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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.

Ford dinged by OSHA for asbestos at Buffalo plant

Ford has come under fire from the Occupational Safety and Health Administration (OSHA) for violations regarding asbestos exposure in a company metal stamping plant in Buffalo, NY. OSHA has cited Ford for eight violations in total, according to an Automotive News report, and faces fines of up to $41,800. 537 workers are employed at the stamping facility.
The violations include a pipefitter at the facility being exposed to asbestos-containing material while working on a steam line, other workers exposed to the material without respiratory protection and work areas that were not designed to limited the number of workers in contact with asbestos. Further, areas in which asbestos was present were not properly restricted, and levels of asbestos in the air were not monitored.
According to an unnamed Ford spokesperson in the AN report, the company feels that the OSHA citation is erroneous saying, "We have fully cooperated with the local OSHA officials and we don't believe the citations are warranted." Ford also maintains that it will work with the authorities to resolve the issue.

50 new vehicles by 2025: Ford making big push in China

SHANGHAI — Ford will launch 50 new vehicles in China by 2025, including 15 electrified vehicles, the U.S. firm said at an event in Shanghai on Tuesday, as it looks to rev up sales growth in the market and shift towards cleaner electric cars. Ford's sales in China have been weak in recent months, and the company is scrambling to come up with electric and hybrid vehicles to comply with strict Chinese quotas over production and sales for so-called new energy vehicles, or NEVs. The U.S. automaker is undergoing a broad review of its China operations, part of a strategic re-think under new Chief Executive Officer Jim Hackett, which will likely see the company focus on electric commercial vans as well as electric cars. "Between now and 2025, we will launch 50 new vehicles in China, and of those 50 new vehicles, 15 of them will be all-new electrified vehicles," said Peter Fleet, Ford's head of Asia Pacific, pointing to big growth in the "utility" segment. Fleet also said Ford's China revenue would grow by 50 percent over the same period. China is pushing automakers toward electric and hybrid petrol-electric vehicles, setting tough quotas for NEVs that come into play in 2019, and has signaled a longer-term shift away from traditional internal combustion engine cars. The major shift in the world's largest auto market has jolted some automakers, sparking a spate of recent electric vehicle (EV) joint ventures in the market. Ford has announced an EV tie-up with China's Anhui Zotye Automobile Co Ltd. "We've never seen change like we do today," said Ford Executive Chairman Bill Ford. "Everything is being disrupted" by the development of autonomous vehicles, trends such as ride-sharing and electric vehicles, he added. "It's clearly the case that China will lead the world in EV development, and so we at Ford are investing enormous amounts of money both here in China and globally to bring electrification into fruition." Reporting by Adam JourdanRelated Video: Image Credit: Reuters Auto News Green Plants/Manufacturing Ford Lincoln Electric Hybrid Shanghai Jim Hackett