Injectronics: Australian Automotive Aftermarket - Essay Example

?Introduction In order to provide maximum support to automotive repairers as engines become ever more sophisticated is essential with the use of electronic management system. However, several problems in modern engines can result from any on the several on-board electronic systems; thus, Injectronics company realises that repairers can waste both time and money in replacing incorrect electronic component when seeking to rectify a problem which is difficult to diagnose. Diagnostics is the greatest and most significant challenge facing technicians today with the increased tools of diagnostics and codes to understand. Moreover, there are pressures in the effective use of these new tools to diagnose and repair vehicles correctly, once the vehicle comes into bay (Weiland, n.d). Automotive maintenance has undergone radical changes since the introduction of electronics as well as mechatronics in vehicles. Rapid introduction of computer controls to operate engines, steering, braking, suspension and other safety and transmission or comfort functions in today’s vehicles is a huge challenge to both service processes and manufacturing technologies along with failure diagnosis requirements. Many of the modifications in automotive repairs are a result of the initiation of microcontrollers and other electronics in functions within a vehicle. These changes require the remanufacturing companies for such electronic components to improve as significant changes are continually taking place in the industry (Weiland, n.d). Before the advent of electronic controllers, definition of automotive remanufacturing was clear: meaning the renovation of used vehicle parts in accordance with the accepted state so that they can perform similar to new ones. This conventional remanufacturing may be relevant in future to mechatronics; nevertheless, the definition will be tailored for electronic controllers. Electronic parts have no mechanical parts; thus, they do not need to disassemble the entire unit completely. To service and repair vehicles with repaired parts or used parts is not a good choice since used parts never get tested for any potential problems thus they have a limited life expectancy. Not only does the use of these ‘used parts’ uneconomical choice, but also their function is uncertain although they are environmentally friendly. Currently, vehicles average 35 microprocessors in a vehicle, which are located in various several electronic modules throughout a vehicle and range from simple applications to sophisticated engine controls. The high content level highlights the importance of long-term service plan for electronic control modules. In these vehicles, the service expectations include corresponding electronic modules at least every 4-10 years’ service life with most vehicles lasting 15 years; nevertheless, other vehicles have a high service life of up to 25 years or more. Electronic modules present a difficult service challenge due to many factors such as the fact that microprocessor manufacturers and network manufacturers never have the volume requirements in the service life of a vehicle in order to maintain a production line for producing these service components (APRA global connection, 2009). Market and Competitors Most Electronic Control Module (ECM) utilise four to eight custom-produced microprocessors to deter competitors and grey marketers capable of replicating the electronic control module. Therefore, electronic components are often produced in a limited manner and usually the first components to be given as end-of-life production. Remanufacturing of electronic modules is possible through the availability of sold units removed from vehicles or cores; thus, injectronic faces the challenges of maintaining a sufficient collection system that maintains constant return of failed units to sustain the remanufacturing program. Moreover, the core is a failed unit, which has been in use within vehicles for several years; therefore, it is likely that the part is not the latest part since many revisions could have taken place over the life of the vehicle. This is a huge challenge since the goal of producing remanufactured product is to produce a remanufactured product with the latest hardware and software for best functionality to the customer and high quality product. Thus, Injectronic Company envisages the problem of cataloguing the core to ascertain the level of modification the core inventory yields. Remanufacturing has its limitation; thus, it has to be cost effective to make an attractive alternative to manufacturing. Another concern for Injectronics Company understands the valuable life of components remanufactured for use in electronic modules. In validating original electronic control module in engine, the modules are tested in more than 10million cycles. However, there is no way to know how many cycle the original core experienced in its life unless there is a cycle counter in place during design; otherwise, it is impossible to know if the original component on the board experienced high or low cycle rates (APRA global connection, 2009). The most difficult yet essential challenge facing Injectronics Company in the remanufacturing industry is confronting counterfeiters and competing against the counterfeiters’ strategies (Newton, 2012). Remanufactured units that are properly built to meet the original manufacturer’s specification, become better units since the product gets upgraded within remanufacturing process with the latest hardware revision and receiving latest software application. Remanufacturing of electronic components faces the challenge of testing and component sourcing, with the core challenge being obtaining of components to repair electronic or mechatronic parts. The challenge begins when attempting to source some components such as transistor drivers and the usual IC’s (Integrated Circuits) obtained from electronic component part suppliers. In addition, the industry faces the challenge of manufacturers of IC chips customising their product for ECM (Electronic Control Modules) manufacturers making some of the components inaccessible through the traditional market channels. In some cases, before a demand for remanufacturing an ECM it could be five years since the device was manufactured; thus, the component has finished its production run making it obsolete (APRA, 2009). Remanufacturing has to address the market and supply challenge and the original and performance as well as quality has to be ensured in Injectronics. This requires testing of equipment and software to validate functionality of Electronic Control Unit (ECU); moreover, Injectronics has to ensure that spare components are available from suppliers. Remanufacturers have the concern of maintaining volume, which necessitates the ability to handle several parts from various suppliers. The key component of remanufacturing is flexible, low cost equipment that offers versatility. Therefore, the industry faces the challenge of building equipment that is flexible and supports various products across several suppliers over a long period. The equipment needs to be developed while considering remanufacturer requirements in addition its development cost has to be spread across products and models in order to offer common, strong components and software at low costs and long-term maintenance at a reasonable cost. Remanufacturing as a new concept has only one way to get it right, which involves development of individual company knowledge base through support and advice from all those working in the industry. Electronic failure at work, home or on the road frustrates consumers when they result from cell phones, Automotive ECU or computer failures. Service lifetime between 10 to 15 years requires repair parts long after original manufacturing lines cease production. This results in issues between both the consumer and the ECU supplier. For many years, transmission was controlled by an ECM, which was mounted externally to transmission unit; however, the increasing trend mounts ECM in the transmission itself. This necessitates the transmission remanufacturer to test and validate the workmanship of the remanufactured transmission as well as the function of the ECM, a huge challenge for Injectronics. While testing hydraulic function in electronic power steering to see if it functions the same way as the traditional belt driven pump, Injectronics Company face the challenge of having the test equipment capable of monitoring and supplying enough current and commanding the pomp operation. The above challenge includes obtaining information and test equipment and deciding if remanufacture will occur in house or externally. One essential process in remanufacturing of vehicle electronics and mechantronic is the ability to test the functions of a module fully, which can be done before or after remanufacturing process. The equipment for this is not readily available, the remanufacturing company has to design and manufacture its own gadget (APRA, 2009). Government Pressures In order to address the issue on the quality of remanufactured electronic components, reputable electronic and mechatronic remanufacturing companies develop exceptional quality over a long period with some obtaining ISO9001:2000 quality certification like Injectronics. When a remanufacturer cannot access certain circuit board and component information, then it necessitates reverse engineering the assembly. Many electronic components have identification marking; however, relation information may be inaccessible for the component; therefore reverse engineering enables the possibility of establishing and sourcing replacement component of a high rating to ensure that it does not fail again. The industry faces government pressure with the introduction of internationally recognised vehicle safety technology, which aims at preventing crashes especially in single vehicle crashes thus saving lives. Introduction of electronic stability control was previously advocated for by the Australian motoring clubs, which welcomed the initiative by the government. The initiative has been proven to save life especially by effective decrease of single vehicle accidents. For instance, Monash University research showed that electronic stability control reduced 27% of single car crashes and 68% of single four-wheeled vehicle crashes. The initiative is mainly concerned with safety of all the Australian motorists as well as their families (Australian Automotive aftermarket, 2008). References Automotive Parts Remanufacturers Association. 2009. Official publication of automotive parts remanufacturer association. [Online] Available at: http://www.apra.org/News/GC_09/0609_GC.pdf [Accessed 30/04/2013] Australian Automotive aftermarket. 2008. Australia’s Leading Automotive parts and accessories Industry magazine. [Online] Available at: http://www.aftermarket.com.au/aftermarket/magazines/AM_JUNE_08.pdf [Accessed 30/04/2013] Newton, K. 2012. Don’s big back yard: The sparky who covers Australia’s most unforgiving territory. [Online] Available at: http://www.tat.net.au/pdfs/editions/Issue29Oct2012.pdf [Accessed 30/04/2013] Weiland F. J. (n.d). Remanufacturing Automotive Mechatronics & Electronics. [Online] Available at: http://www.apra-europe.org/dateien/News/ebook_FJWeiland_Remanufacturing_Automotive_Mechatronics_and_Electronics.pdf [Accessed 30/04/2013] Read More