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Ford Vehicle Production Struggling To Reach Pre-Pandemic Levels

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COVID-19 continues to impact nearly every aspect of life for most individuals on planet Earth. For companies that depend on a highly complex, globalized supply chain, the pandemic has also represented an obstacle in bringing back normal production levels. A Ford Authority analysis of 2020 Ford vehicle production in North America paints a pretty clear picture of exactly how much the pandemic has impacted output.

FoMoCo Vehicle Production - North America, First 10 Months 2020
Model/Plant 10 Months 2020 10 Months 2019 10 Months 2018 2020 vs. 2019 2020 vs. 2018
Ford Explorer 171,034 154,804 285,244 10.5% -40.0%
Ford Taurus 0 7,269 40,538 -100.0% -100.0%
Lincoln Aviator 20,288 13,562 10 49.6% -
Chicago, Illinois Plant 191,322 175,635 325,792 8.9% -41.3%
Ford Fiesta 0 44,577 55,391 -100.0% -100.0%
Ford Mustang Mach E 1043 0 0 - -
Cuautitlan, Mexico Plant 1043 44,577 55,391 -97.7% -98.1%
Ford F-Series 219,626 315,513 316,852 -30.4% -30.7%
Dearborn, Michigan Plant 219,626 315,513 316,852 -30.4% -30.7%
Ford F-Series Chassis 11,628 14,414 15,968 -19.3% -27.2%
Detroit, Michigan Plant 11,628 14,414 15,968 -19.3% -27.2%
Ford Mustang 57,799 83,790 96,332 -31.0% -40.0%
Lincoln Continental 7,385 12,851 16,069 -42.5% -54.0%
Flat Rock, Michigan Plant 65,184 96,641 112,401 -32.6% -42.0%
Ford Bronco Sport 1,379 0 0 - -
Ford Fusion 99,186 153,858 151,478 -35.5% -34.5%
Lincoln MKZ 13,144 26,695 27,391 -50.8% -52.0%
Hermosillo, Mexico Plant 113,709 180,553 178,869 -37.0% -36.4%
Ford Transit 98,909 157,047 138,119 -37.0% -28.4%
Ford F-Series 219,746 283,490 279,546 -22.5% -21.4%
Kansas City, Missouri Plant 318,655 440,537 417,665 -27.7% -23.7%
Ford Expedition 61,154 79,107 63,305 -22.7% -3.4%
Ford F-Series Super Duty 211,432 305,515 292,111 -30.8% -27.6%
Lincoln Navigator 13,212 22,262 20,298 -40.7% -34.9%
Kentucky Truck (Louisville) Plant 285,798 406,884 375,714 -29.8% -23.9%
Ford Escape 187,923 230,292 270,782 -18.4% -30.6%
Lincoln Corsair/MKC 21,916 35,939 32,475 -39.0% -32.5%
Louisville Plant 209,839 266,231 303,257 -21.2% -30.8%
Ford C-Max 0 0 3,685 - -100.0%
Ford Focus 0 0 86,862 - -100.0%
Ford Ranger 85,776 114,712 207 -25.2% 41337.7%
Wayne, Michigan Plant 85,776 114,712 90,754 -25.2% -5.5%
Ford GT 151 225 215 -32.9% -29.8%
Multimatic Markham, Ontario Plant 151 225 215 -32.9% -29.8%
Ford Edge 99,571 141,466 138,869 -29.6% -28.3%
Ford Flex 0 22,642 17,725 -100.0% -100.0%
Lincoln MKT 0 2,918 2,325 -100.0% -100.0%
Lincoln Nautilus/MKX 27,689 47,670 33,166 -41.9% -16.5%
Oakville, Ontario Plant 127,260 214,696 192,085 -40.7% -33.7%
Ford E-Series 34,657 44,077 45,734 -21.4% -24.2%
Ford F-Series Super Duty 15,037 16,937 12,559 -11.2% 19.7%
Ford F-Series Medium Duty 13,826 17,294 11,757 -20.1% 17.6%
Avon Lake, Ohio Plant 63,520 78,308 70,050 -18.9% -9.3%
Total Car 177,665 329,265 477,961 -46.0% -62.8%
Total Truck 1,515,846 2,019,661 1,977,052 -24.9% -23.3%
Total Production 1,693,511 2,348,926 2,455,013 -27.9% -31.0%

Ford’s ultimate cash cow and crown jewel, the Ford F-150, is currently produced at two plants – the Dearborn Truck plant and the Kansas City Assembly.

