By John 
Ford Motor Company is bracing for a major financial hit after a fire crippled one of its most critical suppliers. The September 16 blaze at Novelis’ aluminum plant in Oswego, New York has disrupted nearly 40% of the U.S. auto industry’s aluminum sheet supply, dealing a serious blow to Ford’s truck operations.
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Analysts estimate the fallout could cost Ford up to $1 billion in lost operating earnings, as production interruptions ripple through the automaker’s most profitable segment. The company temporarily paused output at both its Dearborn Truck Plant and Rouge Electric Vehicle Center, which build the F-150 and F-150 Lightning, respectively.
Ford is the largest consumer of aluminum from the Oswego facility, which produces lightweight sheet metal crucial to the F-Series lineup, including the aluminum-bodied F-150 and Super Duty models. With the Novelis plant expected to remain offline until early 2026, Ford may face production losses of 20,000 to 50,000 trucks through the end of this year alone.
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The timing couldn’t be worse. The disruption follows a recent 50% tariff on U.S. aluminum imports, further tightening supply. Ford’s stock slid 6% on Tuesday and another 1.5% Wednesday, as investors reacted to the compounding pressures on the automaker’s truck business.
Despite the setback, there were recent bright spots: Ford delivered a record 10,000 F-150 Lightnings in Q3, just before the federal EV tax credit expired. Still, CEO Jim Farley has warned that electric truck sales could slow sharply heading into 2026.
The road ahead looks challenging as Ford juggles aluminum shortages, cost pressures, and uncertain demand. With the Oswego plant down for more than a year, America’s top-selling truck may face its toughest production test in a decade.
Shawn Henry