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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.

GM, Ford, Chrysler halt some Michigan operations over natural gas shortage

WASHINGTON - General Motors said late on Wednesday it will temporarily suspend operations at 11 Michigan plants and its Warren Tech Center after a utility made an emergency appeal to users to conserve natural gas during extreme winter cold. Fiat Chrysler Automobiles also said it had canceled a shift on Thursday at both its Warren Truck and Sterling Heights Assembly plants and was considering whether it would need to cancel additional shifts. GM said it had been asked by Consumers Energy, a unit of CMS Energy Corp, to suspend operations to allow the utility to manage supply issues after extreme cold temperatures and a fire at a compressor station. It said workers were told not to report for the shifts at its Orion Assembly, Flint Assembly, Lansing Delta Township Assembly and Lansing Grand River Assembly plants, as well as other stamping and transmission plants on Wednesday evening and early Thursday. GM said it was still assessing when employees could return to work. Workers at its Warren Tech Center were also told to stay home on Thursday. In a video message posted on Facebook, CMS Energy Chief Executive Patricia Poppe said large companies, including Fiat Chrysler, Ford Motor Co and GM, had agreed to "interrupt" production schedules through Friday to tackle the issue prompted by a fire at a Michigan facility and the record-breaking cold. Poppe said the usage cuts by large businesses were not enough, and urged 1.8 million Michigan customers to turn down thermostats as much as they could to cut natural gas use in order to protect critical facilities like hospitals and nursing homes. "I need you to take action right now," she said. Ford said it had also taken steps to reduce energy use at its four Michigan plants supplied by Consumers Energy, but added the situation remained fluid. A spokeswoman said it had reduced heating levels at Livonia Transmission and Van Dyke Transmission, stopped heat treatment processes at Sterling Axle and shut down the paint process at Michigan Assembly. Consumers Energy sent an alert to mobile phones in Michigan asking residents to reduce natural gas use.

2014 Ford Fiesta 1.0L EcoBoost to hit 45 mpg for $16,445*

When Ford first announced its plan to put the 1.0-liter EcoBoost three-cylinder engine under the hood of the 2014 Fiesta, it promised hybrid-like fuel economy without a hybrid-like premium. We're still waiting for official specs on this engine, but thanks to the EPA's fueleconomy.gov website and Ford's retail site, we now know what customers can expect in terms of both fuel economy and price.
All along, Ford has said that it expects the 1.0-liter EcoBoost to get more than 40 miles per gallon on the highway, and now the EPA backs this up with official ratings of 32 mpg in the city and 45 mpg on the highway. These numbers are an increase of two mpg city and four mpg hwy compared to the current fuel-sipping Fiesta (the 1.6 SFE), and it also beats other three-cylinder cars for highway mileage like the 2014 Mitsubishi Mirage (44 mpg highway) and 2014 Smart Fortwo (38 mpg highway); the Fiesta 1.0 EcoBoost is lower than both three-pot rivals, though, in city fuel economy with the Mitsubishi getting 37 mpg city and the Smart rated at 34 mpg city. This model handily beats high-volume small cars like the Honda Fit, Toyota Yaris and Chevy Spark in both city and highway numbers.
As for pricing, the 1.0-liter EcoBoost is offered on both the sedan and hatchback as a $995 option called the SE Manual EcoBoost package, which is aptly named since it's only offered on SE trim-level Fiestas equipped with a manual transmission. Along with the engine, the package also comes with 15-inch steel wheels, regenerative brakes and a decklid spoiler on the sedan. This means the four-door Fiesta 1.0 EcoBoost will start at $16,445*, or $17,045* for the hatchback (*not including $795 for destination).