+ Publish Ad FREE !
Ads stats: last 24h - 35, actual - 941, total - 103080

Takata Review Panel Flags Quality Control Problems

16 February 2016 - Automotive News

Takata Review Panel Flags Quality Control Problems

Questionable product development practices. A lack of unified testing specifications. The need for greater automation in factories. A passive design review process.

An independent review panel appointed by Takata Corp. pinpointed a number of red flags in the troubled airbag maker's quality control.

The report cited several flawed practices, including a troubling habit of allowing products under development to continue downstream even though design milestones were not met.

The panel also recommended adopting "use by" dates for airbags. Under that proposal, the expiration dates would be adopted across the U.S. industry, requiring that old inflators be replaced after a set period of time with new ones less likely to have degraded chemically.

The panel's report, issued this month after nearly a year of studying the Japanese supplier, doesn't shed new light on the root cause of the Takata airbag defect linked to 10 deaths and responsible for tens of millions of vehicle recalls worldwide.

Takata had appointed former U.S. Transportation Secretary Samuel Skinner to lead the seven-member panel in a study focused on assessing quality in everything from product development to manufacturing. The panel included three former U.S. National Highway Traffic Safety Administration administrators: John Snow, who held the post in 1976-77; Marion Blakey, 1992-93; and Dr. Jeffrey Runge, 2001-05.

The panel made several recommendations on ways Takata can improve quality. It also gave the supplier one year to report back on the progress made in implementing the changes.

Shortcuts

It is one of several deadlines the embattled company faces.

For example, manufacturers' operations in states with high humidity, which has been linked to the airbag failures, must have enough parts on hand by March to complete all repairs, under a consent decree Takata reached with NHTSA.

And in November, NHTSA gave Takata until the end of 2019 to demonstrate the long-term safety of inflators using ammonium nitrate-based propellant.

If it can't, all Takata ammonium nitrate inflators, including those not currently under recall, would have to be replaced. That could add millions to the recall tally.

The suspect inflators can explode with too much force, showering the car's occupants with shrapnel. Analysis so far, while failing to find the root cause, has linked the problem to manufacturing glitches and chemical deterioration of the inflators due to heat and moisture.

The Skinner panel found gaps that may have exacerbated defects.

"After conducting an extensive review of Takata's quality-related operations and organization, the Panel concludes that Takata must improve in several areas," the group's 49-page report says.

Chief among them is a product development practice called "conditional approval." This happens when Takata waves a product through to the next stage of development even though it hasn't completed or fully addressed certain review milestones.

The panel said conditional approvals help create an environment where quality problems "slip through the cracks."

If the design issue is fixed later in review stage, it further complicates production engineering and could lead to hastily made assembly line changes that impact manufacturing quality.

The panel did not say how often Takata resorts to conditional approvals, but said it happened "more often than not." It recommended Takata reduce instances to 20 percent of the time.

Lack of rigor

Takata must also improve the design review process to make sure that the relevant people rigorously vet technology.

The current process is "more of an exercise in completion than a rigorous quality evaluation," the panel said.

"Takata's general practice is to invite large numbers of people, in some cases 100 or more, to its design review, but only a handful of those invited actually attend," the panel reported.

The report was also critical of Takata's practice of manufacturing inflators to a range of varying standards for customers but lacking testing specification of its own for parameters such as thermal shock. Takata needs its own testing specs "based on its own view of what is best from a quality perspective," it said.

The findings mirror the experiences of former employees-turned-whistleblowers who criticized Takata's review process when it decided to adopt the controversial ammonium nitrate inflators.

Among them is Mark Lillie, a former chemical engineer at Takata's Moses Lake, Wash., plant, who was asked to conduct an engineering review in 1999 when the company debated the switch.

"The design review was basically pro forma so that we could check the box off and say we did a design review," he said.

"They probably do and did have manufacturing errors that amplified the design problem," Lillie told Automotive News last year. "But even if you fix all the manufacturing problems, there is still an underlying design problem."

"Use by' dates

The panel largely praised Takata's manufacturing facilities as "state of the art." But it said some critical operations are still done manually, such as the loading of inflator propellant.

Takata should also invest in machine-assisted airbag folding, noting that some airbag folding requires 200 steps. It would be better to break that up among multiple workers or introduce machines for part of the folding rather than relying on one person to complete all 200 steps, the panel said.

"Best-in-class manufacturing pro- cesses are generally moving toward full automation, especially in safety-critical areas," it said. "Takata should follow suit as quickly as it is able."

