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Ford Explorer problems gutted third-quarter sales

In early September, the Detroit Free Press published a feature noting numerous problems Ford's having with the 2020 Explorer and 2020 Lincoln Aviator launches. Issues with both SUVs, built at Ford's Chicago Assembly Plant, were so rife and dire that the automaker was trucking the vehicles 275 miles away to Michigan for repairs. Bloomberg reported earlier this month that Explorer's third-quarter sales dropped 48 percent compared to the previous model in 2018, with dealers unable to get enough units on lots for customers. Nor is the snafu over: Automotive News reports that another "batch of about 2,500 Explorers in need of repairs" arrived recently in Michigan, and sales through the first nine months of 2019 are down 31 percent. Sales dips during model changeovers are to be expected as old inventory gets sold down and new production ramps up, but this is different. Ford U.S. sales boss Mark LaNeve told Bloomberg earlier this month, "We’ve got adequate inventory in our stores. For Q4, availability wonÂ’t be an issue. WeÂ’ll be able to hit our stride with Explorer starting now." It's hard to know whether that's true, with thousands of Explorers still piling into Michigan; the batch AN mentioned represents about 5 days of sales during an average month in 2018, before the drawdown and interruptions hampered matters. And when Consumer Reports tested the Ford Explorer it bought this summer, it titled the review, "2020 Ford Explorer drives nicely but has many flaws / Poor interior quality and a high price overshadow the SUV's improvements."   On top of that, the AN piece mentions a new impediment to uncorking the Explorer sales stream: Worker strife in the Chicago plant. Allegedly, "Roving groups of workers are intimidating other employees, creating a hostile environment, the people said. ThatÂ’s driving up turnover and leaving some vehicle assembly unfinished, contributing to the company having to complete the work at the Michigan factory or at dealerships, the people said." Ford's been fined twice before for the same kinds of issues at its plants, once in 1999, again in 2017, but a spokesperson said Ford isn't aware of any such problems now. The pressure otherwise has got to be unpleasant for everyone on the Explorer team, from CEO Jim Hackett down. The automaker was meant to be "turning the corner" in April, but as of now, shares are down, credit rating is down, earnings are down.

Is that the Ford GT Le Mans racer in the background of this Forza video?

Shortly after the reveal of the new Ford GT in Detroit a couple of weeks ago, Microsoft announced that it was putting the new American supercar on the cover of the upcoming sixth installment of the Forza Motorsport video game series. Now it has put out a video of the process of digitizing Dearborn's latest. Whether you're into Detroit steel (or carbon fiber and aluminum in this case), exotic supercars or video games, the video is worth a watch in and of itself. But our eyes were focused on something else. In the background of one shot (around the 1:49 mark) you can see a design board with renderings of what looks to be the rumored racing version of the GT – complete with reshaped air intakes, deeper side sills, a bigger rear wing and a central rear fin like you'd find on the latest LMP1 racing prototypes. It wouldn't be the first time we've caught wind of the prospect of the Blue Oval's new supercar going racing. We first heard of the plans last October, further reinforced in December with reports of the new GT coming to Detroit. And as we reported just a couple of weeks ago following the supercar's reveal, a return to Le Mans could be in the cards – which would be fortuitous timing, since next year will mark the 50th anniversary of the original GT40 scoring its landmark 1-2-3 finish in the 24-hour race.

Ford reveals new rapid prototyping and low-volume production techniques [w/video]

It's called "F3T," and that stands for Ford Free-form Fabrication Technology. The process that The Blue Oval has developed means being able to sidestep the weeks-long process of tool-and-die making when engineers want to construct a new part, allowing them to fabricate a three-dimensional part from a two-dimensional sheet of metal in just hours.
While F3T is being developed it is limited to "low-volume prototyping or even low-volume niche vehicles," but the next step is to evaluate it for use in Ford's global manufacturing facilities. You can find out more about it in the video and the press release below.