News: 0184084184

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Ford Rehires 350 Engineers After AI Fails To Preserve Expertise or Train Juniors

(Thursday June 25, 2026 @05:00PM (BeauHD) from the engineers-in-the-loop dept.)


After Ford's automated quality-control systems and AI tools fell short, the automaker [1]hired 350 veteran engineers over the past three years to mentor younger staff and reprogram the underperforming technology. "Artificial intelligence is a fantastic tool, but it's only as good as the information you use to train it," Charles Poon, Ford's vice president of vehicle hardware engineering, told reporters on a call Wednesday. "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." Bloomberg reports:

> Those engineers were "at the heart" of Ford's efforts to turn around quality problems, said Kumar Galhotra, chief operating officer. They now run mandatory meetings that rigorously troubleshoot quality problems and they have reprogrammed AI tools to head off glitches before they happen. "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 return of the veteran engineers at Ford cuts against the prevailing wisdom -- and fear -- that AI will replace all kinds of knowledge workers. But Ford found the machines couldn't replace experience. "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," Poon said. But "we recognized that for us to enhance some of our automation and machine learning and artificial intelligence tools we needed to ensure that they were trained by the most experienced individuals."

>

> As a result of the efforts of the old hands, Ford vaulted above quality stalwarts such as Toyota and Honda on [2]JD Power's bellwether survey that measures the quality of a car during the first three months of ownership. Only luxury brands Porsche and Genesis topped Ford this year.



[1] https://www.bloomberg.com/news/articles/2026-06-25/ford-has-been-rehiring-quality-inspectors-after-ai-fell-short

[2] https://www.cnbc.com/video/2026/06/25/j-d-power-new-auto-quality-survey-here-are-the-results.html



Re: Charles Poon (Score:3)

by Tomahawk ( 1343 )

Just like every other CEO that thinks AI is a magic bullet.

Poon is a funny sounding name (Score:2)

by sabbede ( 2678435 )

And that's all I wanted to say.

Re: (Score:3)

by ac22 ( 7754550 )

He's actually extremely well regarded within the car industry. He was mentored by the legendary Richard Minge before he retired. It's likely that Brian Clunge will ultimately take his place at the top table.

Re: (Score:3)

by saider ( 177166 )

Earlier in his career he had a law firm with Michael Tang

Shows you what they were thinking (Score:5, Insightful)

by MIPSPro ( 10156657 )

They actually thought that shit would work. They could just fire all those engineers and AI would just work itself out. Breathtaking hubris.

Re:Shows you what they were thinking (Score:5, Interesting)

by 0123456 ( 636235 )

The surprising part is that any of the engineers went back after the company had treated them like that. I guess they'll just be saving money until they get sacked again.

Re: (Score:3, Interesting)

by Anonymous Coward

There's a good chance that the rehired engineers will be hoarding critical information from this point forward. Unethical, but they've been treated unethically preemptively.

Re:Shows you what they were thinking (Score:4, Interesting)

by 93 Escort Wagon ( 326346 )

> The surprising part is that any of the engineers went back after the company had treated them like that. I guess they'll just be saving money until they get sacked again.

What alternative do you think these guys had? They've got bills to pay and families to feed, and all of these companies have been dumping skilled employees like crazy due to leadership's sophomoric belief that AI can do everything.

Re: Shows you what they were thinking (Score:2)

by AvitarX ( 172628 )

Generally laid off high end talent gets 3x hourly on rehire (based on my friend's parents).

Re: (Score:2)

by taustin ( 171655 )

> Breathtaking hubris.

Mixed with first rate marketing.

Re: (Score:2)

by ArchieBunker ( 132337 )

You're forgetting one thing. Even accounting for this fuckup, in the end was it still cheaper than simply paying people? If the answer is yes then this behavior will continue.

Re: (Score:2)

by sarren1901 ( 5415506 )

Well, it was until they had to rehire them, presumable at very high wages.

This is certainly debatable, but (Score:4, Insightful)

by pr0t0 ( 216378 )

It's not just about how to build the widget. I've long held that one of the most valuable assets an employee brings to his/her employer is their historical and institutional knowledge. Why all the various choices were made all along the way, where the skeletons are buried, and how to handle a specific vendor or customer to achieve the desired outcome often provide greater value than just how to tighten the nut on the bolt. A failure to recognize that is a failure of leadership.

Re: (Score:2)

by gweihir ( 88907 )

They still seem to think this is going to work, with minor adjustments. Well, a bunch of fool is at the start of mist spectacular failures.

Re: (Score:2)

by MIPSPro ( 10156657 )

These stock idiots definitely think AI is going to replace coders the same way Pets.com was going to replace pet stores. They aren't super interested in history.

Re: (Score:2)

by gweihir ( 88907 )

They are not super interested in thinking. Just in getting rich without effort, including mental effort.

Incidentally, I just saw a study that predicts that in 2028, LLM-code will be more expensive to get than code written by people. And that does not take insecurity, review-resistance, bad maintainability, loss of engineering skills and institutional knowledge, etc. into account. The whole thing is a massive hallucination by completely disconnected idiots.

Re: Shows you what they were thinking (Score:2)

by AvitarX ( 172628 )

I'm shocked that Ford had a standard of quality that let them notice.

I read an article recently where Ford was bragging about testing one engine a day off an assembly line for quality control. Ford felt that was an amazing dedication to quality.

GIGO (Score:5, Insightful)

by Thud457 ( 234763 )

I hope Ford gave all those hapless engineers back pay for the whole time they were fired. (Hapless, because they took the offer to come back instead of finding an employer that properly valued their expertise and experience.)

It seems that the gestalt of the era is not just plain incompetence, but a complete disdain for competence. Fuck these bad managers and slipshod stewards.

Re: (Score:2)

by stabiesoft ( 733417 )

I'd add the engineers should be the ones who get to fire those managers, personally giving them their walking papers. But I doubt the managers got fired. Pity.

Re: (Score:3)

by 0123456 ( 636235 )

The incentive system in modern business cares only about short-term stock prices so the managers can exercise their stock options and retire to Hawaii. A good way to bump up stock prices is to sack all the competent people because they are typically paid more.

A secondary benefit is that those competent people were the most likely to complain about policies which are long-term harmful so you no longer have to deal with anyone complaining about what you're doing.

Re: (Score:2)

by eneville ( 745111 )

This kind of thing has happened previously too, but it was via "outsourcing" in another contract that didn't work out, so they need the employees back, sometimes as consultants.

What's old is new again.

Re: (Score:1)

by Provos ( 20410 )

One of the most aggravating things right now is "AI" in the hiring process - companies use it to screen applicants but then all use a common tool like Workday, which is facing a lawsuit in California that seems to be automatically rejecting applicants at all employers once it rejects the candidate at a single employer. Applicants have no idea they've been blindly rejected and the hiring managers, some of whom are absolutely desperate to hire, are never even seeing the applicants' resumes.

> (Hapless, because they took the offer to come back instead of finding an employer that properly valued their expertise and experience.)

Keep floundering in

...Doofus execs given bonuses (Score:5, Insightful)

by abulafia ( 7826 )

Sure hope those engineers held out for a nice salary bump that should come out of the executive compensation pool, but won't.

Re:...Doofus execs given bonuses (Score:4, Insightful)

by Fons_de_spons ( 1311177 )

Well, if corporate fires you and then tries to hire you back, you have got to demand a serious raise. Do not take it personal. This? It is called doing business.

Ford, if I may make a suggestion (Score:5, Insightful)

by gtall ( 79522 )

Take every idiot manager that had a hand firing those engineers and put a shadow AI right along side them. Let them compete against the AI for why they should continue to work at Ford rather than having a bot take their place.

Re: (Score:2)

by Murdoch5 ( 1563847 )

Yes, 100%. Management loves to assert that AI is some magic solution, well, also asserting it's not ready to replace everyone, but then, they go and fire everyone, since AI can replace them. It's a feedback loop of incompetence, and well, I don't hate AI, it has many good uses, it's certainly making far too many mistakes.

Put their money where their mouths are, and use AI exclusively to manage, plan, schedule, and run their jobs. Once AI destroys a calendar, how fast will AI be parked? Funny how enginee

Re: (Score:2)

by Frissysan ( 659257 )

No mod points today but +1 Insightfull

Re:Ford, if I may make a suggestion (Score:4, Interesting)

by AcidFnTonic ( 791034 )

When I worked there in IT for a few years it was amazing how skilled engineers were essentially not at all part of the design process or planning but instead just "handed" some crappy off the shelf product and told to go "implement" it. This to them was software development. Even things like the supposed Sync, are actually just third party development companies using a crappy product called "SmartDeviceLink".

I recall spending months fighting something called an Infrastructure Control Review (ICR) which to this day I share the experience with my employees as a learning exercise in failure. Every filename had to be known, every click in some gui had to be listed, it was just asinine and none of it was ever followed 5 minutes past the approval stamp that took months and months of circle jerking. Never seen so many six figure salary engineers doing absolutely *nothing* in these meetings spanning months.

Ford pretends to want outside expertise and knowledge but the *instant* they arrive the company culture tells them that questioning anything at all will get you enemies fast. Toe that company line and internally the phrase "Ra Ra Go Ford" was used as a mock of this fake stupid energy that dominated the place.

I doubt that will change anytime soon, especially with Farley trying to "secretly" bribe Trump for a law banning the repair of cars without dealership involvement. But the auto journalists want to check out their stupid small EV truck coming out so no one will run the news. Go google it, Ford and GM just had a private meeting with Trump where they asked for this in secret but Trump was too stupid to keep it secret and mentioned it in news interview.

So Fuck Ford for that initiative. Repairing our own cars is part of respecting the customer which they pretend to do.

Truth behind doublespeak (Score:5, Insightful)

by SouthSeb ( 8814349 )

I understand Ford is trying to gloss over this story, like they're some sort of humble and benevolent company, but the reality is transparent:

"We fired senior, experienced engineers, tried to substitute them with AI and it didn't work. Now we're rehired some of them to train AI more, so we can fire them again in the near future."

Re: (Score:2)

by magamiako1 ( 1026318 )

I read it that way as well. They're still clinging to the belief that they can do exactly that.

Thankfully, that's not likely to come to fruition. The experienced engineers hold the cards now and whether that AI gets trained is entirely up to them. When push comes to shove, the Ford senior leadership isn't going to try that again no matter what they say publicly.

Re: (Score:2)

by gweihir ( 88907 )

You know, even if it works somewhat (which is doubtful), who is going to keep the AI updated when nobody gets to maintain and extend their own expertise?

Methinks we will see a number of really spectacular enterprise deaths and falls to irrelevance in the next few years, most with a clear trace to LLM use.

Re: (Score:2)

by drinkypoo ( 153816 )

> we will see a number of really spectacular enterprise deaths and falls to irrelevance in the next few years, most with a clear trace to LLM use.

Probably, but no US automaker will be among those. The US won't let them fail because they are defense contractors. If we have a war we need them to make vehicles. The bulk of units will be drones, but we will still need tanks and whatnot.

Re: (Score:2)

by gweihir ( 88907 )

You men like Boeing? Probably. Will make the general US population even poorer though.

Re: (Score:2)

by sarren1901 ( 5415506 )

So long as the 1% gets theirs, the rest of us are just here to enrich them. Working as intended.

Re: (Score:2)

by gweihir ( 88907 )

Sad but true.

Re: (Score:2)

by sconeu ( 64226 )

I am shocked, SHOCKED! That AI didn't preserve institutional knowledge.

Re: (Score:2)

by Fons_de_spons ( 1311177 )

Had to study two models of treating staff in an HR course. It was more than 2 decades ago so I may get some details wrong. One was the (Henry) Ford model. People on the work floor are a necessary evil. They cost a lot, they make mistakes. Yuk! Avoid them if possible. If you give them a job, make it as simple as possible so that they do nothing wrong. Do not work well? Toss them out, replace with a fresh specimen. Etc. The other mode, Kensian, I think, it saw staff as something you invest in. Truth is in the

This comes to mind (Score:2)

by Sebby ( 238625 )

> Ford Rehires 350 Engineers After AI Fails To Preserve Expertise or Train Juniors

The phrase "No shit, Sherlock!" comes to mind.

