Ford disassembles 1 engine daily at factories to catch defects
Ford is stepping up its quality game by testing and taking apart one engine every day at its factories, hoping to spot problems before cars hit the road.
After leading the industry with 152 recalls in 2025 (that's nearly 13 million vehicles), Ford has already issued more than 50 recalls so far this year.
This daily teardown is their way of catching issues early and making sure fewer cars need fixing later.
Neil Wilson: teardowns reduce warranty claims
An engine a day gets a deep dive for defects, and workers learn how to identify potential problems and where to look for them.
Neil Wilson, Ford's Essex engine plant manager, says this approach has led to a "rapid decline" in warranty claims and gives "real insight on how to protect quality."
The goal? Move from just reacting to problems to actually preventing them, so your next Ford should be more reliable right from the start.