Car electronization trend in automotive industry

73
Automotive Electronics Trend in Automotive Industry by: Kenji Suzuki ESPEC CORP. Dec. 17, 2014

Transcript of Car electronization trend in automotive industry

Page 1: Car electronization   trend in automotive industry

Automotive ElectronicsTrend in Automotive Industryby: Kenji Suzuki ESPEC CORP.

Dec. 17, 2014

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Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

Page 3: Car electronization   trend in automotive industry

Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

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1890~1970 Local->RegionalCars made locally, using locally supplied partsCars distributed locallyServing the local economy and communityProduct taste matching the locals

2000~ Glocal (multi-domestic)

Export of the whole supply chain and technology“Global platform” with taste matching exterior and design > volume discount with no compromise in tasteHedging currency exchange risk and import duty

Industry Structure Trend

1970~2000 GlobalExport of complete vehicles“Global standard” productsPrice advantage based on volume discountCurrency exchange riskProduct taste not matching the locals

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Industry Structure

Tier 1( System

Mfr. )

Tier 2( Parts Mfr. )

Tier 3( Material Mfr. )

Car Mfr.(OEM)

Suzuki Kenji
In last 10 or 15 years, the relationship between Tier 1 mfr and OEM changed dramatically. The biggest change of all, both GM and Ford spun off their electronics parts division, Delphi and Visteon, respectively. They used to mfr as much as 70% of all parts and caused rise in cost.The idea of using parts mfr in Europe and US began as an outsourcing of modules. It was due to difference in labor cost between OEM and Tier 1 mfrs. In Japan, however, the difference was so small, there were no benefit of outsourcing.
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Supply Chain Structure

Source: Ministry of Economy, Trade and Industry

Once believed to have an ideal structure, was denied completely by the earthquake that hit Japan in 2011.

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Industry Structure (Keiretsu)

Takanichi

04 年合併

23.51%

5.45%

22.25%

Toyoda Koki Automotive

23.62%

22.56%

Merged ‘06

24.77%

9.1%

7.85%

39.36%

Toyota Boshoku Corp.

Arakawa Auto Body

Note: Numbers show the percentage of stake owned by Toyota

Toyota Ind. Corp.

22.57%

42.8%

31.16%

Suzuki Kenji
Toyota has been increasing the amount of share of their group companies. This is called Keiretsu and some American and European economists criticizes this as a disclosed system. However, group companies, on the other hand, they want to have relationship with other OEMs hedge their risk.Due to this structure, Toyota has been able to maintain their lead in technology along with strong partners such as Aisin and Denso. Also, due to this structure, the new comer in the parts industry is mostly Tier 2.
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Industry Structure Type

1. Closed: Owning parts mfr. as a division or a group within a company.

2. Semi-Closed: Parts supply to be outsourced to limited number of companies (Owning a fair amount of their stake).      KEIRETSU

3. Open: Having parts supply to be outsourced as an open bid as required.

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OEM and SuppliersOEM

( Car Mfr. )

Tier 1( System

Mfr. )

Tier 2( Parts Mfr. )

Traditional Relationship

Tier 1 Supplier( System

Mfr. )

OEM( Car Mfr. )

Tier 2 Supplier(Parts Mfr.)

Current Relationship

In the past, OEMs dealt directly with Tier 1s and only with their Tier 1s. There was no direct communication between OEMs and Tier 2s. However, today, the relationship is more triangular rather than vertical, OEMs communicate with both the Tier 1s and Tier 2s at the same time.

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OEM and Suppliers

Cooperation of Parts Mfr. And OEMA must-have relationship to adapt the latest and best electronic technologies available.

Adaptation possibilities and cultivation of “Newborn Tech” to car applications. Key: Adaptation to Car Applications

< Examples >

1. Automotive Microcomputer

2. ACC* Radar ( milliwave, laser, camera)

< Progress >

3. OEM + Parts Mfr. 「 Fundamental Development 」

4. + System Mfr. 「 Product Development 」

Tier 1 Supplier( System Mfr. )

Tier 2 Supplier( Parts Mfr. )

OEM(Car Mfr. )

Tier 1 Supplier( System Mfr. )

Tier 2 Supplier( Parts Mfr. )

OEM(Car Mfr. )

Courtesy :  Nissan Motors Corp.*ACC: Automatic Cruise Control

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Development Lead Time

Source: Initia Consulting

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Vehicle Development – The Difference

Source: Roland Berger

RegionDevelopment Time Cost Quality

Rating Reason Rating Reason Rating Reason

EU/NA Short

•By modularization - Specifying modules in pre-development stage - Less newly developed parts

Low

•Scale merit by utilizing modules to multiple vehicles•Clear development time frame•RFQ to multiple suppliers

High•Improvement per module or architecture•Efficiency in production

JPN Short

•Good understanding by parts suppliers - Instant understanding of OEM's request - Acucmulation of daily meetings

Low

•Cost reduction by working together•Becoming difficult to meet price requirements in global competition environment.