The panel concludes by arguing airbags would benefit from "use by" dates because the components tend to degrade over time.

It drew comparison to pharmaceuticals and said cost should not be a deterrent because inflators go for around $30.

"Any other chemically driven product we purchase for health and safety -- from pharmaceuticals to carbon monoxide detectors -- has a "use by' date," the report said, contrasting that with airbags. "Yet, even with the advancing age of the vehicle fleet, there is no plan in place for replacing these components."

News By Tags

2011 models2012 models3D printing458 italia6-series coupeA1A2abc motorsabu dhabiaccidentaccidentsaccordACIMacuraadidasADSUadvertisingafricaagalegaAIair pollutionairbagairbagsairbusairportAlan GanooAlbionalcotestalfaalfa romeoalgeriaalibabaAllemangeAllied MotorsAlmaalpineAmauryamazonamendesamphibiousandroidAnil BachooAnse-la-Raieappappleappointmentsappsapriliaarabiaargentinaarielarnold schwarzeneggerarsenalArtashok leylandasiaastonaston martinAston Martin ZagatoauctionaudiAudi E-TronAudi Q3Audi Q8audit reportaustraliaAustralian Grand Prixaustriaautoauto industryauto shanghaiauto showauto-écoleautonomous carautonomus carAutopilotautopont de Decaenautopont Decaenautoroute M1aventadorawardsAxessBABagatellebahrain grand prixBAIBaie-du-TombeaubajajBalaclavaBambousBangkok International Motor ShowBangkok Motor ShowBangladeshBarklybatmobilebatterybattlebeachbeachesBeau-BassinBeau-ChampBeau-VallonBeaux SongesBeaux-SongesbeetleBeijing Auto ShowBeijing Motor ShowBel-AirBel-EtangBel-Ombrebelgian grand prixBelgiumBell VillageBell-VillageBelle-MareBenellibentleyBentley Bentaygabernie ecclestonebetamaxbetamax casebicyclebicyclesbikebikesbiodieselBlackBerryBlue-BaybmwBMW 3 SeriesBMW 4 SeriesBMW 8 seriesBMW i8BMW ix3BMW M2BMW M3BMW M4bmw m5BMW X2bmw x3BMW X5BMW x6BMW x7BMW z4boatboatsboeingBogota Auto ShowBois-MarchandBois-Marchand accidentBois-PignoletBologna Motor ShowBon-Accueilbondboschboston dynamicsBPObrabusbrakesBramsthanbrazilbrexitbribebribesbridgebridgestonebrioBrisée-VerdièreBritish Grand PrixbudgetbugattiBugatti ChironBugatti La Voiture Noirebugatti veyronbuggybuickburnoutbusbusesbuyingbydcadillaccalebassescamaroCamp ChapelonCamp-ChapelonCamp-de-MasqueCamp-DiableCamp-LevieuxCanadacanadian grand prixCandosCanotCap-Malheureuxcaporal Chooluncarcar buying tipscar dealercar dealerscar firecar importcar industrycar loancar marketCar Of The Yearcar rentcar rentalcar salecar salescar servicecar sharingcar showcar theftcar washcarbon fibercarburantsCarlos GhosnCarPlaycarscartingcascavelleCaudanCCIDCCTVCEBcelebretiescelebritiescentre de fitnessCentres De Fitnesscertificat de fitnesscertificats de fitnessCESChamarelChamp de MarsChamp-de-MarsChebelChemin-GrenierChengdu Motor ShowcherychevroletChevrolet CamaroChevrolet CorvetteChicago Auto ShowchinaCHINESE GRAND PRIXChris EvanschryslerCité Vallijeecitroencivicclassicclassic carclassic carsclassicsClémenciacode de la routecollectioncommercialcomparisonconceptconceptsConfinementConstanceconsumer reportsContract buscontraventionsconvertiblecoromandelCoronaviruscorruptioncorvetteCottagecour suprêmeCourtCourtscouvre-feuCOVID-19CPBcr-vcrashcrash testcrash testsCristiano Ronaldocrossovercrowdfundingcruise shipCubaCupraCurepipecurfewcustom bikecustom carcustomsCUVCWACybertruckcyclonedaciadaihatsudaimlerdakardakar rallydartzdash camdashcamdatsunde tomasodealersdéconfinementdecongestion routiereDelhi Auto