How Ford Overhauled Its F-150 Plants

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Our friends at Popular Mechanics have taken a deep-dive behind-the-curtain look into the risk and reward of Ford's major overhaul of its two biggest production plants: the Dearborn Truck Plant in Michigan and the Kansas City Assembly Plant in Missouri where F-150s are born.

The story maps out the level of detail needed to gut and reconstruct Ford's two plants during an eight-week nonevent. The key players were Joe Hinrichs, Ford's executive vice president and president of the Americas, and Bruce Hettle, vice president of North American manufacturing. Both men have huge manufacturing knowledge that was pushed to its limits; they were responsible for coming up with a plan to get this job done as fast as possible with the least amount of downtime.

Major sections of the Dearborn plant were partially assembled in alternate facilities around Detroit, with many of the bugs worked out before they were assembled at the plant. Six months later Ford repeated the process in Kansas City. Now both plants are running more than 60 F-150s down the line per hour.

You can expect Ford will rely on what it learned during this endeavor as it gets ready to rebuild the Kentucky Truck Plant outside Louisville for the next-generation Super Duty.

Cars.com photo by Mark Williams

 

Comments

Looking forward to see the next-generation of Ford Super Duty trucks.

Back to Back Motor Trend Truck of the Year | 2013 & 2014 RAM 1500

Best in class fuel economy

All the tow and hauling capability you need

Best value in the class

Why buy another other truck?

Why Buy Any Other Truck?

Picture this. You’re in the market for a new product, something substantial—let’s say it’s a new light-duty pickup truck. As a smart buyer, you compare two or even three generally similar products, weighing the upsides of each in relation to the others.

When you went through this process in the past, maybe for a new laptop computer, you didn’t always know for certain which product would be the best, even after all your research was complete. But this time, and with regard to pickup trucks, the outcome is less in doubt—the 2015 Ram 1500 is the clear choice for the best light-duty pickup truck currently available.

Bold claims need strong supporting evidence—we’re well aware of that. See below for evidence that helps support our case.
Reasons to Buy Ram Trucks over Ford or Chevy

The Ram 1500 has better resale than Ford or Chevy*
Better brand reliability over Ford and Chevy^
40,000 miles more warranty than Ford**
EPA-estimated best-in-class 29 mpg highway for the 2015 Ram 1500 EcoDiesel^^
Class-exclusive link coil and air suspension***
Class-exclusive Torqueflite™ eight-speed transmission

Of course we realize the bias involved in calling our truck the best, and we don’t expect any potential buyer to go on our word alone. In fact, we encourage independent research. Why not start with this comprehensive list of recent awards earned by Ram Trucks such as Motor Trend Truck of the Year?

*Based upon ALG 2013 MY forecast effective January-February 2013; non-sales weighted average of all light-duty crew cabs for each model at 36 mos; 15,000 per year
^According to JDP 2013 US Vehicle VDS of 2010 model vehicles
**Based on Ram 5 Year/100,000 mile powertrain warranty vs Ford 5 year/60,000 mile powertrain limited warranty
^^Based on standard pickup class. EPA-estimated mpg based on V6 4X2. Actual results may vary.

I saw on Autoline Detroit TV on Saturday that FCA is in debt over 8 Billions dollars. Also they only make 4% profit on each unit sold. GM & Ford are making 12-15% profit per unit. That is why Fiat President Sergio Marconni is trying to sell the brand

@HEMIman: Not as widely available as Ram's but GM do offer an 8-speed auto in some 1500s.

That Ram 100K mile warranty does you no good if you don't put a ton of miles on your truck per year. In fact, on a normal lease of 12-15K miles per year, anything over that would be penalized at the end of the term.
A
So, if you want to impress me, make it 100K miles or 10 years which ever comes first. If Kia can do it, so can Ram.

Also, since you can't get a normal looking extended cab from Ram, they all look like stupid shortened crew cabs since 2002, Ford would be my only choice in that cab style unless Nissan keeps the king cab body style in the next generation Titan. Not everyone wants to look like they're driving a "soccer dad" four door truck.