VeryHigh

•Broad approach to safety, quality, and reliability•Approach done at every stage of suppliers•Possibilities of over quality

CHN Short

•Using conventional parts and modules•Least amount of evaluation and testing•Less demanding market

VeryLow

•Volume purchase of conventional parts•Stringent request of cost reduction•Self-production as an option

Low

•Many copies and counterfeit by reverse engineering•Unbalanced vehicle dynamics•Low interest in NVH

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Vehicle Architecture

This is not a matter of right or wrong, but manufacturers are always looking for better ways to make profit. The European manufacturers failed to pursuit the Japanese way of building cars. They found their style in modularization, pioneered by Volkswagen.

80’s and 90’s Current Majority Volkswagen and a fewSource: Roland Berger

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Modular Design (VW)

The idea of “module” has been implemented in all levels from components to vehicle.The base is to utilize what’s already available.

One of the prominent characteristics of the Modular Transverse Matrix is the uniform mounting position of ALL engines.

Volkswagen Modular Transverse Matrix (MQB)

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Group Responsibility in Dev. (VW)

1. Vehicle Architecture-Related・ Make design rules and vehicle architectures on ALL VW and Audi vehicles

2. Module-Related・ Continuous development per modules・ Module Manager will decide what will be used for each vehicle・ Non-module parts are developed by orders from Project Team.

3. Vehicle-Related・ Organized team per vehicle・ Responsible for the total packaging of a vehicle excluding modules・ Utilize modules already available and consider development of what is not available

Unlike many of their Japanese rivals, the vehicle project manager is NOT in charge of that

vehicle.

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Modularization

Mazda Common Architecture

Toyota New Global Architecture PSA Peugeot Citroen EMP2 Efficient Modular Platform

Renault/Nissan Common Module Family

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Megaplatforms

  OEM Platform

Volume

(in mn)No. of Models Sample Models

1 VW MQB 6.3 41 VW Golf; Passat, Audi A3

2 Toyota MC 5.2 25 Auris, Corolla, Vibe: Scion xB

3 Hyundai/Kia HD 3.0 16 Hyundai i30; KiaCee'd

4 GM Delta 2.5 19 Opel Astra; Chevrolet Cruze

5 PSA EMP2 2.3 24 Peugeot 308; Citroen C4, DS4

6 Renault/Nissan B 2.2 10 Renault Clio; Nissan Cube, Juke,

Leaf7 Ford C1 2.2 18 Focus, C-Max, Kuga8 Hyundai/Kia PB 1.9 18 Hyundai i20; Kia Rio; Venga

9 Renault/Nissan CMF1 1.9 20 Renault Megane, Nissan Qashqai

10 Ford B2E 1.8 11 Fiesta, B-Max; Mazda2/DemioSubtotal 29.4 202  

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Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

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a. Pursuit of Better Efficiency and Safety

GREEN : Low (Zero) emissionMultiple powertrain (Hybrid)CVT, DCT and other high efficiency transmission

Safety : Advanced Emergency Brake System (AEBS)Adaptive Cruise Control System (ACCS)Lane Departure Warning System (LDWS)Pedestrian AirbagAlcohol Ignition InterlockTraffic Avoidance System

Comfort: Cabin Air quality managementLinear Motor Suspension

Wellness : Health monitor of occupants

Courtesy :  Nikkei BP ( Hitachi )、 Dräger Safety AG & Co. KGaA 、 TEAC Corp.

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CountryRate per100,000

population

AbsoluteDeaths

China 16.5 96,611Indonesia 16.2 16,548Vietnam 16.1 12,800Thailand 19.6 12,492Japan 5 6,639

Malaysia 23.6 6,282Bangladesh 12.6 4,108Afghanistan 39 1,779Cambodia 12.1 1,668Myanmar 23.4 1,638

Philippines 20 1,185Singapore 4.8 214

Bhutan 14.4 111

b.   Priority…Greener and Safer

Protection of pedestrians and occupants, and earth’s environment is a MUST, regardless of geographical area. These are GLOBAL ISSUES!!

