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How Chevy Silverado, GMC Sierra will take on the Ford F-150 profit machine

FORT WAYNE, Ind. — When General Motors engineers were developing the 2019 Chevrolet Silverado and GMC Sierra pickup trucks, some of them joined public tours of Ford's Dearborn, Mich., factory to watch aluminum-bodied F-Series trucks go down the assembly line. The redesign of the Ford F-Series trucks, launched in 2014, set a new standard for fuel economy and lightweight vehicle construction. But armed with stopwatches and trained eyes, the GM engineers believed they saw problems. "They had a real hard time getting those doors to fit," Tim Herrick, the executive chief engineer for GM truck programs, told Reuters. His team did more intelligence gathering. They bought and tore apart Ford F-Series doors sold as repair parts. Their conclusion: GM could cut weight in its trucks for a lower cost using doors made of a combination of aluminum and high-strength steel that could be thinner than standard steel, shaving off kilograms in the process. These pounds-and-pennies decisions will have major implications in the highest-stakes game going in Detroit: dominance in the world's most profitable vehicle market, the gasoline-fueled large pickup segment. What's more, GM is banking on strong sales of overhauled 2019 Silverados and GMC Sierras to fund its push into automated and electric vehicles — a business many investors see as the auto industry's long-term future. The risks are high given the hits automakers have taken from U.S. President Donald Trump's trade policies. Rising aluminum prices spurred by Trump's tariffs are driving up costs on the Ford's F-Series, while rising steel and aluminum prices likewise drag on GM results. GM also has a significant risk should the United States, Mexico and Canada fail to agree on a new NAFTA trade deal, given GM trucks built at its Silao, Mexico, factory could face a 25 percent tariff if NAFTA collapses. Major profit per truck Interviews with GM executives and a tour at its factory here in northwest Indiana provide a detailed look inside GM's plan for the most important vehicles in its global lineup. These big pickups are everything Tesla's Model 3 or Chevy's Bolt electric car is not. The mostly steel body is bolted to the truck's steel frame, rather than the one-piece body and frame electric vehicles. The majority of trucks will have a V-8 gasoline engine powering the rear wheels — like the classic GM cars of the 1950s. Some Silverados will have new four-cylinder engines, but there is no electric or hybrid offering as of now.

LG Chem's troubled Chevy Volt battery plant hiring once again

The Michigan battery plant known for paying its workers to do nothing has turned things around and is now hiring more workers, specifically to do something. South Korea-based LG Chem, which runs the factory to supply the Chevrolet Volt extended-range plug-in vehicle with its lithium-ion batteries, held a job fair recently to bring on 40 new employees in order to meet higher battery demand, according to WZZM, the ABC affiliate for Grand Rapids, MI. The LG Chem factory is in Holland, MI, about 30 miles west of Grand Rapids, and it made its first batteries last year. Prior to that, though, the factory gained notoriety after a US Department of Energy (DOE) probe found that workers there were getting paid to do, well, nothing. That's because demand for the battery packs was so low that it cost less for the plant to sit idle. The DOE was conducting the probe because of its financial grant to LG Chem. But that was then and today is today. LG Chem is looking to ramp up production in advance of the second-generation Volt. That 2016 model-year version is said to have a longer all-electric range and better performance and will ride on a new chassis, but few official details have surfaced. We will know more when we get our first look at the car at the Detroit Auto Show in January.

Personal testimonies show real-world effect of plugging in with Chevy Volt

At this point, there are tens of thousands of individual stories about what it's like to live with a Chevrolet Volt. But it also remains informative to take a look at one of these in depth. For example, one Atlanta-area Volt owner says he's cut his cents-per-mile ownership costs by almost 40 percent compared to his previous car primarily because of his ability to drive almost all the time on electric power. Jeffrey Cohen told Clean Technica that he put about 14,000 miles on his Volt extended-range plug-in hybrid for the year that ended October 2013, and that more than 92 percent of those were on electrons. He estimates his "lifetime" miles per gallon rating at a whopping 384 mpg, a figure pushed upward by the fact that he installed a Level 2 charger at home while his employer added an external 110-volt charger at work. Cohen is spending 45 cents a mile for his car, compared to 73 cents in his Infiniti M35. As a result, he's spending 45 cents a mile for his car, compared to 73 cents a mile with his prior vehicle, an Infiniti M35. About two-thirds of those Volt costs are for the $349-a-month lease payments, while 15 percent is insurance, 11 percent is for the charger and seven percent for the gas and electricity that actually powers the car. Helping lower that last figure is an overnight electricity rate that's about 10 percent of Cohen's daytime rate. Chevy parent General Motors hopes such testimonies will re-trigger sales for the Volt in 2014. Last year, GM sold 23,094 Volts, down 1.6 percent from 2012. We expect our readers have similar stories they'd like to share in the Comments. Related Gallery 2011 Chevrolet Volt: Review View 22 Photos News Source: Clean TechnicaImage Credit: Lead image: AP Photo/Jae C. Hong Green Chevrolet GM Electric running costs