Automotive industry Quality and Engineering

Veljko Massimo Plavsic

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This podcast is dedicated to Automotive Industry,innovation,research and development,quality and engineering and official vehicle recalls occured. If you want to share with me this passion for cars and engines you're in the right place and I would like to give you a warm welcome.

11/28/2025

IVECO CSR/ Iveco-IATF 16949

Iveco Group Customer Specific Requirements for IATF 16949 Executive Summary This briefing document outlines the key customer-specific requirements (CSR) established by Iveco Group, which supplement the IATF 16949:2016 quality system standard for its suppliers, referred to as "Organizations." Dated 24/11/2025 (Revision 01), these requirements mandate a comprehensive and proactive approach to quality, safety, and corporate responsibility that extends beyond standard compliance. Key takeaways include: • Expanded Supplier Accountability: Suppliers are responsible not only for product quality but also for demonstrating compliance with core sustainability pillars, including personnel safety, environmental protection, and regulatory adherence (e.g., REACH). • Rigorous Management of Special Characteristics: The document places significant emphasis on identifying, documenting, and controlling "Key" product characteristics that impact safety, legal conformity, or customer satisfaction. Suppliers must maintain related qualification and process documentation for a minimum of 15 years. • Proactive Quality Assurance and Performance Monitoring: Organizations must conduct regular, planned quality checks, including complete self-qualifications every two years and annual dimensional/material controls. Supplier top management is required to conduct monthly performance reviews analyzing customer satisfaction metrics, audit outcomes, and the costs of poor quality. • Strict Communication and Escalation Protocols: The requirements mandate immediate and clear communication. Suppliers must inform Iveco Group of any production disruptions within six hours of a sudden interruption. They are also obligated to notify their own Certification Body within five working days if placed on "New Business Hold" (NBH) or a high-level "Controlled Shipment Level" (CSL). • Cascading Requirements Through the Supply Chain: Suppliers are expected to enforce Iveco Group-like quality standards, particularly for the product approval process (PPAP), upon their own sub-suppliers, ensuring that quality standards are maintained throughout the entire value chain. 1. Document Overview and Scope The "IVECO GROUP CUSTOMER SPECIFIC REQUIREMENTS FOR IATF 16949" is designed to complete and specify the IATF 16949:2016 Quality System Requirements for all suppliers (termed "Organizations"). It integrates with existing technical documentation such as Drawings, Norms, Procurement Specifications, and Requests for Quotation (RFQ). The contractual Statement of Requirements (SOR) should be consulted as the main reference for additional guidance. 1.1. Core Procedural Framework The customer-specific requirements complement a set of fundamental procedures that govern the supply relationship between Iveco Group and its Organizations. These core procedures are detailed in the following table:

11 min
11/03/2025

Three AI Revelations That Are Redefining Car Safety

Introduction: Beyond Buckles and Airbags For decades, the story of car safety has been one of reaction. Seatbelts restrain you during an impact. Airbags cushion you. Anti-lock brakes engage when you're already skidding. These are brilliant, life-saving technologies, but they all share one thing in common: they are designed to mitigate a disaster that is already underway. Now, a new paradigm is emerging, shifting safety from reactive to predictive. By leveraging artificial intelligence to analyze immense volumes of driving data, engineers are uncovering surprising truths about the root causes of accidents. A new automotive safety initiative, Project Sentinel, is at the forefront of this shift, and its findings challenge some of our most fundamental assumptions about what it means to be safe on the road. This article explores the three most counter-intuitive takeaways, revealing how AI is learning to prevent accidents before they even begin. -------------------------------------------------------------------------------- 1. The Over-Confidence Trap: Why "Perfect" Drivers Can Be a Liability The first surprising discovery turns a common assumption on its head: drivers with spotless records can sometimes pose a greater risk than those with minor infractions. Project Sentinel's AI found that a history devoid of incidents can foster a complacency that leads to a critical weakness when facing sudden, unpredictable hazards—what the project team calls "Black Swan" events. The "why" is rooted in hard data. The project's AI found that drivers with zero logged infractions over a five-year simulation had a 15% slower reaction time to these "Black Swan" events compared to drivers with a history of minor, infrequent infractions. This "Complacency Curve," as the project calls it, challenges not just insurance risk models but the very way we design training and licensing for an automated future. This insight is impactful because it challenges our very definition of a "safe driver," shifting the focus from a perfect historical record to the necessity of constant situational awareness. -------------------------------------------------------------------------------- 2. The Urban Illusion: Slow Speeds Don't Mean Low Risk Most drivers feel a sense of relative safety when crawling through slow-moving city traffic. The speeds are low, and control feels high. However, Project Sentinel’s data reveals this feeling to be a dangerous illusion. The data shows an extremely high frequency of low-speed collisions in dense urban environments. The reason is cognitive overload. While the speed is low, the number of complex, unpredictable variables a driver must track is immense, averaging 12 to 15 dynamic variables simultaneously, from pedestrians to cyclists and intersections. This creates a staggering mental burden. A key finding from the project highlights the sheer complexity of this environment, even for a machine: "The sheer density of unpredictable variables in urban environments makes low-speed navigation one of the most computationally challenging problems for an AI." If navigating this chaos is one of the most difficult tasks for a powerful AI, it represents an even greater cognitive strain for a human driver. This is precisely why this seemingly "safe" environment is actually fraught with a high probability of risk. -------------------------------------------------------------------------------- 3. Smart Data Over Big Data: The Myth of "More is Better"

