Ford rehired 350 veteran engineers after an aggressive push to automate quality control via AI resulted in severe defect rates and high recall costs.
The company realized that AI can process documentation but cannot replicate the tacit judgment gained by engineers over decades of real-world product cycles.
The "gray beard" specialists are now actively training both younger employees and the AI systems, preventing defects before they hit the manufacturing floor.
The reversal serves as a stark warning to startups and enterprises looking to use AI merely to slash senior payroll costs without accounting for institutional memory.
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