ExpodeloreandesignDetroitDetroit Auto Showdéviationdéviationsdéviations routièresdieseldiesel scandalDIYDLCdodgedodge demonDonald TrumpDPPdragdrag battledrag racedrag racingdriftdriftingdriver licensedriverless cardrivers licensedrivingdriving licensedriving schooldriving schoolsdriving testdriving tipsdronedronesdrug racedrugsdrunk drivingdsDubaiDubai Motor ShowducatiDysonD’EpinayearthquakeEbayebeneecoecologyeconomyEducationEICMAelecticelectionselectricelon muskemissionsEmmanuel Macronengen motor showengineenginesEOCethanoletios livaEUEuropeeveventsexamens de conduiteexcès de vitesseexpofacebookfailfakefake policeFast And Furiousfaux coupons de parkingfaux permisfaux permis de conduireFCAfeeder busfeeder busesfermetureFernando Alonsoferrariferrari 812ferrari romaferryFIAfiatfiestafilmsfinancesfinefinesfinlandFireFirefightersfishingfiskerfitness centerFlacqFlic-en-FlacfloodFloodsFlorealflying carflying taxiFond-du-SacFootballForbachForbach accidentforce indiafordFord BroncoFord F-150ford fiestaford focusFord mustangFord Rangerforest-sideformula Eformula1forza motorsportFrancefrankfurtfrankfurt motor showfraudFSCfuelfuel economy scandalfuel pricefuel stationfuel stationsfunnyfutureGaikindo Indonesia International Auto ShowGaikindo Indonesia International Motor Showgamesgare de Rose-HillGare du Nordgare VictoriageargeelygenesisGeneva Auto Showgeneva motor showgerman grand prixGermanygirlsgmgodzillagolfgolf carGoodlandsgoodwoodGoodwood Festival of Speedgooglegoogle glassgoogle mapsGoProgovernmentgpsgran turismogrand tourgrand-baieGrand-BassinGrand-BoisGrand-GaubeGrande-RivièreGrande-Rivière-Nord-Ouestgreat wallgreecegreengreen energygrnoGros-BoisGros-CaillouxGRSE accidentGTAGymkhanahackershakershamannharley davidsonharley-davidsonHatchbackhealthcarehellcatHennesseyHenriettaHermitageherohertzhighlandshistoryhit and runhitachiholdenHollandHollywoodhondaHonda AccordHonda BrioHonda Cityhonda civicHonda Civic type rhonda cr-vHonda Ehonda fitHonda HR-Vhonda jazzHonda s2000Honda VezelHong Konghorsepower falsifyingHospitalhospitalshot rodhot wheelshotelhotelshoverbikehoverboardhow toHuayrahummerHummer H1Hummer H2humorhungarian grand prixhurricaneHusqvarnahybridhydrogenhypercarhyundaiHyundai CretaHyundai ElantraHyundai i20hyundai ioniqHyundai KonaHyundai Santa Cruzhyundai Santa Fehyundai sonataHyundai TucsonHyundai VelosterHyundai Venuei3i40ICACiframacIIHSillegal racesillegal racingillegal rallyillegal taxiillegal transportIMCimportindiaIndia Auto ExpoIndian Motorcycleindian motorcyclesIndian OilindicaIndonesiaIndonesia International Motor Showindonesia motor showinfinitiInfinityinfotainmentinfrastructureinsuranceintelinteriorinteriorsiPadiphoneiranirelandIRPisraelisuzuIsuzu D-maxIsuzu MU-Xitaliaitalian grand prixItalyjaguarJaguar Land Roverjamesjames bondJames MayJan Palach stationjapanjapaneese carsjapanese carjapanese carsJapanese Grand PrixJawajazzJDMjeepJeep CherokeeJeep GladiatorJeep Grand CherokeeJeep Renegadejeep wranglerJeremy ClarksonjettaJin FeijobjobsJohn DeerekartkawasakiKawasaki Ninjakei carken blockKenyakhankiaKia CeedKia ForteKia NiroKia OptimaKia SorentoKia SportageKia Stingerkia TellurideKoenigseggkoreaKoshik ReesaulKTMKTM DukeLALA Auto ShowLa Brasseriela butteLa ChaumièreLa FloraLa GauletteLa MarieLa PrairieLa Tour KoenigLa VigieladaLallmatielamborghiniLamborghini Aventadorlamborghini gallardolamborghini huracanLamborghini SiánLamborghini UruslanciaLancia Stratoslandland cruiserland