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2015 Ford F-150 begins rolling off line at second factory

Ford needs more F-150s. Yeah, we just told you that a few days ago. The Blue Oval is reporting that its trucks are spending a mere 18 days on dealer lots, following a January that was the truck's best month in over a decade. Considering both of those facts, the timing is perfect for Ford to ramp up production of its all-aluminum truck by bringing its Kansas City, MO factory online. KC Assembly has been building F-150s for decades, and completed a $1.1-billion expansion to accommodate the all-aluminum 2015 truck (as well as for work on the Transit van). Similar to what was done at Ford's Dearborn, MI factory, the Blue Oval spent 13 weeks upgrading the plant's body shop, paint shop and a road-test course. Over 900 jobs were added as part of the update. Combined with the equally upgraded plant in metro Detroit, Ford can build 700,000 trucks per year. "The all-new F-150 has surpassed our expectations – setting new standards for fullsize truck capability, technology and efficiency," Joe Hinrichs, Ford's Americas president said in a statement. "With production starting at Kansas City Assembly, we are better poised to start meeting growing customer demand for our pickup." Scroll down for the official press blast from the Blue Oval. Related Video: KANSAS CITY ASSEMBLY PLANT COMES ON LINE AS SECOND U.S. FACTORY BUILDING ALL-NEW FORD F-150 2015 Ford F-150 starts production at Kansas City Assembly Plant; along with three shifts in operation at Dearborn Truck Plant, Ford is now producing even more units of the toughest, smartest, most capable F-150 ever All-new F-150 is turning more than four times faster than the overall full-size pickup truck segment; In addition to producing all F-150 models and cab configurations, Kansas City exclusively builds specialty F-150s with 8-foot cargo boxes and heavy payload packages to meet the needs of commercial fleet customers Kansas City Assembly Plant facilities transformed with the latest in manufacturing technology to build the first mass-produced truck in its class featuring a high-strength, military-grade, aluminum-alloy body and bed CLAYCOMO, Mo., March 13, 2015 – Ford today marks the official start of production of the all-new 2015 F-150 at Kansas City Assembly Plant, which joins Dearborn Truck Plant in building the toughest, smartest, most capable F-150 ever. This means Ford has expanded production of the first mass-produced light-duty pickup truck with a high-strength, military-grade, aluminum-alloy body.

Automakers' rush on aluminum may result in shortage

Aluminum is the new buzzword in the automotive industry. The latest Range Rover and Range Rover Sport both take advantage of the lightweight material to shave huge amounts of body fat (only it's called "aluminium" over there). Audi and Jaguar have been using the stuff for years in their A8 and XJ, respectively, and now, aluminum is going mainstream, arriving on the 2015 Ford F-150.
While we're excited to see aluminum make an impact outside the premium market, its widespread adoption apparently won't come without some problems, notably in terms of supply. "There isn't an automotive manufacturer that makes vehicles in North America that we're not talking to," Tom Boney, of Novelis, the largest global supplier of aluminum sheetmetal, told The Detroit News.
According to Boney, Ford's use of aluminum on such a large scale has forced auto manufacturers in "every boardroom" to reconsider their plans following the F-150's unveiling, for one simple reason: there's not exactly enough aluminum to go around, at least in the short term. The auto industry presently only accounts for six percent of the aluminum sheet produced, but as the material is adopted by more and more brands, that figure is expected to swell to 25 percent within the next six years.

How did Ford keep the GT a secret before Detroit?

True secrecy is a rarity in the automotive industry. Sure, companies try to keep their future projects under wraps all of the time, but usually a spy shot or blurry development photo leaks out. The complete lack of any hard details before its unveiling likely helped make the Ford GT one of the biggest stars of the 2015 Detroit Auto Show. Not only was it the favorite of Autoblog's editors, but the supercar scored a prestigious EyesOn Design Award, too. Rumors about the vehicle had circulated for weeks before the show, but no one really knew much about the GT until it rolled onto the stage for Ford's press conference in Joe Louis Arena. Amazingly, the Blue Oval kept things mostly a secret during the car's 14- month gestation period prior to its debut. According to Automotive News, the GT project began in late 2013 by a skunk works team, including six designers, that guided the supercar along from birth until the unveiling. Ford kept things clandestine by locking the vehicle in a basement storage room, and only the group members got a key to the lock. Much of the development was also done at night to further keep the secret, but occasionally the prototype was hauled outside on weekends to check it out in natural light. Because of the speed in getting the development done and for even more stealth, the designers didn't get input from the Blue Oval's other styling teams around the world. But that was somewhat of a double-edged sword. "You don't actually get to bounce opinions off people," Ford design boss Moray Callum said to Automotive News. "We were on tenterhooks ourselves until the first people saw it." Even now, there are still mysteries surrounding the GT. There's still no official word on the supercar's power; just that it's over 600 horsepower. There are also the persistent rumors going back months that the Blue Oval plans to take the GT racing to celebrate the 50th anniversary of automaker's Le Mans victory. Although, maybe this time the secrecy wasn't so good because we might have got a glimpse of the racer, recently. Related Video: