Case study
23 May 2025

Enhancing Safety and Efficiency at Ford's EV Battery Testing Facility

Summary

Ford's EV battery testing operations faced elevated safety risks due to manual monitoring and lack of real-time fire detection. By combining MultiSensor AI’s infrared imaging and AI-powered software, Ford transitioned from a reactive approach to a proactive safety system—reducing response time and improving safety. This proactive approach now delivers real-time alerts, minimizes the risk of thermal runaway, and helps prevent costly product loss.

Challenge

Ford’s EV battery testing facility operated with traditional, reactive monitoring of their EV battery tests. Outside of standard fire alarms, there were no automated safeguards in place—posing a significant risk in the event of a lithium-ion battery thermal runaway. The potential consequences ranged from catastrophic product loss to safety hazards and serious operational delays. Without real-time visibility, security and response teams were left in the dark until it was too late.

Solution

MultiSensor AI partnered with Ford to overhaul their monitoring infrastructure. The first phase involved deploying 36 Summit-series thermal cameras, with 20 additional visual and thermal cameras planned. Our advanced cameras provide a wide field of view, allowing comprehensive coverage with fewer devices—cutting complexity and cost.

The cameras were integrated with MultiSensor AI’s software platform to detect specific alert patterns, minimizing false positives and ensuring that only credible threats triggered alarms. With seamless setup and intelligent detection—including people recognition and thermal anomalies—the system now provides around-the-clock situational awareness.

The Challenge

Results

1. Real-Time Safety Alerts

Multisensor AI's system delivers instant alerts when potential thermal incidents are detected, dramatically improving response times and situational awareness.

 

2. Zero Incidents Since Implementation

Since the system went live, there have been no recorded thermal runaway events, highlighting the effectiveness of proactive monitoring.

 

3. Automated Incident Workflow

Ford's security team now receives automated alerts, shifting from passive monitoring to active intervention. Future plans include direct integration with emergency services to further streamline response.

Highlights

Conclusion

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Thermal Monitoring Delivers 8x ROI for Global Online Retailer’s Operations

A global online retailer implemented MultiSensor AI to monitor its High Speed Gapper Beds—critical assets in the material handling process. Real-time thermal monitoring led to early detection of belt tension issues, MultiSensor AI reduced downtime by 30%, increased throughput 11.4x, and cut maintenance costs by 40%, delivering a 20x return on investment.

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