Reliability, Safety, Quality of Remanufactured · PDF filewarranty as a new part [5] and, ......

Reliability, Safety, Quality of Remanufactured Parts

Peter J. Bartel APRA-Europe

Content • General ongoing discussions about reman

• Reliability, Safety, Quality

• Remanufacturing Definition • Safety relevance of vehicles with high

integration of functionalities • ASIL • Additional demands on the remanufacturer • Position of APRA Europe

20/03/13 APRA-Europe 2

Ongoing discussions (1)

• The benefit of remanufacturing is accepted • Major companies are investing in this

sustainable business • Beside financial invest, lobbying activities

have started to protect market share. Main arguments: – Automotive parts are safety relevant – Only major companies have the capability to

produce reliable, save, quality reman parts


Ongoing discussions (2) • Remanufacturing is by definition a process

– Not defining the final quality of the product. – A relation between the specification of the

remanufactured unit and the original new unit is evident.

– The customer is expecting a product with a similar function as the original part.

– Quality and the reliability of the reman product is depending of the remanufacturer.

• The customer is expecting remanufactured parts as good as new


Reman definition

• Purpose, where to be used: – If we want to high light the advantages of our

business, we have to define where for the statements are valid.

– Basics for political and social lobbying

• Why a common definition: – If we want to be successful, we have to give a

clear statement to our audience. – We should not confuse with similar, but slightly

different wordings


Reman definition: Remanufacturing Definition * :

A remanufactured part fulfills a similar function as the original part [1] It is restored from an existing part (core[2]), using standardized industrial processes [3] in line with specific technical specifications [4]. A remanufactured part is given the same warranty as a new part [5] and, it clearly identifies [6] the part as a remanufactured part and the remanufacturer.

*This is the common definition of APRA, CLEPA and FIRM, supported by MERA and RIC.


Reman definition:

Footnotes (1): • [1] Original part, matching quality part

– BER 461/2010/EC Article 1, Para h) in connection with supplementary guidelines 2010/C 138/05, Para 19

– BER 461/2010/EC Article 1, Para h) in connection with supplementary guidelines 2010/C 138/05, Para 20

• [2] Core – A core is a used original or matching quality part which will be remanufactured

• [3] Industrial processes – An industrial process is an established process, which is fully documented. – The size of the industrialized production batch is not limited; only one part could be

remanufactured. – In case of remanufacturing the minimum procedures used in the industrial process are: core

management, core sorting, dismantling, cleaning of all internal and external components, replacement of all missing parts, restoration of all impaired, defective or substantially worn parts to a sound condition or replacement thereof, reworking, machining or performing such other operations as are necessary to put the part in original working condition or better, components assembly and final testing of each remanufactured part.


Reman definition:

Footnotes (2): • [4]Specific technical specifications

– Specific technical specifications, established by the remanufacturer and consistently applied

• [5] Warranty as new part – The remanufacturer must give a warranty for the remanufactured part which is the same as the

warranty required by law for a “new part”, if one is required by law.

• [6] Clearly Identifies – A non-removable, sustainable and un-coded marking is put on each remanufactured part


Safety

• Should we remanufacture safety relevant automotive parts?

• What has to be respected?


Safety • Definition of Safety:

– A system is safe, if it is free from unacceptable risks [a]

• Definition of Risk: – A risk is defined by the probability of accordance

and the expected impact. [a]

• Safety relevant of a system: – A system is safety relevant if a miss function leads

to a health risks and the situation can not be controlled by the user (driver). [a]


Safety relevance of integrated automotive systems

•The braking system of the car is safety relevant. •The system in total has to be type approved. •Main functionalities are redundant. •Singular failing of most of the components inside the integrated brake system is not safety relevant. •Critical spare parts have to be type approved according ECE R90. (Friction pads and linings / in the future additional drums and discs )


Methods

• SIL (Safety Integrity Level) – DIN EN 61508 – Focus non automotive

• ASIL (Automotive Safety Integrity Level) – ISO 26262 – Focus electric, electronic automotive components


Safety relevance, ASIL

• A measure of the relevance of automotive safety systems and functions, the ASIL = Automotive Safety Integrity Level.

• The ASIL is divided into four stages, from ASIL A (lowest level) to ASIL D (highest).

• Non-security systems are classified with QM.


Evaluation/Malfunction • The relevance of a safety system or a function

results from its potential malfunctions. • The malfunctions of the system may have a

different safety relevance. • Safety relevance of the system resulting from

failure of those with the highest safety relevance.

• A remanufacturer has to be capable to evaluate the safety relevance of possible malfunctions of his product!


Influence Factors • Probability of the situation (E = Exposure)

How frequently I find myself in a situation in which the malfunction may occur?

• Controllability (C = Controllability) How can I control the occurrence of the fault (assumed in the above situation)?

• Impact severity (S = Severity) If the malfunction (in the above-assumed situation) occurs and can not be controlled, then how important is the severity of the impact?