Re: (Score:2)

by gweihir ( 88907 )

Yep. Nobody could have expected that, except everybody with a working mind. But these seem to be really rare on C-level ...

Haha (Score:2)

by ambrandt12 ( 6486220 )

Called it!

If I was there, I'd demand 4X pay to come back and fix their major f-up.

You say that's too much?

Which of us has a SCSI card and tape drive working in Win10?

Re: (Score:2)

by gweihir ( 88907 )

You are clearly too cheap at 4x.

Re: (Score:2)

by ambrandt12 ( 6486220 )

Remember, bid too high and you get nothing... bid too low, you get ripped off (this is one of those things big contractors know).

Same Ford asking for bills to outlaw repair (Score:5, Informative)

by AcidFnTonic ( 791034 )

Same Ford asking for bills to outlaw repair. Don't forget they really could care less about your ability to repair your own vehicle.

Re: (Score:2)

by 0123456 ( 636235 )

> Same Ford asking for bills to outlaw repair

C'mon man. Only dealerships can be trusted to repair cars properly. We must ban third-party repairs FOR THE CHILDRUN.

If it only saves one life...

Ford...meh (Score:2)

by Ritz_Just_Ritz ( 883997 )

There's a reason why Ford's stock has been more or less flat for the past 25 years...bouncing around between about $2 and $20 while remaining deeply in debt.

They're circling the drain.

"AI is a fantastic tool"... (Score:2)

by gweihir ( 88907 )

... except that it is not. It is just a tool and it cannot deliver miracles. I mean, their failure is staring them in the face and they still make that deranged claim? How mentally incapable can you be?

No duh (Score:2)

by LordAba ( 5378725 )

The only reason LLMs that individuals interact with seem intelligent is that they are pulling from massive systems. As soon as you insert your proprietary Vector database for the RAG to grab things usually turn to into just a glorified search engine (granted, a potentially good one that can pull context).

Mr. Mom (Score:2)

by silvergig ( 7651900 )

The movie Mr. Mom has come true again.

Those of us who train AI (Score:2)

by toxonix ( 1793960 )

There needs to be a new law, and it needs to be backdated to the first commercial foundational models.

Any human's who is used to train AI must be given equity in the monetization of that model, and any model derived from it, forever.

If we as knowledge workers do not organize or provide this requirement to the politicians we support, then we're going to be left in the dust.

I hope they got huge raises (Score:2)

by homerbrew ( 10094532 )

Seeing as how they are doing Ford a HUGE favor, they should get some hefty raises

AI is no replacement for an engineer (Score:2)

by wakeboarder ( 2695839 )

I have had gemini invent complete fake products that it swears are real until you ask it. Claude does a reasonable job of document translation and generation, but none of them have scope. Sometimes giving them enough scope and prompting would take about the same time to generate the document. So no, with LLM's you won't get rid of engineers. It accelerates work, that's for sure, but it doesn't replace an engineer. AI won't be able to do any testing either.

Also FYI for all you corporate overloads. ASML exist

I hope they bent Ford over a barrel. (Score:2)

by sarren1901 ( 5415506 )

I really hope each and every one of those engineers demanded double their prior wage. Take it or leave it Ford. It's nothing less then they deserve.

Kumar Galhotra, chief operating officer (Score:2)

by bill_mcgonigle ( 4333 ) *

Who made the call to fire these guys?

Were they Americans who did the firing? Were they Americans who got fired?

It's important to understand the sociology potentially putting huge American enterprises risk

And why would we believe the claim that a 1-year reliability rating had anything to do with this?

Anybody who vaguely understands automotive manufacturing knows that cars that were sold over one year ago were designed several years ago and tooling takes months to years for a new model.

This article seems desi

What could possibly go wrong? (Score:1)

by Bitbeard ( 1665499 )

AI designing cars, AI driving cars. What could possibly go wrong?

Everything that you know is wrong, but you can be straightened out.