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A Swedish supplier Autoliv's scientists say GM in the late 1990's asked the supplier to match Takata's airbag that saved several dollars per airbag. The problem say the scientists at Autoliv was that the Takata airbag that was made at lower cost used a dangerous volatile compound. Autoliv cited here by Tabuchi of the NYT, says it refused to do this. Years later 100 million of the Takata airbags are installed on cars in the U.S. made by GM and other automakers.  The chemical ammonium nitrate used by Takata is still being used to make airbags with modifications to reduce its explosiveness. In this indepth account Tabuchi looks at the evidence against using ammonium nitrate, the warnings that were not heeded from Autoliv, and the work of Italian and other scientists that confirm the explosiveness of the substance when exposed to temperature and moisture changes. Here Tabuchi cites reports from suppliers of the nitrate who were hesitant to supply the substance to Takata because of liability issues. And he points out that there was manipulation of testing quality control for the defective airbags that passed the test, so that in addition to the use of the faulty chemical, the company failed to maintain strict quality control as required by the automakers. The pressure from automakers for cost reduction is given as one of the reasons for the problem, just as the pressure from BP to cut costs led to some of the faulty work done by suppliers at oil wells leading to explosions on a oil rig in the Gulf of Mexico. Before the approval of the faulty chemical for airbags Takata airbag business was in dire straits leading to management looking for ways to develop a viable business, as other propellants had failed to deliver results. It is at that point that Takata approved ammonium nitrate despite evidence of its explosiveness that led to TRW, another airbag maker, to reject it.  ...

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Takata struggled with a faulty airbag recall crisis and failures in quality control that go back to 2004, with a crisis in 2015-2017 as a result of about 14 deaths. Takata's liabilities now run to over $15 billion according to Tokyo Shoko Research because of claims against it from banks, automakers and others. Takata declared bankruptcy on June 25, 2017. Takata was sold to a Chinese owned manufacturer based in Michigan, Key Safety Systems, for $1.6 billion. Takata had hoped for a white knight investor or some of the automakers such as Honda to save it. But the liabilities were too great and automakers in Japan resisted the idea because it might upset shareholders and it made no sense to assume growing liabilities. As a result the Takata company name will go out of business- for a company that started in 1933. The Chinese company taking on the business, a quarter of the market share for the airbag market, is Ningbo Joyson Electronic Corporation. A related article in the NYT in 2014 by Tabuchi shows how management at Takata failed to act responsibly when the early beginnings of the crisis happened in 2004. See the link. [article-54918]  At that time testing of an exploding airbag in Alabama was kept secret and later closed down without informing safety regulators, according to former employees. By not taking responsible action management failed in the 2015 airbag crisis leading to this bankruptcy, the largest in Japanese history.  ...

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Even after bankruptcy of Takata, this WSJ article points out that the job of replacing 54 million defective airbags in just the U.S. could go on and on for many years. Honda the carmaker most affected has set aside $4.9 billion over 2 years to cover recall costs. The airbags failed because of manufacturing defects.

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This NYT article by Tabuchi cites former Takata employees who revealed to the NYT that the Takata problems go back to 2004 when things were kept hush-hush and an investigation into a faulty airbag that exploded was closed down without informing safety regulators in Japan.  

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The Takata airbag recall increases by 35 million to about 63 million, about one in 4 cars in the U.S. by May 2016. The issue is connected to Takata's use of ammonium nitrate which poses a safety risk leading to explosions. The findings by 3 separate investigations from Honda Motor, Takata, and 10 automaker consortium have led to the massive recalls. A Takata engineer raised questions about the use of ammonium nitrate in the 1990's, and the company has fumbled in its response to the safety concerns.

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The U.S. Senate's Commerce Committee report on Takata airbags failures says the company stopped safety audits between 2009-2011 for financial reasons. At least 8 deaths and 100 injuries have been reported from faulty airbags which rupture and spray shrapnel when they fail in vehicles as a result of propellants degrading over time. The report cites problems on the manufacturing lines revealed in emails inside the company. This has led automobile companies to fix the problem in 34 million automobiles, in the largest ever recall in the U.S. The Senate report also says the regulators at the National Highway Traffic Safety Administration (NHTSA) were slow to respond. The Transportation Department inspector general's report is critical of regulators at the NHTSA. Takata and 10 automakers are conducting separate investigations for root causes.

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A new CEO, Takahiro Hachigo, takes over at Honda Motor in Feb. 2015, following quality issues and problems with the faulty Takata airbags. Hachigo is a younger engineer who was managing officer for China. Executives with more experience were bypassed in the selection. This follows Toyota's selection of Akio Toyoda, a younger executive with international experience as CEO, and his successful track record in handling the Toyota recalls for unintended acceleration. This may have persuaded Honda to go with an unconventional choice.

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Cracks are appearing in Japan's manufacturing model in recent years. Kobe Steel, Mitsubishi Materials and Subaru Corp have admitted to manipulating quality inspections. Takata Corp, maker of airbags is a case study in what can go wrong, as the company declared bankruptcy after failing to tackle safety problems and supplying defective airbags. The case is all the more astounding as airbags are designed for ensuring the safety of automobile passengers, a key feature of every automobile.  The situation is one of failure of management to take the right actions. This also happened with Toyota as management missteps worsened the issues related to faulty acceleration of vehicles, leading to media focus on Toyota in the U.S. Japan is not unique in this area of management failures as VW's actions in the diesel emissions case have clearly shown. Pressures to cut costs are part of the problem as this report shows. In Japanese companies quality checking staff employees are the targets of cost cutting layoffs resulting in the faulty step of outsourcing quality checks, which is contrary to what the country's pioneers sought to do when they adopted American Total Quality methods in the 1960's. This creates opportunities for China today, and for India in the future if it is able to capitalize on the opportunities in manufacturing desperately needed for job creation.    ...