Ford brings back skilled engineers after AI falls short

Ford Enhances Quality Control with Veteran Engineers

Ford has brought back experienced human engineers to address gaps in its artificial intelligence (AI) tools, which were intended to improve quality in its manufacturing processes.

This initiative has helped Ford achieve the top spot in J.D. Power’s 2026 U.S. Initial Quality Survey (IQS) for the first time since 2010, thanks to notable improvements in the quality of its new vehicles. The company has learned that AI can’t entirely replace the expertise of human workers in production.

“AI is a valuable tool, but the quality of the data we use for its training is crucial,” stated Charles Poon, Ford’s vice president of vehicle hardware engineering, during a press conference. He acknowledged, perhaps somewhat regrettably, that the contributions of their most experienced engineers had not received enough attention over the years.

Poon reflected on a previous misjudgment, saying, “We thought merely introducing AI along with our design specifications would guarantee a high-quality product.” He emphasized that AI tools lack the depth of training and experience that their veteran engineers possess. Unfortunately, many of these knowledgeable engineers had left the company before their insights could be applied to enhance AI performance.

According to Poon, it became clear that to optimize automation and machine learning tools, input from experienced personnel is indispensable. As part of this effort, Ford has onboarded around 300 seasoned engineers in its vehicle engineering sector over the past few years.

With their regular production duties lifted, these engineers now function as internal auditors, conducting weekly design reviews to identify and rectify potential issues before blueprints are sent to the factory.

Kumar Galhotra, Ford’s Chief Operating Officer, highlighted that having experienced engineers and technical professionals “at the heart” of their strategy is vital for enhancing production quality by addressing process challenges early in the workflow.

Additionally, CEO Jim Farley mentioned that these strategic changes have positively impacted the company’s financial health by lowering warranty costs and recall expenditures, which ultimately benefits the automaker through significant cost savings.

This year’s J.D. Power IQS positions Ford at the forefront for the first time in 16 years, ranking models such as the Ford F-150, Mustang, and Super Duty as leaders in their segments for the second consecutive year.

Moreover, the Ford Escape, Explorer, Expedition, and Maverick also secured top-three spots in their respective categories, meaning seven of Ford’s top ten models ranked among the best.