Courtesy: AltEnergyStocks.com

Global Emission Standard TimelineSE Asia Traffic Death Statistics

In the past, it was common to see so-called “Trickle down effect” in car features. The latest and best technologies were only available to those sold in developed countries. But Not anymore! They have to provide as much hi-tech and new technologies to ALL of their customers.

Courtesy: WHO survey 2009

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Cars on DietSource: Automobili Lamborghini S.p.A.

Source: BMW AG

Source: Nissan Motor Company

Source: General Motors Company

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Higher Voltage

1920s 1955 2015? 20XX

7V(6V Battery)

14V(12V Battery)

42V(36V Battery)

Multiple-Voltage

Load: Accessories- Lamp- Ignition

Load: Body electronics- Lamp- Engine management

system- Audio- Navigation System

Load: PWR electronics- HEV, ISG- X-by-wire- High fuel-efficiency- Low emission

HEV, FCEV 150 – 300V- Power: 42V- ECU: 7V

Merit:• Higher voltage = lower amps (1/3 less) = thinner cables, smaller

connectors, and smaller motors = Weigh less = better fuel efficiency• Be able to use high-wattage system (E-air compressor, motor

generator, integrated starter generator, E-heated windshield, and etc.)• Less use of converters = less power loss = better overall efficiency

Source: Tatsuo Teratani Edited by author

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Internet of Things (IoT)Internet connection is something we cannot live without. That is also true for cars…at least that’s what people in governments, IT and auto industries think.

But how it should be disclosed by the government and/or the companies who are involved, and the security of data and privacy protection are something that must to be solved.

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Regulations or …

Source: Automotive Technology Magazine translated by author

Assessment of technology and disclosure of test results by institutions may encourage manufacturers to implement and improve the technology earlier than their original plan.

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System in SyncTrend of Vehicle System

Individual Control System Vehicle Integrated System

Vehicle + Infrastructure Integration

Vehicle Integrated System( Application

SystemSoftware

Integrated APHardware

・・・

Engine Brake Steering

Steering

AP

Brake

AP

Engine

AP

Next GenerationPresentPast

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Evolution in Brakes

Shrink in size, IntegrationEx: Used to be a separate unit, but now they are integrated as one.

ABS CPU

ABS Hydraulic Pump

ABS Unit

Camera or RadarUnit

Seatbelt

SynchronizationEx: A group of parts work in-sync to execute a function, as a system.

70’s ~ 80’s

80’s ~ 90’s

2000’s ~

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Increase of Electronics (1)

• In semiconductor industry, sales to automotive industry was US$11 billion in 2000. However, that number reached US$25.5 billion in 2012, and by 2017, it is expected to reach US$40 billion. (Annual growth of 11%)

• Cost of Electronics in a Vehicle2005 Avg. 20%2015 >Avg. 40% (expected)

Courtesy : PricewaterhouseCoopers

Courtesy :  Nikkei BP

2012 2013 2014 2015 2016 201705

1015202530354045

25.5 27.931.1

34.537.4

40

Worldwide Automotive Semiconductor Growth

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1990’s Today 2020’s

Application for MCU will continue to grow

Increase in number of 32 bit MCUs used in ECUs may be small. However, due to new applications such as vision and sensor systems, number of 8 and/or 16 bit MCUs will increase.

By integrating multiple ECUs, the number should decrease….

However, introduction of new systems will require more complex system LSI and graphic LSI, which may lead to increase in number of ECUs.

Number of ECUs stabilizes, while number of MCUs continue to grow.Integration of multiple ECUs has begun. However, there are new systems that requires MCUs to control, are waiting to be adapted. As a whole, number of ECUs may stabilizes while the number of MCUs expected to continue to grow.

