Ford aluminum supply disruption continues after Novelis Oswego fire impacts F-Series production

Ford aluminum supply disruption remains unresolved more than four months after a fire halted operations at a Novelis aluminum plant in Oswego, New York, affecting material supply for Ford’s high-margin pickup trucks. According to two people familiar with the situation, aluminum production at the facility has still not fully resumed, extending uncertainty across Ford’s truck manufacturing plans.

Delayed recovery at Novelis Oswego plant

Following the fire at the Oswego facility in September, Novelis had indicated that full aluminum production was expected to restart by the end of December. That recovery timeline was later disrupted after a second fire occurred in late November, pushing any reopening date into uncertainty and complicating supply planning for automotive customers.

Revised production outlook after second incident

The additional fire significantly altered earlier expectations. Novelis stated that it “will continue to leverage alternate sources, including its global network of plants and industry peers, to mitigate impact.” The company has not confirmed when full operations at the Oswego site will resume, leaving downstream supply chains exposed.

Impact on Ford F-Series production

The Ford aluminum supply disruption has had direct implications for F-Series pickup production. Ford previously confirmed that it is sourcing aluminum from other Novelis facilities to maintain manufacturing continuity. Despite these measures, the disruption has constrained output planning for some of its most profitable vehicle lines.

Production losses and mitigation strategy

Ford said last year that it expects to lose production of up to 100,000 F-Series pickup trucks through the end of 2025, with an estimated financial impact of up to USD 2 billion. The automaker plans to offset roughly half of that loss by increasing production of F-150 and Super Duty trucks by more than 50,000 units at its Dearborn Truck Plant and Kentucky Truck Plant in 2026.

Broader supply chain considerations

While Novelis supplies aluminum to multiple OEMs, Ford remains one of its most significant customers due to the extensive use of aluminum in the bodies of F-150 and Super Duty trucks. This reliance highlights how disruptions at a single upstream facility can ripple across the automotive aluminum supply chain. A Ford spokesperson said the company will provide an update on the situation when it reports its Q4 2025 earnings on February 10. Until then, the Ford aluminum supply disruption underscores ongoing challenges automakers face in stabilizing material supplies amid operational setbacks at key supplier facilities.