Ford Is Tearing Down Engines Every Day In A Bid To Cut Recalls

Ford is tearing down engines daily to cut recalls, marking a bold shift in quality control. The company now removes a different engine from the production line each day for extensive testing and complete disassembly, a departure from quarterly checks. Ford says the daily teardowns, aided by predictive AI analytics, are already improving warranty-related quality metrics by catching issues earlier. The new practice requires more labor and equipment, but Ford argues that the investment is justified if it prevents costly recalls and warranty repairs later. Engines are selected using AI-based monitoring that flags subtle production anomalies even when outright specifications appear normal. Technicians then inspect every component during teardown, enabling targeted investigations that can reveal wear patterns or assembly defects that traditional QA might miss. Ford traced the program to its high-performing Valencia, Spain plant, whose quality practices inspired the global rollout. While the initiative won't eliminate recalls overnight, Ford says that daily inspections and AI-driven screening are meaningful steps toward steadier quality and fewer service campaigns.