Ford is acknowledging the challenges it faced with AI production and design systems after the automaker recently claimed the top spot in JD Power’s initial quality ranking for mainstream brands for the first time in 16 years. According to Ford, attempting to replace highly-skilled employees with AI-powered systems was a mistake.
The Verge reports that Ford has revealed that its reliance on artificial intelligence and automated systems in vehicle production and design created significant quality problems, forcing the company to bring back experienced engineers and technicians to correct mistakes made by its robots.
Charles Poon, Ford’s vice president of vehicle hardware engineering, explained during a briefing with reporters this week that the automaker believed simply introducing AI and adjusting existing design requirements would automatically yield high-quality vehicles. “Mistakenly, we thought that by just introducing artificial intelligence and adjusting the design requirements that we had, that that would produce a high-quality product,” Poon said.
The problem was compounded when some of Ford’s most experienced personnel departed before their accumulated institutional knowledge could be fully captured by the company’s automated systems. This loss of expertise proved particularly damaging because the effectiveness of AI depends entirely on the quality of data used to train the models. Ford had underestimated the value of veteran engineers who had worked through multiple vehicle-development cycles and possessed deep understanding of potential problems that could emerge during production.
To address this gap, Ford hired, promoted, or brought back more than 350 experienced engineers to rebuild its technical expertise base. These seasoned professionals were tasked with retraining the automated systems and mentoring younger engineers who were struggling to maintain vehicle quality standards. “That’s where some of our most experienced engineers have had experience solving and identifying those problems before they creep into the system,” Poon said.
Ford’s quality challenges have been well documented in recent years. The automaker currently leads the industry in number of recalls, with quality ratings declining over several years. Difficulties intensified during launches of the Explorer and Aviator models, supply-chain disruptions during the COVID-19 pandemic, and a growing number of vehicle recalls that damaged consumer confidence.
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