Ford hired 350 veteran engineers after executives said automated quality checks fell short
Ford has hired 350 veteran engineers, some of them former employees and others from suppliers, after "artificial intelligence and automated systems failed to deliver the desired quality level", TechCrunch reported on 28 June 2026, relaying Bloomberg's account of a press briefing. Chief operating officer Kumar Galhotra said Ford had been "relying more and more on automated quality systems". Fortune reports that the hiring ran over three years and that recalls were costing Ford $4.8 billion a year by mid-2024. Ford kept the AI: its camera checks on hose and electrical connections run in 33 plants. The veterans, "internal auditors" in a Ford representative's words to Fortune, run mandatory weekly design reviews and reprogram AI tools that were not working.
Why it matters: Ford's executives describe a planning assumption. "Mistakenly we thought that by just introducing artificial intelligence and ingesting the design requirements that we had, that that would produce a high-quality product," Charles Poon, vice president of vehicle hardware engineering, said, according to TechCrunch. The same assumption sits in any plan that removes experienced checkers once an automated check is live, whether the work is parts, invoices or support replies. Fortune gives the price of one miss: a recall with an estimated $570 million charge for nearly 700,000 crossovers, about $814 a vehicle ($570 million ÷ 700,000).
The catch: Ford has not said what the 350 engineers or the AI tools cost, or which defects the automated checks missed. Ford now ranks first among mainstream brands in J.D. Power's Initial Quality Survey, both outlets report, and no source separates the engineers' effect from other changes. Chief executive Jim Farley credited lower warranty and recall costs with "literally hundreds and hundreds of millions of dollars", per TechCrunch. Ford still expected more than $1 billion in warranty and material costs this year, Fortune reports.
What to do: Before you reduce the people who check work because an AI check is live, run both on the same items for a month and count what each misses. Keep the people until that count says otherwise. Ask HR to list, before any retirement or redundancy round in a team that is being automated, who holds knowledge that is not written down, and to agree terms for bringing them back. Give your most experienced reviewers sign-off on any change to what the tool checks.
Our coverage →TechCrunch: Ford rehires 'gray beard' engineers after AI falls short (28 Jun 2026) ↗Fortune: Ford on why it hired 350 'gray beard' engineers (29 Jun 2026) ↗