Novelis, Ford's primary aluminum supplier, expects to complete repairs at its fire-damaged Kentucky plant by June following a March blaze. The Atlanta-based manufacturer disclosed at least $255 million in estimated repair costs, with insurance expected to cover a portion of expenses. Operations remain partially suspended at the facility producing lightweight auto body sheets.

Ford revealed the outage will cost $2 billion in lost earnings this year, as the plant supplied materials for F-Series trucks and other high-volume models. The automaker has temporarily shifted some production to other Novelis facilities but faces ongoing supply constraints. Aluminum shortages could pressure margins across the industry as inventories tighten.

The disruption exposes vulnerabilities in automotive supply chains still recovering from pandemic-era shocks. Novelis supplies 40% of North America's automotive aluminum sheet market, making full restoration critical for Ford and rivals like GM. Repair timelines now hinge on equipment lead times and workforce availability in Bowling Green.