"Back to Back Motor Trend Truck of the Year | 2013 & 2014 RAM 1500

Best in class fuel economy

All the tow and hauling capability you need

Best value in the class

Why buy another other truck?"

After reading the 3rd line I fell off my chair cracking up laughing!

This is a major change by Ford.

Over 60 per hour? That would give Ford over 43 thousand pickups for the month of May or 536 thousand a year.

Hmm........we'll see in a few days if this isn't just more Ford propaganda regarding the aluminium F-150.

^^^^^^^^^^^^^^BREAKING NEWS!^^^^^^^^^^^^^^^

GM Is Set to Face Criminal Charges Over Ignition Switches
General Motors will likely be prosecuted over ignition switches linked to deaths.

Federal prosecutors are closing in on criminal charges against General Motors Co. over a faulty ignition switch linked to more than 100 deaths, but they are still weighing whether to charge individual employees, according to people familiar with the matter.


I vote the U.S. Government prosecute them all.

After reading the 3rd line I fell off my chair cracking up laughing!


Posted by: woopud

"All the tow and hauling capability you need"

Only if a CUV or 4 door sedan was your two other choices. or you are a repeat Ram 1500 buyer.

Been keeping up with this site for many years but never really wanted to comment. Think I'll try it. These Ram guys are hilarious. This Hemi fellow needs to clean up his own backyard before he steps in others. He brings up recalls and then when Ram has one he says they are just taking care of business and taking care of the public. How stupid is that? Ford seems to have everything covered as they have for umpteen teen years now. Ram makes a very nice truck but people like him make them look very bad. Ford will lead the way and all the other trucks will follow. Ram is the farthest behind and Fiat don't help. Just can't help but laugh at him.

This is a major change by Ford.

Over 60 per hour? That would give Ford over 43 thousand pickups for the month of May or 536 thousand a year.

Hmm........we'll see in a few days if this isn't just more Ford propaganda regarding the aluminium F-150.


Posted by: Big Al from Oz | May 25, 2015 1:51:44 PM

Prolly so. As the 2 f150 plants covers every where the f150 is sold..... As well as it takes 3-4 weeks for trucks to arrive at there dealerships. Doubtful all 60 an hour end up in the U.S. Only. Canada buys a large amount of f150's which the f150 dominates the Canadian market. Not sure sale figures for the rest of the world but those sold in those countries are built in the good old USA!!!! Here is a list of countries where you can buy an f150.

As of 2015, the Ford F-150 is sold in the United States, Canada, Mexico, most Caribbean countries (except Trinidad and Tobago, Saint Kitts and Nevis and Cuba), Suriname, Ecuador, Peru, Chile, the Middle East, Iceland, Nigeria, the Dutch territories of Aruba, Curaçao, Sint Maarten and the British overseas territory of the Cayman Islands

"All the tow and hauling capability you need"

Only if a CUV or 4 door sedan was your two other choices. or you are a repeat Ram 1500 buyer.


Posted by: Lou_BC | May 25, 2015 5:03:03 PM

Why don't you give me the price on this dream F 150 of yours Lou_BC?

Are you comparing price?

Are you comparing Engines?
Are you comparing trim?

I can buy more truck at Ram for less than Ford.

Hemi V8, if FCA goes bankrupt who is gonna look out after all you lemmings? You wont be able to give your pos away. May happen sooner than we think, with all the foot dragging over jeep gas tank recall. FCA saying around 100,000 jeeps can't have recall done because of rust issues, this is not a joke. NHTSA may require them to buy back those vehicles. Ford bought back minivans, FCA can do the same, if they have the funds. Why do you think Maraschino wants a partner? BTW, seems no one is interested.

I like the 2014 F-150 better than the 2015.
The 2015 doesn't seem rough and tough to me.
The jury is still out on the aluminum
Ford is asking full price without any discounts
Instead of dropping the eco-boost as a failure they added another 2.7 eco-boost engine.
Ford went too extreme making changes and it's scaring people away.
The 2015 F-150 is more of a car than a truck, it wasn't made for me.
Ford designed the F-150 for new buyers leaving the repeat buyers out in the cold.
Ford will not only harm their truck sales it will also effect their car and SUV sales - their cars and SUV's sale good based on the reputation of the F-150.
The ship is sinking at Ford, I got off a long time ago.