roverLand Rover DefenderLand Rover DiscoveryLarsen & ToubroLaventurelawlawslazarethLe HochetLe MornelealLebanonLeevy Frivetlegolewis hamiltonlexuslicenselicense platelight metrolimousinelincolnLionel MessiLockdownlondonLos Angeles Auto Showlotuslow cost carLRTluxuryluxury carluxury carsL’AventureL’EscalierM1m2m3macondemad maxMadagascarmaha shivaratreeMahebourgmahindramaintenancemalaysiamanmansorymanual transmissionmanufacturingMapoumapsMare d’AlbertMare-d’Albertmarketmarketingmartinmarutimaruti suzukiMaruti SwiftMaruti Wagon RmaseratiMatt LeBlancMauricioMauritiansmauritiusmaybachmazdamazda 3Mazda 6Mazda MiataMazda Mx-30Mazda Mx-5Mazda RX-7mazda3McLarenMcLaren 720smecedesMELmercedesMercedes AMGMercedes E63Mercedes G-ClassMercedes G63Mercedes GLEMercedes X-classMercedes-MaybachMESmetroMetro Expressmexican grand prixmexicoMGmichael schumachermichelinMicrosoftMidlandsminimini cooperminivanMITDmitsubishiMitsubishi DelicaMitsubishi EclipseMitsubishi L200mitsubishi lancerMitsubishi MirageMitsubishi OutlanderMitsubishi PajeroMitsubishi TritonMitsubishi XpandermitsubushimitsuokaMMMMokamonacomonaco grand prixMont-ChoisyMont-RochesMontagne-BlancheMontagne-LonguemontebelloMontebello accidentMontée Smontereymoose testmoparmorganMorneMoroccomotomoto-écoleMotoClub Racing TeammotorMotor Racing Clubmotor showMotor Vehicle LicenceMotor vehicle test centremotorcyclemotorcyclesmotorsportmotorsportsmotosportmoviemoviesMPAmpvMRAMRCmugenmuscle carMusicmustangmv agustamv augustaMVDANADA Auto ShowNandanee SoornackNando BodhananonascarNational Coast Guardnavigationnavigation systemnavigation systemsNavin RamgoolamNCGNDUNepalnetherlandsnew carnew york auto shownew zealandnfsNHTSANigerianikolanissanissanNissan 370ZNissan 400Znissan altimaNissan AriyaNissan FrontierNissan GT-RNissan GT-R50Nissan JukeNissan KicksNissan LeafNissan Leaf NismoNissan MicraNissan navaraNissan NoteNissan PatrolNissan RogueNissan SentraNissan SkylineNissan TerraNissan TitanNissan X-trailNissan ZnorwayNouvelle-FranceNTANTCNTLANürburgringoff-roadoffroadOlympic GamesOnline Renewal of Motor Vehicle LicenceopelOpel Corsapaganipagani huayraPagani ZondaPaillesPakistanPalmarPamplemoussespanasonicpapamobileParisparis motor showparkingparliamentPebble Beachpenaltiespenalty pointsPereyberepermis de conduireperoduapetit raffrayPetit-RaffrayPetite-RivièrepetrolPetrol Retailers AssociationpeugeotPeugeot 2008Peugeot 208peugeot 508PhilippinesPhoenixPhœnixpickuppickupspininfarinapirelliPitonPlace de l’ImmigrationPlace D’ArmesPlaine MagnienPlaine-des-PapayesPlaine-des-RochesPlaine-LauzunPlaine-MagnienPlaine-VerteplayboyPNQPointe-aux-PimentsPointe-aux-SablespolandpolarispolestarpolicepoliticspollutionpompiersPomponettepontPont ColvillePont-BlancPont-FerpontiacpopemobilePor Louisporscheporsche 911Porsche CayennePorsche MacanPorsche TaycanporsheportPort LouisPort-LouisPoste-de-FlacqPoste-LafayettePoudre-d’Or-HamletPPCPPPprankPravind JugnauthpricepricespriusproguardprotestsprotonPSApublic transportpublict transportQ3qorosQuartier-MilitaireQuatre Bornesquatre-bornesr8Raceracingrainrallyrallyerallye illégalrallye motoramrangerange roverratingsRDArecallrecallsrecordrecordsred bullred bull car park driftreduitrenaultRenault ClioRenault Kwidrenault meganeRenault TwingorenderingRenewal of Motor Vehicle Licencerent a carrepairreplicaretroReunionRezvaniRHTRiambelRichard DuvalRichard HammondRiche TerreRiche-TerreRichelieurickshawrimacRimac C_TwoRing