The best-selling vehicle in the US has just run into another roadblock. Ford has been struggling with F-Series pickup production and supply chain issues since last year, but the latest four-day stoppage has nothing to do with aluminum. This time, Ford is having hood problems, and it is working to stamp them out. Die Job Has Stopped Truck Production Dead Ford According to a report from the Detroit Free Press, Ford was forced to pause F-150 pickup production at its Dearborn Truck Plant in Michigan on Thursday night. The report said that it was expected to be closed for four days, and that could lead to missed production of thousands of trucks and more than $100 million in revenue.The problem isn't at the Truck Plant, it's at the nearby Dearborn Stamping Plant. Like the name suggests, this plant is used to stamp out body panels.According to the report, there is a broken hood die at the stamping plant, and that means Ford can't make hoods. A stamping die is a massive part and is completely custom-made for the part it produces. Even Ford wouldn't have a spare die or even a spare stamping machine just waiting around.Stamping body panels is like the large-scale version of those penny crushing machines at every National Historic Site gift shop. A piece of sheet metal, in this case pickup truck hood-sized, is placed in the machine between two mold pieces called dies. The machine compresses the two together and the hood in the middle gets sandwiched into shape. It's a lot of force, and a lot of money involved.Ford is already working flat-out at the plant. It has been running two 10-hour shifts because Ford needs to make up for the estimated 60,000 or so trucks it has fallen behind by. Production has been affected by a fire at aluminum supplier Novelis, which made it hard to get the blank sheets that go in the dies. Could Add 2,500 Lost Units To 50,000 Already Behind Ford The report says the plant could miss out on 2,500 units of production depending on how long it takes to get the stamping plant back up and running. That will mean even more extra work to build enough trucks. That could mean extra shifts, though Ford is already running some extra shifts.Ford has already worked to add shifts to truck plants at Dearborn and in Kansas City, and added more staff to existing operations, including the stamping plant. Production of the Super Duty trucks is set to start at Ford's plant in Oakville, Ontario, later this year to help meet demand. The report also says that Ford is planning to skip its usual summer shutdown at the truck plants, a move that could increase production by "more than 50,000 trucks."It's not easy staying at the top, especially in the US pickup truck market. Ford has managed to do it for nearly 50 years, aided in part by GM's insistence on separating the Chevrolet and GMC brands.Rushing to catch up on lost production introduces more chances for more problems and more lost production, so will Ford end up losing the number one spot this year? We'll have to wait and find out, but Ford is certainly spending hundreds of millions of dollars to make sure it stays on top.
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