales of the F-Series in the United States fell nearly 10 percent last month, while the rest of the pickup market rose 17 percent. Related Video:

2016 Ford Fusion hybrid, plug-in getting $900 price cut

While the overall the green car market in the US suffered a slump in 2014 with a 6.5-percent drop in sales, the demand for electric vehicles and plug-ins actually jumped a healthy 28 percent. The Ford Fusion Energi plug-in was among the winners in the segment with a nearly 90 percent boost to 11,550 examples sold for the year. To keep the ball rolling in the face of low gas prices and updated challengers entering the field, the Blue Oval is slashing $900 off the cost of both the Energi and standard Fusion Hybrid to make them even more attractive to buyers. Ford's Monique Brentley told Autoblog that, the reduction was done, "basically, just to attract more customers and promote sales." The cut affects every trim of both electrically assisted versions of the Fusion for the 2016 model year, according to Cars Direct, and it comes without the removal of standard equipment. On the contrary, the Energi reportedly gets a new EcoSelect driving mode that activates additional regenerative braking and more gentle acceleration. The $900 pricing adjustment is only for these models and not available on the versions with only an internal combustion engine, which makes it clear Ford wants to tantalize green car buyers towards this pair. According to Cars Direct, the models should go on sale in late 2015. The least expensive 2016 Fusion Hybrid S will retail for $25,675, plus $825 destination on all of them, and a 2016 Energi start at $33,900. Autoblog's own pricing pages for them show the same numbers (here and here). Cars Direct also predicts for the Blue Oval to keep most incentives in place even after the adjustment. Assuming these figures don't change before the sedans actually go on sale, the price cut makes a 2016 Energi less expensive than a 2015 Chevrolet Volt starting at $34,345 (plus $825 destination). The cost of the updated 2016 model for the Chevy isn't announced yet.

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.