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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.

Report: GM struggling to market turbo technology

In the automotive realm, marketing can sometimes prove just as important as the actual product. Take, for instance, Ford's well regarded EcoBoost technology, which couples turbocharging with direct injection to produce more horsepower and reduce fuel consumption. Would it surprise you to hear that General Motors has had similar technology on the market for over three years?
It's true. GM's first turbocharged, direct injected powerplants hit the market for the 2007 model. The 2.0-liter Ecotec mills put down an impressive 260 horsepower and a matching 260 pound-feet of torque, and they were lauded by the press in the engine bays of the Pontiac Solstice, Saturn Sky, Chevrolet Cobalt SS and Chevrolet HHR SS. But few people outside a core group of enthusiasts actually remember this fact.
Says Uwe Grebe, executive director of GM's global advanced engineering, "We didn't have a badge and say, 'This is the most important thing we will put on all our brochures.'" Ford, however, did just that, and it's EcoBoost engines are right at the tips of all our tongues when we discuss today's most advanced powerplants. So, how does The General fix its mistake?

Toyota, Ford decide to end hybrid collaboration before it starts

Not all so-called Memorandum of Understanding pacts end in actual collaborations. For instance, after a two-year "feasibility study," Toyota and Ford have just announced that they will not be developing hybrid systems for use in light trucks and SUVs as previously planned, and the two automakers will instead continue to develop their own hybrid technology independently.
The would-be collaboration was first announced in August of 2011, and would have seen a rear-wheel-drive hybrid platform that would "improve the efficiency of trucks and SUVs while still allowing them to be driven in the way customers expect," according to our initial post on the topic.
Keep in mind that this announcement isn't to say we shouldn't expect hybrid pickups and SUVs from the two automakers, but that they probably aren't coming very soon - Ford says it will have a system "before the end of this decade" and we haven't heard much from Toyota on the hybrid truck front since the 2008 A-BAT Concept (pictured above) - and that they will not share any components between them (and they never have, for what it's worth).