Ford is overhauling quality control procedures following a record-breaking 153 recalls in 2025. These recalls affected nearly 13 million vehicles last year. Key facilities like the Essex Engine Plant in Canada now perform daily engine teardowns instead of quarterly inspections.
The new strategy utilizes an AI-powered predictive monitoring system to identify potential faults. This system flags engines for inspection even when components fall within manufacturing tolerances. This data-driven approach aims to intercept defects before vehicles reach customers.
Ford modeled the program after successful quality control initiatives at its Valencia plant in Spain. The company reports that warranty claims have already declined since the implementation. This offensive targets long-term vehicle reliability and a reduction in future defects.