Introduction

Artificial intelligence-powered photographic inspections, 3D-printed tools, and augmented-reality training headsets are part of Ford Motor Co.’s strategy to improve vehicle quality, which has been a significant concern affecting its financial results.

Financial Impact

The Dearborn automaker faced a more than 5% decline year-over-year in net income in the second quarter due to unexpectedly high warranty costs on pre-2021 vehicles. This decline follows years of negative financial impacts from poor quality results, prompting the company to seek solutions through new leadership, revamped manufacturing systems, and advanced technology.

Improving Processes

Ford’s new procedures for launching vehicles, such as the Super Duty, have cost about $1 billion, but executives believe these changes will yield better results in the long run. The brand made a significant leap in J.D. Power’s 2024 U.S. Initial Quality Study, climbing from No. 23 to No. 9.

“To see a full market brand make a big shift like that is significant,” said Frank Hanley, J.D. Power’s senior director of auto benchmarking.

Quality Checks

Ford is enhancing its quality checks and communication flow to address issues more swiftly. The company is also reforming its purchasing approach to ensure better quality.

AI Cameras

One notable implementation is the Mobile Artificial Intelligence Vision System (MAIVS), which uses smartphone cameras and AI to inspect parts kits. This system has been installed in over 300 stations across 20 plants globally, conducting more than 60 million inspections last year.

3D Printing

Ford is utilizing 3D printing to create tools that help operators perform their jobs more efficiently. The Van Dyke plant has multiple 3D printers running 24/7, allowing for rapid prototyping and tool creation.

Augmented Reality Training

Dearborn Engine has integrated Microsoft HoloLens into its training program, enhancing employee training with augmented reality. This technology breaks down complex tasks into manageable steps, making it easier for workers to learn new skills.

Conclusion

Ford’s commitment to improving vehicle quality through innovative technology is evident in its various initiatives. As the company continues to evolve, these advancements may lead to significant improvements in both product quality and employee efficiency.

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