Ford Shifts Workers from F-150 Lightning to Boost Gas and Hybrid Production Amid Supply Issues

• Ford transfers all hourly staff from Rouge Electric Vehicle Center to Dearborn Truck Plant to accelerate F-150 production.

• The pause prioritizes profitable gas and hybrid models amid slowing EV demand.

• A fire at Novelis’ Oswego facility could cost Ford up to $2 billion in Q4 2025 adjusted profits, per the company’s finance chief.

Discover how Ford’s F-150 production shift impacts EV strategy and truck manufacturing. Learn key details on supply chain challenges and recovery plans—stay informed on automotive industry updates today.

What is Ford doing with F-150 Lightning production?

Ford F-150 production is taking center stage as the company pauses assembly of the all-electric F-150 Lightning at its Rouge Electric Vehicle Center in Dearborn, Michigan. All hourly staff from the EV facility are being reassigned to the nearby Dearborn Truck Plant to ramp up output of gas and hybrid F-Series trucks. This move aims to recover lost volume and meet strong customer demand for these more profitable models.

Why is Ford freezing its EV push for gas trucks?

A fire at Novelis’ Oswego aluminum plant in September disrupted Ford’s supply chain, as the facility provides a significant portion of the aluminum used in its trucks. Ford’s Chief Financial Officer highlighted during the company’s Thursday earnings call that this incident may reduce Q4 2025 adjusted profits by up to $2 billion. CEO James Farley emphasized, “We are adding up to 1,000 new jobs to increase F-Series production to recover lost volume and fulfill strong customer demand.” The F-150 Lightning, which requires more aluminum, is being deprioritized in favor of gas and hybrid variants that align better with current market profitability and resource availability. Ford’s press release states that assembly at the Rouge Electric Vehicle Center will remain paused while focusing on these core models. This isn’t the first setback; production was halted for seven weeks in late 2024 to address softening EV demand and control costs. Despite these challenges, Ford reported $50.5 billion in Q3 revenue, a 9% increase from the prior year, with its stock rising 11.6% over the past year, demonstrating resilience in its truck segment.

Frequently Asked Questions

How will Ford increase F-150 production in 2026?

Ford plans to boost F-Series output by 50,000 trucks in 2026 by reassigning workers from its EV center and adding up to 1,000 new jobs at the Dearborn Truck Plant. This strategy counters supply chain disruptions and capitalizes on demand for gas and hybrid models, which are key profit drivers for the company.

What caused the pause in F-150 Lightning production?

The pause stems from a fire at supplier Novelis’ Oswego plant, disrupting aluminum supplies critical for vehicle manufacturing. Combined with prior production halts in late 2024 due to weak EV demand, Ford is shifting focus to more viable gas and hybrid F-150 variants to maintain profitability and meet market needs.

Key Takeaways

• Worker Reassignment: All hourly staff from the Rouge EV Center are moving to the Dearborn Truck Plant to enhance F-150 assembly efficiency.
• Supply Chain Impact: The Novelis fire could slash Ford’s Q4 2025 profits by $2 billion, underscoring vulnerabilities in aluminum sourcing.
• Strategic Shift: Prioritizing gas and hybrid trucks over EVs positions Ford to recover volume and sustain revenue growth amid evolving demand.

Conclusion

Ford’s decision to pause F-150 Lightning production and accelerate Ford F-150 production for gas and hybrid models reflects a pragmatic response to supply chain hurdles and market realities. By leveraging its strong F-Series lineup, the company aims to offset losses and drive future growth. As automotive trends evolve, stakeholders should monitor how this pivot influences Ford’s broader EV ambitions and overall profitability.