The Ford Dearborn Truck plant, which is solely responsible for manufacturing the F-150, can pop one truck out every 52 seconds. But production from January through October 2020 is down about 30 percent when compared to the same period in 2019 and 2018. One major contributing factor is the generational changeover for the all-new F-150, which took place in September. The switchover is likely responsible for most of the reduced output, which also seems to have affected sales in November.

Ford vehicle production also took a hit at the Ford Kansas City Assembly plant, with the facility building a total of 318,655 vehicles through October 2020. That figure did not compare favorably to previous years, as production decreased 27.7 percent when compared to 2019 and 23.7 percent versus 2018. Again, the switchover to the redesigned 2021 model likely influenced output.

Other FoMoCo plants are also struggling to match pre-pandemic levels of production. The Ford Chicago Assembly plant, which produces the Ford Explorer and Lincoln Aviator, churned out 191,322 vehicles through October 2020. That’s down a staggering 41.3 percent when compared to 2018, although it represents an 8.9 percent increase in Ford vehicle production during the same period in 2019. Problems in launching the 2020 Explorer may have caused disruptions at the plant, so COVID-19 may not have played as much of a factor in Chicago as a cursory glance would suggest.

There are also other FoMoCo plants in North America have reduced output but have not recently experienced a model changeover event. The Ford Flat Rock Assembly plant currently has a line dedicated to the Ford Mustang and until recently, also built the Lincoln Continental. Ford vehicle production at the facility decreased substantially through October 2020, with the facility producing 32.6 percent fewer vehicles compared to the same period the prior year. Compared to 2018, production was down 42 percent.

Even plants that build crossovers are experiencing slowdowns. The Ford Oakville Assembly plant, which builds the Ford Edge and Lincoln Nautilus, suffered a rather steep 40.7 percent drop in output through October 2020 when compared to the figure in 2019 for the same period, plus a 33.7 reduction from 2018. Sales are once again a factor here, with the Edge and Nautilus both experiencing double-digit declines in demand compared to last year.

COVID-19 clearly impacted Ford vehicle production either directly or indirectly. Every Ford plant in North America experienced a minimum 21.2 percent decrease in output throughout October 2020. As a whole, The Blue Oval’s entire North American operation built 28 percent less vehicles during the first 10 months of 2020 than it did in 2019.

Global auto production across the industry was down for about two months, spanning the first and second quarters of 2020 due to the pandemic, with Ford being no stranger to the shut-down. Even so, the Dearborn-based automaker effectively adapted its facilities to resume production and keep workers as safe as possible.

We’ll continue bringing you the latest about Ford’s production, so subscribe to Ford Authority for the latest Ford business news and continuous Ford news coverage.

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Ed owns a 1986 Ford Taurus LX, and he routinely daydreams about buying another one, a fantasy that may someday become a reality.

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Comments

  1. NCEcoBoost

    Take away the dramatics with discontinued models, models in wind-down and new model ramp-ups and it isn’t half bad. Not nearly as bad as the title leads one to believe. A bit of overdramatics, me thinks.

    Reply
  2. Motorpsychology

    For the Chicago Assembly figures, they were also producing the Taurus all of 2018 into March 2019.

    Reply
    1. Motorpsychology

      Oakville Assembly was also making the Lincoln MKX, MKT and Ford Flex in 2018, dropping MKX production in 2019, etc, etc.
      as I read the article, Covid-19 has not been a significant a factor in reduced sales and production. Sales/Production is off the pandemic, but less so of it, IMO .

      Reply

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