Ford rehires 350 engineers after AI falls short on vehicle quality

NEW YORK, June 30, 2026 — US carmaker Ford has rehired around 350 experienced engineers after finding that automated quality control systems driven by artificial intelligence [AI] failed to achieve the standards expected in vehicle production.

Like many global manufacturers seeking to capitalise on the AI boom, Ford expanded the use of artificial intelligence across its operations in a bid to cut costs and improve productivity. However, the company acknowledged that AI alone could not replicate the judgement and practical expertise required to maintain high product quality.

Charles Poon, Ford’s Vice President for Vehicle Hardware Engineering, said the company underestimated the value of experienced personnel.

“Artificial intelligence is a fantastic tool, but it’s only as good as the information you use to train it,” Poon told the BBC.

“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.”

According to Poon, the automated systems lacked the practical insight and accumulated knowledge of veteran engineers, many of whom had already left the company before their expertise could be incorporated into training and refining the AI tools.

“Mistakenly, we thought that by just introducing artificial intelligence and ingesting the design requirements that we had, that would produce a high-quality product,” he said.

The move comes after Ford’s Chief Operating Officer, Kumar Galhotra, said last year that the company was “deploying AI across the entire industrial system”.

As part of that strategy, Ford installed around 900 AI-powered cameras across its manufacturing facilities to detect quality issues early and minimise supply chain disruptions.

General Motors Faces Criticism Over Automation Drive

While Ford is bringing experienced workers back into its operations, another major US carmaker has faced criticism over its own automation strategy.

Labour unions have criticised General Motors after the company cut more than 1,000 jobs at its main Detroit assembly plant and introduced 50 robotic units as part of its manufacturing operations.

General Motors said the deployment formed part of a broader effort to modernise production and remain competitive, while also improving workplace safety and ergonomics.

“We’ve been installing cobots across our manufacturing footprint as part of a broader push to bring more advanced technology into our operations,” company spokesman Kevin Kelly said.

“At Factory ZERO, we are implementing them alongside our team, helping improve safety and ergonomics, while keeping our operations flexible and competitive.”

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