Defects, Recalls, and Quality Assurance

By Terrance Malkinson

During the first three months of 2014, General Motors (GM) recalled 2.6 million of its small cars of various models due to faulty ignition switches, which could shut off the engine during driving, while at the same time preventing airbags from inflating. On 31 March, GM announced it was going to recall more than 1.5 million more cars, of six different models, due to faulty power steering. The total number of cars recalled during 2014 as of 1 April, is 6.26 million. Recalls are not unique to GM or to the automotive industry. Other automobile manufacturers and industries have also issued recalls.  Engineering and manufacturing defects are more than just an annoyance people have been seriously injured and deaths have resulted. Even more serious is that defects are often known by the company for many months and in some cases years prior to being disclosed to regulators and the public, and a recall is declared.

In the case of the ignition switch failure, the switch indent plunger, which is designed to provide enough torque, or pressure, to keep the ignition from accidentally turning off, did not supply enough torque. This defect, like many others, is inexcusable, as the body of knowledge to design, manufacture and test a fault-free component exists.  Why is this happening? There are many possibilities, most of which, in this author’s opinion, distill down to irresponsible business practices of maximizing profitability, and the dumbing down of the workplace.

Engineers, because of their training and professionalism, must be returned to positions of leadership and given the authority to ensure that quality is a mandatory and non-negotiable priority throughout every process in every business sector.  Check out John Platt’s June Career Focus article Quality Assurance Engineering and the IEEE quality assurance technical navigator.

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