Probability The probability of the situation (E = Exposure) is

estimated on the basis of 5 categories in the table below [c]:


Classes E1 E2 E3 E4

Probability Very low Low Medium High

Definition Not specified < 1% of average operation time

1 – 10% of average operation time

> 10% of average operation time

Examples Highway – Loss of load

Mountain Pass – Descending with engine off

Trailer pulling Driving in Snow

and Ice Reversing Refueling Parking –

Sleeping person in vehicle

Driving in Tunnel Driving at night

without street lighting

Driving on wet roads

Traffic jam on Autobahn

Accelerating Braking Steering Parking Driving on Country

road Lane change in

the city

Controllability The Controllability (C) is estimated on the basis of four

classes in the table [d] below:


Classes C0 C1 C2 C3

Controllability General Simpel Usual Difficult or not controllable

Definition distracting, disruptive ≥ 99% usually the driver and other traffic can handle the situation

≥ 90% usually the driver and other traffic can handle the situation

< 90% usually the driver and other traffic can handle the situation

Examples Radio is unexpectedly getting lauder

Faulty seat adjustment while driving

ABS malfunction during emergency braking

ABS malfunction during emergency braking at curving on snow and ice

Impact severity The Impact Severity (S = Severity) is estimated on the

basis of four classes in the table [e] below:


Classes S0 S1 S2 S3

Impact Severity No injuries Minor Injuries Serious, potentially life-threatening injuries

Life threatening injuries, Surviving unlikely

Examples Minor collision Damage by

parking or by leaving

Side collision by v < 15 km/h

Simple rollover

Side collision by 15 < v < 25 km/h

Several rollovers

Side collision by v > 25 km/h

Rollover with collision (for instance a tree)

ASIL-Rating • For any malfunction of the vehicle givens, the

following three parameters are to be estimated: 1. Exposure E: How frequently will the malfunction occur

[E0…E4] 2. Controllability C: Controllability of the malfunction

in the relevant situation [C0…C3] 3. Severity S: Severity of the impact

in the relevant situation in terms of lack of controllability of the malfunction [S0…S3]

• Based on E, C, S the ASIL rating

can be found in the table[b]: (the classification E0, C0, S0 always leads to QM)


C1 C2 C3

S1

E1 QM QM QM

E2 QM QM QM

E3 QM QM A

E4 QM A B

S2

E1 QM QM QM

E2 QM QM A

E3 QM A B

E4 A B C

S3

E1 QM QM A

E2 QM A B

E3 A B C

E4 B C D

Additional demands

A remanufacturer has to • be capable to evaluate the safety relevant of

possible malfunctions of his product. • know the influence of his remanufacturing

process on the functionality of his product. • be able to ensure that non original spare parts

have no influence on the safety of the vehicle. • fulfill specific engineering and production

standards for high safety relevant products.


Position of APRA Europe

• Remanufacturing is not safety critical, only technical modifications.

• The basic information and know-how to evaluate if an automotive part is safety relevant or not have to be provided to the remanufacturing industry.

• Ensure, that the ongoing discussion is not missused to close markets.


BACK UP


FMEA / SIL / ASIL

Comparison of D-FMEA (B) / SIL / ASIL


D-FMEA (B) According to VDA ASIL Severity (S)1 No Effect 02 Very Slight Effect 03 Slight Effect 04 Minor Effect 05 Moderate Effect 06 Significant Effect 07 Major Effect 08 Extreme Effect 09 Serious Effect 010 Hazardous Effect 1-3

• Starting with existing D-FMEA the B-Value can be translated in ASIL S-Value.

• If the Impact is according to VDA a hazardous effect the validation has to be precise according to ASIL Severity

• Standard translations ASIL / SIL are existing

• SIL4 components should not be installed in a vehicle

• ASILC is partly covered by SIL2 and SIL3

Source / Footnotes • [a] Stefan Benz. Eine Entwicklungsmethodik für sicherheitsrelevante Elektroniksysteme im Automobil. Universität Karlsruhe (TH), Karlsruhe, 2004. / Elena Root.

Aspekte des Sicherheitsbegrifs in automotiven Anwendungen. Universität Koblenz-Landau, 2009 • [b] ISO 26262-3 (BL17), Table 4 (normativ). • [c] ISO/DIS 26262-3, Table B.2 (informativer Annex B). Klasse E0 („incredible“) hier nicht berücksichtigt. • [d] ISO/CD 26262-3, Table B.4 (informativer Annex B). • [e] ISO/DIS 26262-3, Table B.1 (informativer Annex B). • [1] Original part, matching quality part

– BER 461/2010/EC Article 1, Para h) in connection with supplementary guidelines 2010/C 138/05, Para 19 – BER 461/2010/EC Article 1, Para h) in connection with supplementary guidelines 2010/C 138/05, Para 20

• [2] Core – A core is a used original or matching quality part which will be remanufactured

• [3] Industrial processes – An industrial process is an established process, which is fully documented. – The size of the industrialized production batch is not limited; only one part could be remanufactured. – In case of remanufacturing the minimum procedures used in the industrial process are: core management, core sorting, dismantling, cleaning of all internal and external components, replacement of all missing parts, restoration of all impaired, defective or substantially worn parts

to a sound condition or replacement thereof, reworking, machining or performing such other operations as are necessary to put the part in original working condition or better, components assembly and final testing of each remanufactured part.

• [4]Specific technical specifications – Specific technical specifications, established by the remanufacturer and consistently applied

• [5] Warranty as new part – The remanufacturer must give a warranty for the remanufactured part which is the same as the warranty required by law for a “new part”, if one is required by law.

• [6] Clearly Identifies – A non-removable, sustainable and uncoded marking is put on each remanufactured part


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