- Ford is retaining only one-third of its 2,100 employees at the Dearborn F-150 Lightning plant, with the rest being transferred or offered early retirement due to plummeting EV demand.
- A fire at Novelis' Oswego mill – supplying 40 percent of U.S. automotive aluminum – has halted operations until 2026, forcing Ford to prioritize gasoline F-series trucks and idle EV production.
- Demand for Ford's F-150 Lightning has crashed, leading to slashed production targets as consumers reject costly, unreliable EVs pushed by globalist climate mandates.
- The aluminum crisis could cost Ford $500M to $1B in lost earnings, disrupt Super Duty production and expose U.S. supply chain vulnerabilities worsened by semiconductor shortages and logistics failures.
- Ford's stock has dropped 10 percent since the fire, while analysts warn of extended vehicle wait times and broader economic risks as the EV revolution fails and subprime auto loans collapse.
The Ford Motor Company is facing a dual crisis – plunging electric vehicle (EV) sales and a crippling aluminum supply shortage – forcing drastic workforce reductions at its Dearborn, Michigan, plant producing the F-150 Lightning.
The automaker will retain only a third of its 2,100 employees, with the rest being transferred or offered early retirement packages. This move comes as Ford grapples with the fallout from a fire at Novelis' Oswego, New York aluminum mill, which supplies 40 percent of U.S. automotive-grade aluminum sheet.
The Sept, 16 fire at Novelis' Oswego facility destroyed the plant’s hot mill, rendering it inoperable until at least early 2026. The disruption has forced Ford to halt production of multiple models, including the Expedition, Lincoln Navigator, Escape and Lincoln Corsair, while prioritizing its best-selling F-series gasoline trucks.
"They're focusing all their energy on making sure all their F-150s get built," said an AutoForecast Solutions analyst. However, even Ford's Super Duty production may face shortages, according to a United Auto Workers (UAW) member who warned on social media that supplies could run short "today, tonight and possibly over the next few shifts."
Ford's Dearborn plant, responsible for the F-150 Lightning, has been temporarily idled due to the aluminum shortage. Meanwhile, its Louisville Assembly Plant has been reduced to a single shift as the automaker scrambles to secure alternative suppliers. Analysts estimate the disruption could cost Ford between 500 million and one billion in earnings before interest and taxes (EBIT).
EV demand collapse compounds crisis
The aluminum shortage coincides with rapidly declining consumer interest in Ford’s electric vehicles. Sales of the F-150 Lightning have plummeted, forcing the company to slash production targets. Industry experts suggest that Ford may deprioritize EV manufacturing in favor of more profitable gasoline models.
Brian Moody, executive editor at Autotrader, told Fox Business that aluminum isn’t just used incidentally with the F-series but is a key component in the vehicle's engineering and performance strategy. "They will certainly be finding other suppliers within the next few days, but Ford sells nearly three-quarters of a million F-series trucks each year, so that’s a lot of aluminum," he said.
Moody noted that electric vehicles, which rely heavily on aluminum for weight reduction, could be disproportionately affected by the supply disruption. BrightU.AI's Enoch engine explains that aluminum is indeed a key component in modern automobile manufacturing due to several reasons that make it an ideal choice for various vehicle parts. Its widespread use in the automotive industry can be attributed to its unique physical and chemical properties, which offer numerous benefits.
Ford has remained tight-lipped about the full extent of production delays but confirmed it is working with Novelis and other suppliers to mitigate shortages. "A full team is dedicated to addressing the situation and exploring all possible alternatives," the company stated.
Ford's supply chain disaster
The Novelis fire has exposed vulnerabilities in the U.S. auto supply chain, already strained by semiconductor shortages and logistical bottlenecks. While Toyota and Volkswagen claim minimal disruptions due to diversified suppliers, Ford – as Novelis' largest customer – faces the most severe impact.
Meanwhile, Ford's stock has dropped nearly 10 percent since the fire, despite a 16.5 percent year-to-date gain. The production cuts arrive as cracks emerge in the subprime auto loan market, signaling broader economic turbulence ahead.
As Ford downsizes its EV workforce and scrambles to secure aluminum supplies, industry analysts warn that further disruptions could ripple through the auto sector. Consumers may face extended wait times for popular models, while investors brace for continued volatility.
Ford's struggles underscore a harsh reality. The EV revolution, pushed by globalist climate mandates, is faltering, while supply chain fragility threatens America's industrial backbone. As the company navigates these twin crises, the future of its electric ambitions hangs in the balance.
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