Ford Brings Back Veteran Engineers to Fix Quality Issues AI Couldn’t Handle

Ford Motor Co. has reversed course on its reliance on artificial intelligence for quality control by rehiring 350 veteran engineers—dubbed “gray beards”—over the past three years to address persistent defects that cost the automaker billions. These experienced engineers, many recruited from former roles or suppliers, have taken charge of retraining AI systems and leading rigorous troubleshooting efforts after automated quality checks failed to prevent costly errors. The move has paid off: Ford now ranks as the top mainstream brand in J.D. Power’s 2026 Initial Quality Survey, surpassing industry stalwarts like Toyota and Honda. Only luxury brands Porsche and Genesis ranked higher overall.

Charles Poon, Ford’s vice president of vehicle hardware engineering, admitted that the company had overestimated AI’s capabilities. “Artificial intelligence is a fantastic tool, but it’s only as good as the information you use to train it,” Poon said. “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.” The veteran engineers now lead mandatory meetings to identify failure points before parts even reach the assembly line and have reprogrammed AI tools to preempt glitches.

Kumar Galhotra, Ford’s chief operating officer, emphasized that the engineers were central to the turnaround. “We had been relying more and more on automated quality systems and not getting the desired results,” Galhotra said. “We brought back technical specialists, and they hunt for failure points before a part ever reaches the plant floor.” The automaker’s quality improvements were reflected in the survey, where Ford’s infotainment system saw the largest leap in performance. Three of its models—the F-150 pickup, Super Duty truck, and Mustang sports car—ranked highest in their respective categories.

Despite the progress, Ford remains the most recalled automaker in the U.S., a lagging indicator of past quality issues. The company expects $1 billion in warranty and materials costs this year but anticipates a decline in recalls as its upfront quality fixes take hold in newer vehicles. “Because we’re doing more to prevent issues upfront, we believe these recall numbers are going to steadily come down with the newer vehicles,” Galhotra said. “I can’t give you a very specific date on when the number will turn.”