30-40 years ago aluminum siding on houses was very popular when today its all almost impossible to find.
aluminum siding was a failure cause of the extreme expansion and contraction between the heat and the cold.
- that constant movement of expansion and contraction caused the siding to become loose, pulling the nails out then when high winds come along the siding blew off.
I remember you can hear it, the siding would "Bang" when the sun came out and "Bang" again when it got cooler at night.

Can any of the intelligent guys here explain to me why the same thing doesn't happen on the aluminum F-150?
The panels are either glued or rivet together.
yea, yea, I know they use a special glue that expands and contracts with the aluminum, but what about the rivets?
are they special rivets?
When the F-150 is sitting out in the hot sun at 90 degrees then the sun goes down and it rains and cools off to 50 degrees try to tell me nothing happens.
Is it a special alloy of aluminum that it doesn't happen?

Could someone here leave a message to this guy?
He is really taking it hard cause of the minor rust issues of his new Ram 1500.
I told him its not that bad , no big deal but he's taking it to an extreme like he's the only one with that problem.
I explained to him we have a lot of experts here that may be able to help him out so please leave him a message.
http://www.ramtruckproblems.com/

Why stupid people buy a Dog Lamb, the least capable truck around VVVVVVVVVVVVVVVV

Why Buy Any Other Truck?

Picture this. You’re in the market for a new product, something substantial—let’s say it’s a new light-duty pickup truck. As a smart buyer, you compare two or even three generally similar products, weighing the upsides of each in relation to the others.

When you went through this process in the past, maybe for a new laptop computer, you didn’t always know for certain which product would be the best, even after all your research was complete. But this time, and with regard to pickup trucks, the outcome is less in doubt—the 2015 Ram 1500 is the clear choice for the best light-duty pickup truck currently available.

Bold claims need strong supporting evidence—we’re well aware of that. See below for evidence that helps support our case.
Reasons to Buy Ram Trucks over Ford or Chevy

The Ram 1500 has better resale than Ford or Chevy*
Better brand reliability over Ford and Chevy^
40,000 miles more warranty than Ford**
EPA-estimated best-in-class 29 mpg highway for the 2015 Ram 1500 EcoDiesel^^
Class-exclusive link coil and air suspension***
Class-exclusive Torqueflite™ eight-speed transmission

Of course we realize the bias involved in calling our truck the best, and we don’t expect any potential buyer to go on our word alone. In fact, we encourage independent research. Why not start with this comprehensive list of recent awards earned by Ram Trucks such as Motor Trend Truck of the Year?

*Based upon ALG 2013 MY forecast effective January-February 2013; non-sales weighted average of all light-duty crew cabs for each model at 36 mos; 15,000 per year
^According to JDP 2013 US Vehicle VDS of 2010 model vehicles
**Based on Ram 5 Year/100,000 mile powertrain warranty vs Ford 5 year/60,000 mile powertrain limited warranty
^^Based on standard pickup class. EPA-estimated mpg based on V6 4X2. Actual results may vary.

#3, I was a GC for years. I never installed Al siding but did install thousands of feet of vinyl siding. Most of the older vinyl has been replaced, didn't have enough uv protection. Probably anyone who has tried to weed eat around one of these houses found that if you hit the siding it would fracture, very brittle. Modern siding is supposed to be much better, but it will still expand and contract, prob not as much as aluminum. I have seen it falling off from improper installation, especially long runs. I did some repair on an older home recently, prob built in the 50's. Had aluminum siding, still in good shape. Maybe not as old as the house but older than any vinyl. Still a lot of al siding around. I doubt expansion on the truck would be a problem due to the short runs. As far as rough and tough I expect the thicker aluminum will hold up longer than steel, it's not going to rust when the paint is chipped like thin steel. It will oxidize then stop when that layer forms. How many stop signs do you see rusting away? I expect the used market will favor aluminum bodied vehicles, probably increasing resale. Like it or not, more manufacturers will be jumping on the wagon. Maybe not cash strapped FCA though.

