Ford says it is bringing back hundreds of experienced “veteran” engineers after AI- and automation-based quality systems did not meet the company’s reliability standards. Multiple reports cite Ford executives describing an increased reliance on automated quality checks over recent years, followed by disappointing results. Ford COO Kumar Galhotra is quoted saying the company “brought back technical specialists” to identify failure points before parts reach the plant floor, as the AI tools were not cutting it for the level of inspection needed.

The reporting converges on the same scale and timing: Ford rehired about 350 “gray beard” engineers, including former employees, over roughly the past three years. Ford’s leadership also frames the move as both a quality-control measure and a workforce capability effort, with some accounts noting the engineers support mentoring and the training or reprogramming of AI systems.

Ford links the change to improving outcomes in reliability and cost, with executives pointing to reduced warranty coverage and recall costs. Other outlets add context on Ford’s recent quality and reliability challenges and the wider trend of companies reassessing where AI can supplement rather than replace human expertise.