Ford Resumes Rouge EV Center Production; F-150 Lightning Production Capacity to Triple by Fall

Lightning Production Restarts Rouge Electric Vehicle Production

Production of the F-150 Lightning has resumed at Ford’s Rouge Electric Vehicle Center after a six-week pause for an expansion and retooling project. This undertaking aims to triple the production capacity of this acclaimed electric truck, targeting an annual output of 150,000 units by autumn.

The upgrades at the Rouge Electric Vehicle Center encompass layout improvements and the introduction of new tools designed to enhance efficiency and maintain high-quality manufacturing standards. This expansion enables Ford to meet the growing demand for the F-150 Lightning, particularly in high-demand trim levels such as the XLT.

While the temporary shutdown affected customer deliveries, it is a crucial step in accelerating the ramp-up process to meet the increasing demand for this electric pickup truck. The Rouge Electric Vehicle Center is poised to manufacture over 70,000 F-150 Lightning units in 2023, with production for U.S. customers set to escalate in the coming months. This expansion marks a significant milestone in Ford’s commitment to electric vehicle production and sustainability.
Scaling Ford F-150 Production at Rouge Electric Vehicle Center

We are all looking forward to getting these F-150 Lightning trucks into the hands of our customers – from the U.S. to Norway. This milestone is the result of a lot of hard work and collaboration.

- Debbie Manzano, Director of Manufacturing, Ford
Ford’s commitment to quality is reinforced with the introduction of new tooling at the Rouge Electric Vehicle Center. This state-of-the-art equipment is now being used to autonomously assess and confirm the precision of exterior body fit, ensuring impeccable margins and flushness. Remarkably, this marks the debut of such cutting-edge tools within Ford’s North American plants. Furthermore, a third station has been incorporated to validate wheel alignment and headlamp aim, crucial for advanced driver-assist technology.

To support these advancements, a comprehensive three-week training program is underway for an additional 1,200 manufacturing employees. These new recruits are being integrated swiftly through a buddy system, where they shadow experienced colleagues, facilitating a rapid onboarding process. This investment in both technology and human resources reflects Ford’s unwavering dedication to maintaining the highest standards of quality in its electric vehicle production.

Battery pack manufacturing is also scaling up operations at the Rawsonville Components Plant, while the Van Dyke Electric Powertrain Center in Michigan is boosting the production of electric vehicle power units to align with the increased scale of F-150 Lightning assembly at the Rouge Electric Vehicle Center. This strategic expansion across multiple facilities underscores Ford’s commitment to meeting the surging demand for electric vehicles.

Meeting Customer Demand

The expanded capacity at the Rouge Electric Vehicle Center plays a pivotal role in reducing order-to-delivery times for customers. It primarily focuses on producing high-demand trim levels like the XLT, which constitutes over 50% of recent orders. Additionally, Lightning Pro units are now accessible to retail customers, albeit in limited quantities, and these units have been reserved for dedicated customers who have patiently awaited their opportunity to place orders since the initial launch.

Furthermore, recent adjustments in pricing, while still higher than the launch prices, have significantly boosted web traffic by threefold and customer orders by sixfold. These changes have made the F-150 Lightning more attainable to a broader range of prospective buyers. The increased production capacity also paves the way for expanding the range of trim levels available within the lineup, addressing customer preferences that have emerged since the vehicle’s initial introduction.

We have learned a lot from our first-ever EV truck customers, including a preference for technology and visual differentiation. We continue to refine the F-150 Lightning lineup to make the jump to an EV truck an easy choice for customers.”

- Marin Gjaja, Chief Customer Officer, Model e

The F-150 Lightning, recognized as the 2023 MotorTrend Truck of the Year, represents Ford’s most intelligent and innovative F-150 to date. It offers the convenience of a 9.6-kilowatt smart power plant with Pro Power Onboard and incorporates the top-rated Active Driving Assistance System, Ford BlueCruise, along with the renowned Built Ford Tough capability.

With a commitment to affordability, reducing wait times, and a proactive approach to charging infrastructure, Ford strives to lead the industry in facilitating a customer-centric transition to electric vehicle adoption. The company is currently developing its second generation of electric vehicles, building upon the success of its initial lineup, which includes the F-150 Lightning, Mustang Mach-E, and E-Transit.

Call or Visit Raceway Ford, your local Riverside Ford dealership to custom order your F-150 Lightning.


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