RoadrioRipaillesRiviere-des-AnguillesRivière-du-PosteRiviere-du-RempartRiviere-Noireroadroad accidentroad accidentsroad closedroad closureroad rules & regualtionsroad rules & regulationsroad safetyRoad TaxRoad Traffic (Amendment) BillRoad Traffic ActRoad Traffic Amendment ActRoad Traffic Amendment BillRoad Traffic Billroadsroads safetyrobberyrobotrobotsroche-boisRoche-TerreRodrigo DuterteRodriguesrolls-roycerolls-royce cullinanromeorond-point de Beau-BassinRose BelleRose Hillrose-belleRose-HillroverRoyal EinfieldRoyal EnfieldRoyal Enfield Continental GTRRSRSURuben RacingRue Jemmapesrue VandermeerschrumoursRussiaRussian Grand PrixrvsaabSafe Citysafetysafety ratingsafety ratingssafety testsafety testsSaint-PierreSainte-Croixsalesamsungsamusao paulo auto showSao Paulo Motor Showsaudisaudi arabiascamscandalscaniaschool busschool vanscooterscootersseatsebastian vettelSebastopolsecond hand carsecond hand carssecond hand cars importsécurité routièreself driving carself-drivingself-driving carself-driving carsSEMASEMA showSeoul Motor Showservice stationservice stationsShanghaishanghai motor showShehzad SooraballyshelbyShellshowsingaporeSingapore Grand PrixskodaSlovakiasmartSMFsnakeSobrinho caseSodnacsoftwareSohail Sesungkursolar energySolitudesonysorezesoreze accidentSouillacsoulsound systemssouthsouth africasouth koreaspaceXspainSpanish Grand Prixspare partsspeed cameraspeed camerasspeed limitspeedboatspeedingsportSportscarspy shotsssang yongSsangYongssuSt-JeanSt-JulienSt-LouisSt-Paulst-pierrestar warsstartupstation-servicestations-servicestatisticsSTCste croixSte-Croixstreet racingstrikestudysubaruSubaru BRZSubaru ImprezaSudhir SesungkursudySunshine AutosupecarssupercarssuperyachtsuprcarssurveySUVsuzukiSuzuki BurgmanSuzuki ErtigaSuzuki HayabusaSuzuki IgnisSuzuki IntruderSuzuki JimnySuzuki S-CrossSuzuki Swiftsuzuki vitaraSuzuki Wagon RSuzuki XbeeSwedenswiftSwitzerlandTATaiwantakatatamarintankTanzaniaTarisa Resorttatatata motorstaxtax fraudtaxestaxiTBStechnlogytechnolgytechnologytenderTerre-RougeTerre-Rouge–Verdunteslatesla model 3tesla model stest drivetestsThai Motor ExpoThai Motor ShowthailandThailand International Motor ExpoThe Grand TourThe ValetheftThierry Henryticket pricetipstiresTMRSUtokyoTokyo Auto Salontokyo motor showtoptop geartotaltourismtourism authoritytoyotaToyota 86Toyota AlphardToyota AvalonToyota Aygotoyota C-HRtoyota camryToyota CenturyToyota CH-Rtoyota corollaToyota FortunerToyota HiaceToyota HighlanderToyota HiluxToyota Land CruiserToyota PriusToyota RAV4Toyota RushToyota Siennatoyota supraToyota TacomaToyota TJ CruiserToyota TundraToyota Venzatoyota yaristoystoytatractortrafficTraffic BranchtrailerTranquebartransformerstransporttransport policetrendsTrianontricksTriolettriumphTrois-BoutiquesTrou d’Eau DouceTrou-aux-BichesTrou-d'Eau-DouceTrou-d’Eau-DouceTrou-Fanfarontrucktruckstsunamitug of wartuningtuniningTurkeytvsTyacktyresUAEuberUBIWUBSukukraineunionsUnited StatesuomuralUrban TerminalUSUSAused carused car importused carsVacoasVacoas-PhoenixvalettaVallée-des-PrêtresVallee-PitotValtonvanvarma caseVeer Luchoomunvehicle inspectionVehiclesvelostervenezuelaVerdunVictoria Bus StationVictoria stationVictoria Urban TerminalvideoVienna Auto ShowvietnamVintagevintage carvintage carsVipervivo energyvolvolkswagenVolkswagen Golfvolvovwvw beetleVW Buggyvw golfVW ID.3VW JettaVW passatvw polovw t-crosswaymoWeatherwheelsWolmarWootonWork Access PermitWorldyachtyachtsyamahayariszagato
Sell Your Car