Ford’s EV battery testing facility relied on manual monitoring and basic fire alarms, creating significant risk during lithium-ion battery tests. Without real-time thermal visibility, teams had no way to detect early heat anomalies or precursors to thermal runaway events. Any failure could result in major product loss, operator safety hazards, and severe operational delays. Security and response teams were effectively blind until an alarm sounded—far too late for high-risk EV battery environments.
MultiSensor AI deployed 36 Summit-series thermal cameras, with 20 additional visual and thermal units planned for expanded coverage. Wide-field imaging reduced the total number of devices needed, cutting complexity and cost. Integrated together with the MSAI Connect software platform, the system identifies thermal anomalies and distinct alert patterns while filtering out false positives. Intelligent detection, including people recognition, provides 24/7 situational awareness. Automated alerts now reach Ford’s security and safety teams instantly, enabling rapid, precise intervention and improving response speed across the facility.
Since the system went live, Ford has recorded zero thermal runaway events. The shift to automated alerts reduced manual work orders by 20% and decreased operational downtime by 30%. Enhanced detection minimizes high-risk events that previously would have required containment, cleanup, and costly test interruptions. Ford now operates with real-time visibility over every battery test zone, reducing both safety risk and operational waste.
Zero thermal runaway events since implementation.
36 cameras deployed, with 20 more planned.
30% reduction in operational downtime.
20% reduction in manual work orders.
Wide-field thermal coverage reduced hardware complexity and cost.
MSAI’s thermal intelligence platform - MSAI Connect - helped Ford transition from reactive monitoring to proactive safety control. The facility now benefits from continuous oversight, faster response times, and improved workflow automation. The system prevents costly incidents, increases operational confidence, and supports future integration with emergency services to streamline response even further.