Increase of Electronics (2)

Number of ECUsNumber of Microprocessors

Courtesy: Nikkei Automotive Technology

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ECU Groupings/Integration

Integrationby

Function

Approx. 60 to 100 ECUs Integrated into 4 function groups

►  Powertrain►   Multimedia

►  Body Control►   Safety

Integration of approx. 60 to 100 ECUs to 4F groups.Toyota Motors has announced that they will integrate ECUs to 4 function groups. 4 function groups are:

1. Powertrain  2. Body Control  3. Multimedia  4. Safety

Courtesy: Toyota Motor Company

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Miniaturization Mounting Technique( Semicon 、 MLPC 、 Materi

al )

< Today >

  ECU Placement = Dead Space< Future >

  No more dead space= Miniaturization

Hattori, ( Toyota Motors) MES2005

< Today >

  Following consumer electronics< Future >

  Leading miniaturization technique and technology

Leader not Follower

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Direct-Mount ECU Miniaturization andHigh Temp. Operation

ECU directly mounted on engine to cut the use of wire harness and production cost. Some vehicle even submerge ACU in transmission oil.

< New Technology >・ Aluminum Oxide Substrate・ High-Temp. Application IC・ Bare-chip mounting technique・ Power semiconductor devices

Change in Environment

Photo :  Mercedes Benz CLS 350 CGI

OBDII Electronic Transmission Control Unit

Porsche Cayenne Hybrid ECU

BMW M5 ECU

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Change in Expectations in a Car

For globalization of the business, the expansion of mfg. capability while maintaining the quality will be the key.

50%

10 %

183 %

Courtesy: Denso Courtesy: Nikkei BP

~ Key: Manufacturing Quality ~Car Production per Region

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Something You Want to Avoid

These are the last thing you want to see!!

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The Challenge – Volume Zone

The volume zone is shifting to low-end cars. No bells and whistles but with low, low price tag. These cars are to be sold mainly in BRICs, ASEAN, S. America, Africa and E. Europe, where mobility itself is becoming a part of their life.

N. America, W. Europe, Japan

(Saturated market)

BRICs, ASEAN,S. America, Africa,

E. Europe(Potential market)

TATA NANO

Rs. 2.5 lakh US$ 3,000

DACIA LOGAN

EU 7,600 US$ 9,800

HONDA CIVIC

JPY 1.9M US$ 18,000

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The Challenge – Stay in Business

Large marketLow-Priced

VehiclesLow Profitability

Small marketMid-High Priced

VehiclesHigh Profitability

Earn by VOLUME

Earn by PROFITABILITY

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Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

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Problem Caused by Electronization

All began in a small independent system.Began in power window and power steering but now to

AT, fuel injection, navigation systems and etc.

Independent system no longer valuable. Multiple systems working in

synch are expected.

Harness used to connect these systems increased dramatically.

Causing increase in:

Harness, # of parts (weight) and Cost

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Problem Caused by Electronization

All began in a small independent system.Began in power window and power steering but now to

AT, fuel injection, navigation systems and etc.

Independent system no longer valuable. Multiple systems working in

synch are expected.

Harness used to connect these systems increased dramatically.

Causing increase in:

Harness, # of parts (weight) and Cost

Increase in both

Environmental Stress and

Recalls!!

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Recent Major Recalls by Auto Mfrs. Date Mfr. Cause Affected Vehicles

May 15 GM Brake Lamp 2,700,000Apr. 9 Toyota Airbags 6,390,000Apr. 1 GM PW Steering 1,340,000Mar. 17 GM Airbags 1,750,000Feb. 12 Toyota Software 1,840,000Feb. 10 GM Airbags 2,191,000Jan . 30 Toy/Lex Airbag/Wipers 1,290,000Jan. 16 VW Transmission 1,600,000

Recall Problems

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Recall Problems

0

1,000,000

2,000,000

3,000,000

4,000,000

5,000,000

6,000,000

7,000,000

8,000,000

9,000,000

0

50

100

150

200

250

300

350

400

450

500

Number of Recall

Number of Vehicles Affected by Recall

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Courtesy :  Ministry of Land, Infrastructure and Transport Japan

Recall AnalysisRecalls made 2006 ~ 2010

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Recall Counter Measures

1. If there is to be a recall1. Retrace of trouble

1. Cause-Analysis, Importance (Criticality) Measure2. Influence-Analysis3. Assessment of Counter Measures

2. Recall Announcement1. Redesign & Test (Design of repair need to be done to meet

the original spec. and evaluation test)2. Procurement and/or Manufacturing of Parts Required3. Vehicle recovery, Service and Maintenance

2. Recall Prevention1. Modularization of Platform2. Standardization of Parts without increasing a risk3. Standardization of Design

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Recall Prevention and Cost Balance

Volume (Scale) MeritLimit number of suppliers and

getting as much volume discount as possible would result in lower market price

among competitors. Reliable parts can be used in ALL

vehicles.

