Ford VP claims AI tools weren’t trained well enough to take over for experienced engineers.

Ford Rehires Engineers to Enhance Production Quality

Ford has brought back seasoned human engineers to improve its artificial intelligence (AI) systems that focus on quality issues in the company’s production process. This decision comes after recognizing the limitations of relying solely on AI.

The move has paid off, as Ford recently topped J.D. Power’s 2026 U.S. Initial Quality Survey (IQS) for the first time since 2010. This success follows a series of lessons learned about how AI can’t entirely replace the expertise of human workers.

“AI can be quite effective, but its success depends heavily on the quality of the data it’s trained with,” remarked Charles Poon, Ford’s vice president of automotive hardware engineering, during a press event on Wednesday.

Poon acknowledged past mistakes, stating that the company hadn’t prioritized the insights and experiences of its most skilled engineers, many of whom have been integral through various product cycles.

Collaboration with Filson on New Bronco SUV

Ford has also announced a partnership with outdoor outfitter Filson to develop a new Bronco SUV.

“We mistakenly thought that just implementing AI along with our existing design criteria would lead to superior products,” Poon elaborated.

He pointed out that while AI tools are valuable, they lack the knowledge and training that veteran engineers provide. Moreover, many skilled engineers had departed before they could lend their expertise to bolster the AI tools.

“To enhance our automation and machine learning systems, we realized it was essential that these tools be guided by our most experienced personnel,” said Poon.

Significant Losses Due to EV Transition

Ford has rehired roughly 300 veteran engineers into its vehicle engineering department over recent years. “These engineers, now free from the daily production grind, work as internal auditors to conduct weekly design reviews aimed at identifying and rectifying potential failures before designs head to the factory,” Ford noted in a statement.

Kumar Galhotra, Ford’s Chief Operating Officer, emphasized that seasoned engineers and technical experts play a crucial role in enhancing production quality by addressing process issues early in the workflow.

Vehicle Recall and Quality Improvements

On another note, Ford’s CEO Jim Farley mentioned that recent quality improvements have positively impacted the company’s financial situation. This has led to reduced expenditures on warranty claims and recalls, which ultimately contributes to cost savings.

The latest J.D. Power’s 2026 IQS not only records Ford’s first-place ranking but also sees the Ford F-150, Mustang, and Super Duty leading their categories for a second consecutive year.

Additionally, models like the Ford Escape, Explorer, Expedition, and Maverick are among the top three in their segments. In total, seven of the company’s top ten models are now ranked within the top three in their respective categories.