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Here's how I averaged 31.5 mpg in a Ram HFE EcoDiesel

Few things could be more American than a bright red Ram pickup parked in front of Mount Rushmore. To get there and back on a single tank of fuel from the nearest major city, however, requires a collaboration of international proportions. This particular Ram is a 1500 HFE EcoDiesel, festooned with badges indicating the presence of an Italian turbodiesel V6 mated to a German eight-speed automatic. Some Rams are even built in Mexico, but this one only boasted a 27 percent Mexican parts content. A rather global truck, this one. It is the sum of its parts, but those bits and pieces were curated by a team of engineers in Michigan. At the risk of hipstering its history, the Ram HFE (High Fuel Efficiency) package was truly custom-tailored for one purpose: Achieving an EPA-rated 29 mpg on the highway, which is 1 mpg better than a standard Ram 1500 EcoDiesel. It did just that. No, it did better than that, but more on that in a minute. The Ram has stuck with its "son of big rig" styling for nearly 25 years; opting for the EcoDiesel V6 means you can fill up next to Peterbilts. My goal was to bypass truck stops entirely. I left Denver early in the morning and aimed to enjoy lunch with Washington, Jefferson, Roosevelt, and Lincoln looking over my shoulder before heading home for dinner. Mt. Rushmore is about 370 miles away from the northernmost truck stop within Denver, where I filled the Ram HFE's tank and headed northbound on Interstate 25 toward Wyoming and a series of smaller highways that roughly follow an old stagecoach route from Cheyenne to what is now Mt. Rushmore in South Dakota. The Ram was such a fuel miser that I could have driven an extra 50 miles each way and still avoided the pumps. It's beautifully stark country: the kind of desolate place where the FM radio does a lot of seeking; that's all the audio I had on board because the Ram HFE is decidedly lacking in comfort and convenience features. To get to an EPA-estimated 29 mpg highway figure, Ram engineers had to goals: To strip weight and improve aerodynamics. In the wind tunnel, the medium-size 4x2 Quad Cab with 20-inch wheels and the Ram Express trim level's one-piece front bumper proved the most aerodynamic configuration of the many flavors of Ram available. Interestingly, testing revealed that adding full-length tubular side steps and a tri-fold tonneau cover normally offered in the Mopar accessories catalog aid aerodynamics.

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Ram ramping up MI truck production, does deal with Texas Rangers

Thanks to a host of upgrades at the Warren Truck Assembly Plant in Michgan, Ram Trucks is boosting production of the already strong-selling Ram 1500 to build 28,585 more of them a year. That works out roughly to five more per hour, or an additional 100 per day. The major key to the improvements was redesigning 353 assembly workstations to allow employees complete their tasks more efficiently. According to Ram, the expansion was done to meet growing demand for the pickup.
These kinds of comprehensive changes can't happen over night, obviously. From the end of 2013 through the summer shutdown in August, the Warren Truck plant received automation tweaks in the body shop and upgrades to the color booths in the paint shop.
However, the biggest shift was working with "UAW-represented team leaders and operators" to examine every workstation for efficiency improvements. In that analysis, the company identified and altered over 100 problems that could have caused an injury. What really helped to boost the production rate so significantly was moving about 300 parts, or grouping them into kits for better ergonomics, and eliminating walks to grab tools. Once everything was done, about 63 percent of workers at the factory got updated training.