Ford is taking a smart approach to one of its biggest challenges—recalls worth billions—by putting artificial intelligence to work on the factory floor. With two advanced systems, AiTriz and MAIVS, the company is sharpening its quality control and cutting down on costly rework.
AiTriz, launched in December 2024, taps into live video streaming and machine learning to catch misalignments as they happen, helping operators make quick adjustments. Meanwhile, MAIVS has been in use since January 2024, relying on still images captured by smartphones to confirm that parts are installed correctly. If you’ve ever had to inspect items under time pressure, you’ll appreciate the boost these tools offer.
Recalls have been a persistent headache for Ford over the past five years, and 2025 saw a record 94 recalls, largely affecting models made before 2023. A notable example is the fuel leak recall for Bronco Sport and Escape SUVs, which alone ran up costs of $570 million. By catching issues at the point of assembly rather than waiting for end-of-line inspections, these AI systems save both time and money.
Jeff Tornabene, a manager at Ford’s Manufacturing Technology and Development Centre, explained the new process: every minute brings a new vehicle with a unique set of tasks. These AI-powered cameras act as vigilant assistants, ensuring every connection is sound—even when factory noise or protective gear might otherwise disrupt the process.
Engineering manager Patrick Frye added that even the tiniest misalignment can lead to larger issues down the line as vehicles become more sophisticated. With the AI systems catching potential problems in real time, Ford is able to address discrepancies right at the station.
The advanced live video feed from AiTriz is particularly useful when components get in the way of the view. Today, AiTriz is active at 35 locations across North America, while MAIVS is deployed at nearly 700 stations, a clear sign of Ford’s commitment to innovation in manufacturing.
David Whiston from Morningstar is optimistic about the long-term impact of these systems, saying that effective use of AI could reduce recalls over the next decade. Ford is careful to stress that the goal isn’t to replace human workers but to support them in managing increasingly complex vehicles.
This is just the beginning for Ford’s AI journey. The company sees these tools as an evolving suite of technologies designed to iron out imperfections and keep vehicles safe and reliable, one assembly line at a time.