Quality (Recall) RiskOne defect in a part can affect

ALL vehicles produced. Recalls not only cost them physically, but also in brand’s reputation. OEMS cannot be aware of all new technologies used in their

vehicles.

They need to find a way to balance it out!(Low cost AND low risk)

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Autmotive Electronics

BASICAfraid of RECALLs. Stringent qualitymanagement and reliability evaluationsexpected.

Need to meet demand the industry'sshort product life- cycle. Quickimplementation of the latest technologyis the key.

RequirementsReliability (>10yrs.)・Quality (No dispersion)・Anti- Heat (- 40℃ +150℃・ ~ )Spec. (Relatively Low- Spec.)・

Reliability (3yrs.)・Quality Dispersion accepted)・ (Temp. Range (- 30℃ +85℃・ ~ )Spec. (High- Spec.)・

Test Spec.Temp. Range: - 40℃ +150 180 ℃・ ~ ( )Test Time: 1,000 3,000hrs.・ ~Stress: Temp./ RH/ Cycle/ Vib./・

Cond./ Salt Spray

Temp. Range: - 35(55)℃ +85 125 ℃・ ~ ( )Test Time: 300 ,000hrs.・ ~1Stress: Temp./ RH/ Cycle・

Obstacles

・Establishment of legitimate reliability evaluation proceduresShortening of development lead time・Cost reduction of testing・Quality management of int'l・

procurement

Shortening of development lead time・Cost reduction of testing・

・Expanding business into automotive industry

~ Entry of Electronics Mfrs. ~

Automotive Requirements

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Why So Harsh?

Drive Turn

Stop

Safety

Comfort

Environment

Utility

Major Critical FaultOperational Risk

Fire Hazard

Hot and Dusty (Dry) Dry and Icy

Cold and Windy Hot and Humid

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Obstacles in Car Development

  Development Trend :- Shortening of development lead time- Lowering prime cost while sustaining quality

  Obstacles :- Application environment getting severe- Reliability testing not being able to keep the

pace with development lead time- Cost increase due to increase in both the

number of testing and test samples

What’s ahead :- Improvement of simulation technique

(Implementation of CAE) - Shortening of test time (Adaptation of accelerated test)

- Establishment of legitimate reliability testing procedures

Suzuki Kenji
Automotive Requirements:1. 0 defects. Variations in quality not acceptable.2. Evaluation in various conditions are a must.3. Evaluation is not enough. Expected life plus a margin must also be though-in to the product desing.4. Cost/Reliability and high density/high functionality are not met.
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1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 20139

10

11

12

13

14

15

16

17

18

9.439.27 9.28 9.44

9.639.96

10.410.55

10.77

10.9710.93

11.1

11.6611.67

11.68

12.7 12.4312.16

12.58

9.6 9.6 9.619.48 9.84

10.5310.68

10.9211.23

11.84 11.7211.47

11.92 11.72

13.5

12.72 13.0412.81

13.24

12.3612.53 12.58 12.52 12.64

13.03

13.7213.98

14.41 14.48

15.3415.02

14.83

15.62

15

16.59

17.37

16.82

17.91

Light VehicleCommercial VehiclesBus

Life of Vehicles per Vehicle Type

More than 30% longer!!

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GM Recall

Ignition switch that was approved by GM in 2002 found defective to shut off the engine during driving and thereby prevent the airbags from inflating. The fault had been known to GM for at least a decade prior to the recall being declared.

GM recalled more than 29 million vehicles around the world.

To date, there are:

251 death claims

2,075 injury claims

List of affected vehicles

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Takata Recall

Defects were found in inflator that were made between 2000 and 2002 (installed in the vehicles sold between 2002 and 2008). This defect could lead to over-aggressive combustion to cause the inflator housing to rupture, to injure or to kill occupants.

There are:

4 death claims

30 injury claimsMore than 14 million vehicles were recalled to date.

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An Ideal and Reality

In QA, main goal is to decrease initial and random failures. However, if the products are used in extreme conditions, decrease in wear-out failure will be the key.

