Murata’s solution: “Quality Assurance”
“Quality Innovation” pursues quality required for in-vehicle equipments
Constructing a framework to provide solutions even before addressed

Automobile and in-vehicle equipment manufacturers have strict standards for the quality and reliability of electronic components for the in-vehicle system. In order to respond such requirements, Murata Manufacturing Co., Ltd. is reinforcing its quality assurance system under “Quality Innovation”. Murata has established a special division dedicated to the technology for reliability assessment on electronic components for in-vehicle use in order to provide products in need promptly. This is one example of Murata’s proactive strategy to tackle new challenges to better cope with customers’ needs.

Mr. Seiichi Okada
Chief of automotive reliability engineering section Quality assurance division, Murata Manufacturing Co., Ltd.

“Quality Innovation” is a mid-to-long term theme that Murata is working on company-wide. Right after the announcement of the theme in 2007 by Tsuneo Murata, a President of Murata , various activities have been introduced for quality innovation in a top-down manner. These activities focus on the realization of “Customer oriented quality assurance”. Until recently, we have handled general purpose components. Therefore, our standard business style was either to begin negotiation with our clients based on our standard products or to develop products according to client’s specifications. Currently, we are making efforts to build a system that can provide products that satisfy the needs of quality and reliability of potential clients based on our deep understanding of industry trends and clients’ needs. Murata calls this activity “Quality assurance activity that moves our clients”. (Mr. Seiichi Okada, Chief of automotive reliability engineering section, Quality assurance division, Murata Manufacturing Co., Ltd.)

Setting a target one grade higher

Fig-1. Activities to achieve in-vehicle quality(click to enlarge)

Electrification of automobile has rapidly expanded the electronic component market for in-vehicle use and led Murata to various new activities. “For automotive applications, any defect of just one small part may lead to a serious accident. So the electronic components are required to meet strict standards. Therefore, it is necessary to establish a stricter quality assurance framework that guarantees the long-term durability of 10 years or longer, zero defect, and a support system that can respond within 24 hours in case of any failures.” (Mr. Okada)

Murata implements a quality innovation activity targeting on three points: “Reinforcement of durability”, “Quality improvement targeting at zero defect” and “Reinforcement of claim support system” (See Fig-1). For example, in order to reinforce durability in design, Murata has introduced limit testing, assessment under stress in the actual-use environment while tackling important reliability issues. To achieve zero defects, Murata is introducing complete implementation of source control and scientific management. To build production lines for high-quality in-vehicle components and reinforce claim support system, Murata also makes efforts to improve failure analysis technology and prevent failures from reoccurring. “As a part of reoccurrence prevention, we are proceeding to share system of quality control know-how corporate wide. Also, we will make active investments to enhance accuracies of reliability test and failure analysis. We have already established a failure analysis facility in May 2007 to reinforce failure analysis capability company-wide.” (Mr. Okada)

Fig-2. Quality assurance system (click to enlarge)

At present Murata has a sophisticated quality assurance system centering on quality assurance division at the head office (See Fig-2). Murata’s plants located nationwide and merchandise divisions organized by product categories have their own sections for quality assurance and control while each factory has its own quality control division. Both domestic and overseas plants that deal with in-vehicle use components have the ISO/TS16949 certification, the international quality control standard for automobile components. For each single product, specialists of quality assurance teams at head office, plants, product groups and factories work in collaboration to enforce a strict quality control. These quality controlling systems reflect Murata’s original ideas (See Fig-3). “In design review (DR), discussion and examination are executed focusing solely on quality. As for other matters such as price and delivery time, these aspects are examined after passing DR. Murata is focusing on early detection of a weak point of products. Active discussion on quality risk is engaged by Murata’s cross function team consisting of R&D division and quality control division from early stage of design development before DR since early detection of a risk relating to quality in designing is very important to improve quality of end products. I think not many component manufacturers make their quality assurance divisions execute design validation at such an early stage of development.” (Mr. Okada)

Establishment of reliability assessment technology section dedicated to in-vehicle components

Fig-3. Quality evaluation process in designing(click to enlarge)

What makes Murata’s quality assurance unique is that Murata’s quality assurance division at the head office has an “Automotive reliability engineering section” that specializes in automotive technology. This section was established in 2004 to respond to the strict requirements from automobile manufacturers. The main role of this section is to establish a framework of quality assurance in a severe usage environment unique to automobile. Especially, this section is taking the lead in activities such as figuring out the abrasion deterioration mode and its mechanism, grasping critical lifetime and severe environmental conditions unique to automobiles, establishing corresponding testing standards and design method taking account of critical lifetime and test program to validate it.