60 F150's per hour is slower than their target that's been in place for years. Years ago they would shoot for one rolling off the line every 40 seconds. Of course there is much more on these newer trucks, but I'll bet they plan to improve on the current 60/hr.

"I can buy more truck at Ram for less than Ford."

More truck?

Air ride that does not improve towing or hauling capabilities.

8 speed that still gets beat by TTDI V6.

Diesel V6 that in a Ram can't tow or haul itself out of a wet paper bag.

GM's 8 speed Chevy spanks Ram.

GM's trucks carry more than Ram.

GM's trucks get better V8 fuel economy than Ram.

I haven’t even mentioned Ford or the new Titan.

More Truck????????

To quote woopud

After reading the 3rd line I fell off my chair cracking up laughing!

FCA wants to merge.

Why?

They don’t have the money to develop anything significant or new.

2017 - Ram 1500 – facelift

“Industry sources familiar with the company's plans said Chrysler is not likely to undertake a full redesign of the Ram before 2021 at the earliest.”


Okay, so where is the rest of the article? You know, the part that actually explains "How Ford Overhauled Its F-150 Plants".

To all of the "real truck guys" on this site who diss the choice of using aluminum in a truck, do you REALLY that that all of the possible scenarios about metal expansion on 90-degree days, denting, rivets and glue, flexing, and anything else were not tested by Ford? Here's a newsflash: they didn't just pull an idea out of the air and run with it with no testing on the most profitable product which sells 700,000 - 800,000 per year.

@Lou
So what's the reason RAM is going up every month and Ford is going down every month?

Posted by: Zvera | May 26, 2015 11:00:11 AM

Short term memory loss or something???? Ram has a few more months this year they will be down. Next year they will be off most of the year as the ugly grills and nothing new will catch up to them..... Or they can even throw more incentives on the table in an effort to keep there ssles numbers.
http://news.pickuptrucks.com/2015/04/best-selling-pickup-trucks-march-2015.html

I must be missing all the arguments here, we are back to, my truck can get more MPG than yours(on paper only), mine hauls a tiny bit more than yours(on paper only), mine has better sales, geez people.....

Maybe or maybe not. Tailpipe looks a little dirty for a diesel.... Zoom in on the pipe and it has soot in it. Dpf diesel pipes are very clean and no soot collection. I don't think it's a diesel.

Now ford has said they are going to be doing a hybrid or plug in f150. That is my guess what your looking at possibly with some solar body panels. But also ford has signed a shared developmental cost with a large carbon fiber manufacture... Another guess is this has carbon fiber or composite panels. No need to camoflague the skin unless there is a change....

Go on continue thinking its a diesel as ford needs you and those pee brains people to keep steering people away from what they really got going on. Camoflague body and people say diesel..... Not sure ford could have hoped you guys that hate ford help distract the revolutionary skin on that truck!!!!

@Scott
It's a diesel.

Posted by: Zvera | May 26, 2015 3:28:17 PM

Ford thanks you!!!!

Tail pipe is to dirty to be a diesel that can be operated on us highways

GM had the first 1/2 ton diesel so ford would come with a diesel it would just be copy gm like ram copied GM.

With fords super advanced class leading lightweight military grade aluminum body and class leading 10 speed transmission they would easily hit 35 mpg rap with there crew cab 4x4 f150.

Plug in hybrid ford would push 40 mpg from the f150.

The rushing to market that ram did on there diesel is showing with all the problems they are having.
This ecodiesel is costing Ram tons in repair work

If the performance that the ram 8 speed and the diesel put out is what it is you can keep the last in class performance and capability. Ram should go to gm and see if they can use there 8 speed cause the gm has class leading v8 performance with there combo. Ram is last in the big 3 in everything except 1/2 ton diesel economy.

And as Lou noted, an 8 speed that still gets beat by TTDI V6, and a diesel V6 that in a Ram can't tow or haul itself out of a wet paper bag.

There is a report that Ford’s new solar-powered hybrids can charge up without plugging in
http://www.extremetech.com/extreme/173863-fords-new-solar-powered-hybrid-car-can-charge-up-without-plugging-in



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