When AI Cannot Capture What Was Never Written Down
Ford recorded the most recalled vehicles of any mainstream automaker in 2025 — 12.9 million vehicles across 153 recall campaigns. AI-assisted camera technology failed to address quality control issues at its North American factories.7
Ford subsequently rehired 350 veteran engineers — internally referred to as 'gray beards' — many of them former employees and others drawn from suppliers. Their job was not just to return to the factory floor, but to train younger engineers and help reprogramme the AI tools that had failed to capture what they knew.
“Mistakenly, we thought that by just introducing artificial intelligence and ingesting the design requirements that we had, that would produce a high-quality product. Over prior years, we didn’t pay as much attention as we should have to the experience of our most knowledgeable engineers.”
— Charles Poon, VP Vehicle Hardware Engineering, Ford
AI cannot replace institutional knowledge that was never documented. The round-trip cost — rehiring 350 specialists — saved Ford hundreds of millions in warranty and recall costs.