- Ford plans to recover lost production after a fire at an aluminum supplier.
- A third shift in Dearborn will build over 45,000 additional F-150 trucks.
- F-150 Lightning production will stop as it prioritizes gas and hybrid models.
A fire at a Novelis aluminum plant has disrupted operations for several automakers, including Ford and its top-selling F-150. The setback has been costly, but the Blue Oval plans to bounce back next year by ramping up truck production.
Under the plan, the Dearborn Truck Plant will add a third shift with roughly 1,200 employees. This will be supported by more than 90 new workers at Dearborn Stamping as well as more than 80 additional employees at Dearborn Diversified Manufacturing.
More: 2026 Ford F-150 Lightning Solves Its Biggest Flaws For Free
Thanks to these workers and the extra shift, Ford aims to produce an additional 45,000+ F-150s in 2026. They’ll have traditional powertrains as the F-150 Lightning hasn’t lived up to expectations.
Assembly of the electric truck will “remain paused” indefinitely as the company is prioritizing production of models with gas and hybrid powertrains. The automaker added these types of trucks are “more profitable for Ford and use less aluminum.”
Due to the pause, hourly employees at the Rouge Electric Vehicle Center will transfer to the nearby Dearborn Truck Plant to join the third shift. The shift will also consist of new hires as well as some transfers from other plants.
To increase production of the popular F-Series Super Duty, the automaker is investing $60 million into the Kentucky Truck Plant. These funds will help speed up the production line, so that one additional truck will be built every hour. That might not sound like much, but it will result in more than 5,000 additional pickups.
The funds will also be used to help train new employees. Speaking of which, the plant is expected to add more than 100 jobs.
In total, the automaker will increase production by more than 50,000 units and create up to 1,000 new jobs. Ford’s Chief Operating Officer, Kumar Galhotra, said “The people who keep our country running depend on America’s most popular vehicle – F-Series trucks – and we are mobilizing our team to meet that demand.”
Novelis Fire Could Cost Ford $1 Billion
Novelis
The announcement to ramp up production comes as Ford revealed the “Novelis headwind” could cost them up to $1 billion in losses between 2025 and 2026.
CEO Jim Farley has already visited the damaged plant and said, “We are working intensively with Novelis and others to source aluminum that can be processed in the cold rolling section of the plant that remains operational, while also working to restore overall plant production.” This has enabled them to “minimize the impact in 2025 and recover production in 2026.”
Given the fallout of the fire, Ford now expects to finish the year with an adjusted EBIT of $6 billion to $6.5 billion as well as an adjusted free cash flow of $2 billion to $3 billion.
It wasn’t all bad news as third quarter revenue reached a record of $50.5 billion. That’s up 9% from a year ago and the company posted a net income of $2.4 billion. Unfortunately, Trump’s tariffs cost the automaker roughly $700 million.