Implementation of the idea of “Fail-safe”

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Zero Defect and Fault Tolerance

ZERO DEFECTFAIL SAFE

FAULT TOLERANT

Tier 1( System

Mfr. )

Tier 2( Parts

Mfr. )

Tier 3( Material

Mfr. )

Car Mfr.(OEM)

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Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

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• International, Industrial Standards– ISO, IEC, JEDEC, AEC and etc.– Open to public and available for purchase.

• Corporate Standards – supplier certification– Non-Keiretsu

• New suppliers are welcome.• Standards are available for purchase. (mostly

online)– Keiretsu (mostly Japanese OEMs)

• Basically disclosed.• Test background and how-to are only supplied

certified vendors.

Types of Standards

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Electronics-Related ( 1 )•   International Standards

• ISO16750-2003Road vehicles -- Environmental conditions and testing for electrical and

electronic equipment

• ISO10487-1995Passenger Car Radio Connections

•   Domestic (National) Standard• JIS   Japanese Industrial Standard

• D1601 Vibration Testing Methods for Automobile Parts • C0024 ~ 28 Environmental Testing ( Electric/Electronics )• D0205 Test Method of Weatherability for Automotive Parts

• DIN   Deutsches Institut für Normung (Germany)• DIN 10599 Car radios - Coaxial aerial connectors

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Electronics-Related ( 2 )

• Industrial Organizations and Standards• ( US ) AEC AEC Q100 Rev F2• ( US ) JEDEC JESD22-A100-B

 ~ JESD22-A121AEC was established in 1993, established by Chrysler, Ford, and GM for the purpose of establishing common part-qualification and quality-system standards.

The JEDEC Solid State Technology Association is the semiconductor engineering standardization body of the Electronic Industries Alliance (EIA), a trade association that represents all areas of the electronics industry. JEDEC was originally created in 1960 as a joint activity between EIA an NEMA, to cover the standardization of discrete semiconductor devices and later expanded in 1970 to include integrated circuits.

• ( US ) SAE J2446, J1211, J771 and etc.SAE or Society of Automotive Engineers is one of the oldest trade organization, which was established in 1905.

• ( JPN ) JASO D001-94JASO is standards published by JSAE or Society of Automotive Engineers of Japan.

• Corporate Standards• GM-CM, BMW GS, VW, Delphi, Navistar and etc.

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AEC Standards

• Primary members of the AEC are Tier 1 and Tier 2 manufacturers. The standards are valid mainly among American and European manufacturers.• AEC-Q100-REV F2• Target : Integrated Circuits (IC)

• AEC-Q200-REV C• Target : Passive Components

• Testing Procedures :• MIL-STD-202 Method 103, 106, 107, 108, 204, 210, 213 etc.• JESD22 Method JA-104 、 JESD47 Method JA-105 etc.

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Where Can We Find Them?

• ISO http://www.iso.org/iso/home/store/catalogue_ics.htm

• IEC http://webstore.iec.ch/?ref=menu

• MIL http://www.landandmaritime.dla.mil/

• JIS http://www.jisc.go.jp/app/JPS/JPSO0020.html (Japanese only)

• DIN http://www.beuth.de/cmd?level=tpl-home&languageid=en

• JEDEC http://www.jedec.org/standards-documents

• SAE http://standards.sae.org/automotive/

• AEC http://www.aecouncil.com/AECDocuments.html

• Corporate Standards– IHS http://www.ihs.com/products/design/industry-standards/organizations/– FREESTD http://www.freestd.us/

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Contents

III. Obstacles & Solutions

IV. Related Standards

V. Appendix

I. Structure of the Industry

II. Electronics: Today & Tomorrow

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Failure Rate Trend per Mfr.

メーカー別経年故障率

0

20

40

60

80

100

120

140

160

180

200

1 2 3 4 5 6 7 8 9 10使用年数

故障

ChryslerFordGMHondaHyundaiNissanToyotaVolkswagen

Toyota

Honda

Nissan

Ford

Chrysler

GM

Volkswagen

Hyundai

Source:   Design News (Data provided by Consumer Report)

(10

0台

あた

り)

Years in Use

Failu

re R

ate

per 1

00 V

ehic

le

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Industry average improved 5% from 2012 study and is the lowest problem count since the inception of the study in 1989.The study finds that the fewer problems owners experience with their vehicle, the greater their loyalty to the brand.On the regard, VW is yet to see the effect of modularization, at least in the North American market.

Failure Rate Trend per Mfr.

