Ford rehired veteran engineers after automation errors hurt quality

In short: Ford says it had to bring back experienced engineers and technicians after automated systems made mistakes that lowered vehicle quality.

What happened

Ford is celebrating a new milestone, it was ranked No. 1 among mainstream automakers in JD Power’s initial quality study for the first time in 16 years. Initial quality rankings are based on problems reported early in ownership, closer to first impressions than long-term durability.

In briefings with reporters, Ford leaders said the company had leaned heavily on automated systems in vehicle design and production. These systems included robots and AI, which is software that learns patterns from past data (like training a new worker by showing them lots of examples).

Ford said this approach did not work as smoothly as it expected. The company had to hire experienced technicians to correct errors made by its automated systems, and it sometimes brought back former employees to do it. Charles Poon, Ford’s vice president of vehicle hardware engineering, said the company mistakenly assumed that adding AI and changing design requirements would naturally lead to better quality.

Ford also said some of its most experienced people left before their know-how could be fully captured in the automated systems. In plain terms, Ford learned that a computer system does not automatically “inherit” the judgment that comes from many years of building cars.

Why it matters

Many companies are adding more automation to save time and reduce costs. Ford’s comments are a reminder that automation still needs strong data and experienced people who can spot problems early, especially when the product is something as safety-critical as a car.

Source: The Verge AI