Ford rehires human engineers after AI fails quality checks

Ford has rehired more than 300 veteran quality inspectors in recent years after determining that artificial intelligence systems failed to match the capabilities of experienced human engineers in quality control operations, according to company executives.

The US automaker had adopted AI across parts of its operations, including quality checks, with the expectation of reducing costs and increasing productivity. However, the automated systems proved insufficient for the task, prompting the company to bring back experienced personnel to strengthen inspection processes.

Charles Poon, Ford's vice president of vehicle hardware engineering, said the company had not adequately leveraged the experience of its most knowledgeable engineers in developing AI systems. "Artificial intelligence is a fantastic tool, but it's only as good as the information you use to train it," Poon told reporters. "Over prior years, we didn't pay as much attention as we should have to the experience of our most knowledgeable engineers that have been with us through many product cycles," he said.

The rehiring of veteran inspectors followed improvements in Ford's vehicle quality. The company topped the JD Power 2026 US Initial Quality Study for the first time since 2010, marking a significant achievement in the competitive automotive market.

Ford is among numerous automakers that have sought to capitalize on artificial intelligence technology to streamline operations and reduce expenses. The company's experience with quality control systems illustrates challenges in fully automating processes that traditionally relied on human expertise and judgment developed over extended periods in the industry.