Page 61: Car electronization   trend in automotive industry

“Quality” in Auto Industry

Application Environment

Warranted Spec.

Design

Experiment& Test

Apply for Approval

Sale

Service, Maintenance

Approved

Law, Standards

Customer’s Demand, Actual Usage

Experiment & Testing Procedures

Be sure of the estimation: All cars sold should have

no problems.

Requires approx. 2 years

Any problem = Redesign

Ex.: Engine Spec., Temp. Region, Exhaust Gas Level

Recall as necessary

Courtesy: Ministry of Land, Infrastructure and Transport Japan

エスペック株式会社
この流れに沿って開発すると、実際は4年必要になる。しかし、ある調査によると新型車発表を4年から3年サイクルにすることで、市場シェアを年率2%伸ばせるという統計もあり、各社サイクルを短縮する傾向にある。
Page 62: Car electronization   trend in automotive industry

R. Wayne, IEEE Transaction on Electronics packaging manufacturing, Vo.27, No.3, 2004

General Motors & Delphi Delco

Toyota Motors

Corporate Standard (Test Conditions)

Page 63: Car electronization   trend in automotive industry

Actual Environment

Source: Electronics Cooling

Each manufacturers gather their own data from their own cars. With ambient temperature considered, the temperature that electronic parts may get exposed to, can range from -40 to as high as +600 degrees. (Exhaust gas for sports cars may reach as high as +1,000 degrees!)

Page 64: Car electronization   trend in automotive industry

Sample : Transmission Control Unit

Temperature Profile during an Actual Drive

R. Wayne Johnson ,The Changing Automotive Environmental, IEEE CPMT Society, Vol.3 No.3, 2004

Rapid Rise

Actual Evaluation (DCX & Siemens VDO)

Page 65: Car electronization   trend in automotive industry

Test Result

< Test Time >  Temp. Cycle (-40/+125 )℃  >5000 Cycles< Verdict >  Material testing requires too much time.

Warranty Period( Avg. Speed = 72.4Km/h )

16K km( Today

2000h

3000h

Test

Tim

e Prolonged

Obstacles

24K km( Tomorrow

< Engineers’ Complain > ・ Increasing test samples ・ Far-Stretched test hours ・ Different test procedures among OEMs.

R. Wayne Johnson ,The Changing Automotive Environmental, IEEE CPMT Society, Vol.3 No.3, 2004

Actual Evaluation (DCX & Siemens VDO)

Page 66: Car electronization   trend in automotive industry

Development of Automatic Wiper (1)

They were asked to make an Automatic Windshield Wiper

System for a luxury car segment.

Courtesy: James Fike

Source: BMW

Page 67: Car electronization   trend in automotive industry

Development of Automatic Wiper (2)

Spend more than 2 years in research and development of

fundamental technologies

Source: Robert Bosch GmbH

Page 68: Car electronization   trend in automotive industry

Development of Automatic Wiper (2)

They have done all related international and industrial standards and passed…

However, is that enough?

All the tests done in a lab are simulations. How do you know for sure that this system

would work in real world??What should you consider in addition to

the standards?

NO!!

Page 69: Car electronization   trend in automotive industry

Development of Automatic Wiper (3)

In real world, there are many variations of rain!!

The wiper should work in ALL types of rain.

Page 70: Car electronization   trend in automotive industry

Development of Automatic Wiper (4)

But the rain is not the only thing to obscure your visibility!!

All of these need to be taken into consideration.

How about snow?

How about spray from the vehicles ahead?

What about sleet?

Page 71: Car electronization   trend in automotive industry

Development of Automatic Wiper (5)

They tested their product for months in various parts of Japan and North America, just to verify the technology.

Urban AreaRural Area

Powderly Snow

Hokkaido

Sleet

Hokuriku

NagoyaChugoku

Manitoba

Blizzard

Michigan

Page 72: Car electronization   trend in automotive industry

Development of Automatic Wiper (6)

Their effort was paid off as a Japanese luxury brand adopted the product as a standard equipment on almost all of their cars.

Page 73: Car electronization   trend in automotive industry

Thank you foryour attention

We welcome your questions, suggestions, and/or comments on this presentation!!

ESPEC CORP.3-5-6 Tenjinbashi, Kitaku, Osaka, 530-8550 JAPANTEL: +81-6-6358-4785 FAX: +81-6358-4786E-mail: [email protected]