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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.

Bomb threat closes Ford Romeo Engine Plant [UPDATE]

UPDATE: Ford has released the following statement about what's happening at the factory: "The Ford Romeo Engine Plant was reopened at 12:47 PM after law enforcement investigated and cleared the site. The afternoon and evening shifts are expected to report at their usual start times. Further questions on the investigation by law enforcement can be directed to the Romeo Police Department." Due to a bomb threat, Ford has evacuated its Romeo Engine Plant, and law enforcement is on the scene. According to the Detroit News, police with bomb-sniffing dogs are searching the building, which covers over 2 million square feet. Ford spokesperson Mike Moran wouldn't disclose to Autoblog how the threat was received but said that it came in between 7:00 a.m. and 7:30 a.m. Eastern on July 30. "The day shift was sent home," he said. According to the Detroit News, the second shift was also asked not to come in. About 500 people work at the plant, Moran indicated. At this time, Moran said that there hadn't yet been an update from law enforcement whether anything had been found in their search. The Romeo Police Department confirms to Autoblog that it's handling the investigation. However, the authorities wouldn't comment further about what is happening at the plant at this time. Related Video: