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Detroit automakers keep their masks on to keep the factories running

United Auto Workers members leave the Fiat Chrysler Automobiles Warren Truck Plant in May. Fiat Chrysler along with rivals Ford and General Motors Co., restarted the assembly lines after several weeks of coronavirus lockdown. (AP)   DETROIT — When the coronavirus pandemic slammed the United States in March, the Detroit Three automakers shut their plants and brought their North American vehicle production to an unprecedented cold stop. Now, four months after a slow and sometimes bumpy restart in May, many General Motors, Ford and Fiat Chrysler Automobiles  factories are working at close to full speed, chasing a stronger-than-expected recovery in sales. So far, none of the Detroit Three has had a major COVID-19 outbreak since restarting production, even as the coronavirus is surging in Midwestern and Southern communities outside factory walls. "We have people testing positive, but it's not affecting operations," said Ford global manufacturing chief Gary Johnson. Keeping the pandemic at bay has pushed the automakers and 156,000 U.S. factory employees represented by the United Auto Workers into unfamiliar work routines and extraordinary levels of cooperation among the rival automakers that will have to be sustained for months to come. For automakers, the automakers' COVID response has been as much about instilling new habits as relying on new technology. Workers log their symptoms, or lack of them, into smartphone apps and walk past temperature scanners to get to their work stations. But company and union executives said masks, along with physical distancing, are the key to keeping assembly lines rolling. "The mask is the foundation" of protecting workers on the job, said Johnson. Complaints about masks Autoworkers are accustomed to wearing protective gear such as shatterproof glasses and gloves. Masks that cover the mouth and nose, however, were not standard equipment on auto assembly lines, and were a tough sell at first. "The biggest complaint is wearing a mask," United Auto Workers President Rory Gamble told Reuters. "A lot of our members perform physical tasks. Wearing the mask inhibits breathing." Beyond that, Gamble said, masks and distancing make it harder for workers to have conversations on the job or socialize during breaks. "ThatÂ’s pretty much out the window, and it makes for a longer day," he said. Masks make it harder for co-workers to read each other's expressions — often crucial in the noisy environment of a car plant.

Ford F-150 extended cab struggles in IIHS small overlap test

Update: Ford issued a statement to Autoblog to clarify the results of the test and dispute the IIHS repair cost estimates. A quote from a Ford representative has been added to the story. See the full statement below the IIHS press release. Of all the vehicles undergoing crash tests this year, few will be as closely watched as the new 2015 Ford F-150. That's not only because it remains the top-selling vehicle in America year after year, but also because it features an aluminum body instead of steel. While the F-150 performed well in the Insurance Institute for Highway Safety test, one factor prompted the institute to undertake a second round of testing that uncovered a problem. Like most full-size pickups, the F-150 is available in several cab styles: the regular two-door, the extended SuperCab and the four-door SuperCrew. The IIHS typically takes the most popular version of a particular model for testing, and in the Ford truck's case that meant the SuperCrew. The F-150 performed well in all the tests the IIHS put it through, including the small overlap test in which the vehicle is driven 40 miles per hour into a five-foot-tall barrier impacting the front left corner of the vehicle. Its overall performance in the tests earned the F-150 a Top Safety Pick rating, missing out on the higher Top Safety Pick + rating only because it doesn't have an automatic braking system. But how do the other versions of Ford's best-seller hold up? Given that even less popular versions of the F-150 still sell more than many other vehicles on the market, the IIHS put an extended cab through the same battery of tests. It performed comparably except in one area: the small overlap test. In that case, the extended cab model's steering column was pushed eight inches into the cabin (dangerously close to the crash test dummy's chest), the dummy's head missed the airbag almost entirely and hit the instrument panel, and the dummy's legs would risk sustaining "moderate" injuries. The reason for the disparity is that "Ford added structural elements to the crew cab's front frame to earn a good small overlap rating and a Top Safety Pick award but didn't do the same for the extended cab," according to the Institute's chief research officer David Zuby. "That shortchanges buyers who might pick the extended cab thinking it offers the same protection in this type of crash as the crew cab.

GM readying aluminum-body fullsize pickups

Ford's extensive use of aluminum in its 2015 F-150 is a big deal. A really big deal. Big enough, in fact, that General Motors is reportedly changing its fullsize pickup strategy. According to The Wall Street Journal, The General has locked in partnerships with Alcoa Inc. and Novelis Inc. - companies that will supply aluminum for the next-generation Chevrolet Silverado and GMC Sierra trucks.
"Ford's introduction of the 2015 F-150 pickup truck was a game changer, and it's the first, not the last, conversion of this type," Novelis spokesperson Charles Belbin told the Journal. The switch to aluminum has allowed Ford to shave roughly 700 pounds off its fullsize truck's curb weight. And while official mileage ratings have not been announced, the weight loss should go a long way for improving efficiency, especially when combined other efficiency-minded improvements including better aerodynamics and new, turbocharged V6 engines.
Of course, aluminum-bodied cars are nothing new. But extensive use of aluminum in a major, best-selling product like the Ford F-150 is expected to kick off widespread use of this weight-saving material as availability rises and cost decreases. The WSJ reports that GM had originally explored the idea of moving to aluminum pickups back in 2008, but abandoned the idea due to cost concerns amid economic woes.