Ford has long faced criticism regarding the quality of its products, but in 2025, the problem reached a particularly noticeable scale. The manufacturer set a peculiar record for the number of recall campaigns, initiating 153 global vehicle recalls.

In comparison, Stellantis, which ranked second, conducted only 53 recall campaigns during the same period. Such a significant difference forced Ford's management to reconsider its approach to quality control in production, paying special attention to engines.

Why the old system no longer satisfied the company

Previously, quality control for power units was based on a relatively simple scheme. One engine was randomly removed from the production line and subjected to complete disassembly approximately once every three months. Unscheduled inspections were only carried out when there were suspicions of serious manufacturing defects.

Over time, it became clear that this approach had a serious drawback. A significant amount of time could pass between the emergence of a problem and its detection.

During this time, the following occurred:

• engines managed to leave the factory;
• units were installed on production cars;
• cars were sent to dealers;
• cars reached customers.

As a result, by the time a defect was identified, the number of potentially problematic engines could be in the tens of thousands of units.

That is why Ford decided to radically change its control methodology.

Now the engine is checked every day

According to the new scheme, one engine is sent directly from the conveyor for a comprehensive inspection every day.

The procedure includes several stages:

• a series of intensive tests;
• data analysis using artificial intelligence;
• complete disassembly of the unit;
• detailed inspection of all components.

In fact, the engine is studied down to the smallest detail to identify even minimal deviations from production standards.

This approach allows for much faster detection of potential problems and reaction to them before defective products begin to enter the market en masse.

First results appeared in Spain

The new methodology was first implemented at Ford's plant in Valencia, Spain.

According to the company, this plant, after the introduction of enhanced quality control, became considered Ford's best production facility in the world in terms of assembly quality.

Successful experience prompted management to scale the program to other sites.

The next enterprise was the plant in the American state of Ohio, where some of Ford's most famous engines are produced:

• 5.0-liter Coyote V8 for Mustang and F-150;
• 6.7-liter V8 for the Super Duty family;
• 7.3-liter V8 for the Super Duty line.

These engines are now also undergoing additional daily control.

Why Ford is willing to spend money on this

At first glance, the idea of disassembling a working engine daily may seem too costly.

Such a procedure requires:

• qualified personnel;
• additional time;
• special equipment;
• significant financial costs.

However, the company concluded that the cost of such control is significantly lower than the potential losses from mass recalls.

Each major recall campaign can cost the manufacturer hundreds of millions of dollars. If it's about systemic defects, the total costs can amount to billions.

In addition to direct financial losses, there is another factor - reputational risks. Mass recalls inevitably affect customer trust and can impact future sales.

Therefore, Ford views enhanced quality control as a long-term investment, not an additional expense item.

What role does artificial intelligence play?

One of the key features of the new system is the use of artificial intelligence technologies.

During unit inspection, AI analyzes data obtained during tests and helps identify features of part processing and potential deviations during assembly.

According to the company, such systems are capable of noticing nuances that previously might have gone unnoticed even with traditional checks.

This involves identifying:

• minor manufacturing defects;
• deviations in surface finish quality;
• errors in assembly of units;
• signs of potential problems at an early stage.

Thus, artificial intelligence is used not as a replacement for specialists, but as an additional control tool.

What this means for Ford

The record 153 recall campaigns in 2025 became a serious signal for the American manufacturer. Instead of piecemeal changes, the company decided to revise the very philosophy of quality control and significantly increase the depth of inspections.

Daily engine disassembly, the use of artificial intelligence, and the expansion of the program to key engine plants show that Ford intends to tackle the problem systematically.

How effective the new approach will be, time will tell. However, it is already clear that the company is willing to spend additional resources on preventing defects at the production stage to avoid much more serious costs after vehicles enter the market.

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