“The highest priority in realizing quality assurance for in-vehicle components is to control an abrasion failure in hard use.” (Mr. Okada)

Component failures have three factors: “Internal factor” that exists within a component, “External factor” that is originated from stress from manufacturing process or stress from actual usage as a product, and “Age deterioration factor”. Failures in actual use are caused by the interaction of these three factors. Perfect quality assurance requires the control of these three factors. Although component manufacturers can detect the internal factors and the age deterioration mechanism, it is hard to obtain information on external factors after their components get shipped out to the market and to the hands of users. “So, we have decided to collect information and data on the external factors on our own. If we can obtain accurate information of customers’ requirements for reliability and usage environment relating to important reliability issues, we will be able to provide customers with products that satisfy their requirement on perfect timing.“ (Mr. Okada)

Pioneered the investigation of the inside of the tire environment

Fig-4. Environment inside the tire while running was measured (click to enlarge)

Among various activities by Murata’s vehicle reliability technology section, the technical exchange with customers has brought great results. From 2005 to 2007, Murata’s engineers visited major carbody and electrical component manufacturers so called as “Tier 1” in Japan, Europe, North America and China to discuss and exchange opinions about ideas on reliability and quality. Those engineers have visited 34 companies. “Conventionally engineers in a quality evaluation division meet with customers only when accidents or problems arise. So, we just have very few opportunities to discuss the problems with our customers in detail. Therefore, our customers welcomed our requests of meetings and we could exchange meaningful opinions each other.” (Mr. Okada) Based on information obtained in these exchanges, Murata has steadily established robust strategies and targets for effective reliability control as well as internal reliability assessment standards.

Murata takes the lead in conducting research on usage environment of in-vehicle equipments. For example, Murata engages in research on the environment inside the tire (See Fig-4). “TPMS (Tire Pressure Monitoring System) that monitors air pressure of tire enjoys growing popularity. TPMS will place pressure sensors and transmitter circuits inside the tire. In the past we didn’t have almost any information on internal environment of tire.” (Mr. Okada) Murata has executed various running tests on actual vehicles to investigate internal environment of tire. From the results of rapid braking test, paved road running tests, unpaved load running tests, and curved road running tests, etc., we have found that internal environment of tire is very poor. “By utilizing new information obtained from these experiments, we can propose new products that satisfy our customers’ needs for quality and reliability.” (Mr. Okada)

Fig-5. Murata has developed analysis technology of thermal fatigue crack of solder in chip capacitor. (Click to enlarge)

Murata also makes an effort to develop thermal fatigue and lifetime evaluation technology of Pb-free solder in chip-multilayer ceramic capacitor (See Fig-5). “We are engaging in the development of a simulation technology that recaptures a failure generation process. By reflecting the experimental result using actual samples, we are improving accuracy of simulation. A technology that can accurately simulate the actual phenomenon is closely to its completion.” (Mr. Okada)

Murata works on the development of reliability assessment technology under high-temperature environment of over 175°C (See Fig-6). Conventional guaranteed temperature range was 150°C maximum for in-vehicle use components. But recently auto-related customers have raised requirement of the temperature range to 150°C-200°C. This movement reflects the fact that an increasing number of manufacturers are adopting a method to implement ECU directly into engine and gearbox. However, conventional testing systems don’t have resistance to such high temperature that exceeds 150°C. Murata has developed a new testing system that can work under such high-temperature. “When we conduct experiments at high temperature, new failure that was not been observed in conventional high temperature testing system has been recognized.” (Mr. Okada)

Murata has steadily advanced efforts to realize “Quality Innovation”. Murata’s effort to advance quality and reliability will surely contribute to the evolution of automobiles backed by the trend of electrification.

Fig-6. Murata has developed high-temperature testing method over 175°C