Can AI replace experienced workers? Ford learned the hard way that it cannot. After relying heavily on automated quality systems, the automaker realised its vehicles lacked the expected level of craftsmanship. When senior engineers retired, their crucial real-world knowledge disappeared, leaving AI systems unable to spot early defects. To fix this, Ford brought back over 350 veteran ‘gray beard’ engineers. Instead of just solving problems, these experts are now mentoring young talent and training AI systems with decades of hands-on data, shifting Ford's strategy from fixing defects to preventing them entirely through early collaboration.
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