Automated checks find known defects. Ford shows why companies still need the experience of people from operations

Ford uses more than 100,000 automated tests in parts of its quality control, yet it has also brought 350 experienced technical specialists into this area. The case shows the difference between coverage and judgment: a system reliably looks for something it has been taught to recognize, while an experienced worker may notice an unusual combination of symptoms. Before automating, a company therefore needs to determine how many important rules exist only in experts’ heads.

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