20 min
11/03/2025

Automotive Cybersecurity Risk Analysis

This document provides a systematic analysis of security threats, potential impacts, and mitigation strategies for the modern connected vehicle platform, based on the project's foundational documentation. -------------------------------------------------------------------------------- 1.0 Introduction: The Evolving Threat Landscape for Connected Vehicles The strategic importance of cybersecurity in the automotive sector has grown exponentially. As modern vehicles become more complex and interconnected, their integration of advanced electronics, wireless communication, and external networks creates a vast and evolving attack surface. This increasing connectivity, while enabling revolutionary features, introduces new and significant security challenges that must be addressed proactively throughout the entire vehicle lifecycle. The core objectives of this security project, as outlined in the foundational documentation, are to establish a comprehensive and resilient security posture. These objectives include: • Identification of potential vulnerabilities across all electronic systems and communication interfaces. • Development of robust countermeasures designed to prevent, detect, and respond to cyber threats. • Compliance with international standards, specifically adhering to the rigorous framework established by ISO/SAE 21434. • Integration of security solutions in a manner that does not compromise vehicle performance, safety, or user experience. A robust risk analysis is therefore contingent on a clear understanding of the system's foundational security architecture, which defines the boundaries and interfaces to be protected. -------------------------------------------------------------------------------- 2.0 System Architecture and Security Posture A multi-layered, defense-in-depth security architecture is fundamental to protecting the modern vehicle. This approach ensures that a compromise in one layer does not lead to a systemic failure. This section details the core components of the proposed system, each designed to protect a specific domain of the vehicle's electronic infrastructure and to function as part of an integrated whole. 2.1 Central Security Gateway The Central Security Gateway functions as the vehicle's central firewall and network router. Its primary responsibility is to filter and monitor all data traffic exchanged between different network domains, such as infotainment, telematics, and powertrain. By enforcing strict, policy-based communication rules, it isolates critical systems and prevents unauthorized messages from propagating. It serves as the first line of defense for the internal networks detailed in Section 2.3 and relies on cryptographic identities managed by the HSM (Section 2.2) to authenticate traffic. 2.2 Hardware Security Module (HSM)

9 min
10/31/2025

Toxic spreadsheet

The Automotive Industry Crisis: A Failure of Vision and a Call for Radical Transformation Executive Summary The global automotive sector is facing a profound existential crisis that extends beyond technological disruption. While Western automakers have invested billions in electrification and digital innovations, they have critically neglected their most vital asset: human capital. This has resulted in a severe skills gap, delayed projects, compromised quality, and a rapid erosion of market share and profitability. The core of the crisis is not a lack of technology, but a failure of strategic vision and a deep-seated managerial resistance to change. In stark contrast, China has executed a methodical, decade-long industrial strategy, creating an integrated ecosystem of specialized education, battery production, and government support. This has granted Chinese firms a dominant position, with superior technology, faster development cycles (24-30 months vs. the West's 48-60), and significantly lower production costs. The primary obstacle to a Western recovery is internal. An over-reliance on obsolete tools like spreadsheets, which consume 30-40% of technical professionals' time, combined with a management culture that protects the status quo, is paralyzing innovation. The solution requires a "360-degree industrial transition"—a radical overhaul of processes, culture, and skills. This involves eliminating outdated workflows, embracing end-to-end digitalization, and aggressively adopting Artificial Intelligence not as a threat, but as a tool to amplify human capability. Survival is contingent on the courage to abandon failed past practices and execute this comprehensive transformation without delay.

14 min
10/31/2025

Ford Bronco Seat Bolt Defect: Internal Risk Analysis

Ford Bronco Seat Bolt Defect: Internal Risk Analysis 1.0 Introduction and Purpose This document provides an objective, data-driven risk analysis of the recent National Highway Traffic Safety Administration (NHTSA) recall concerning the Ford Bronco front seat pivot bolt. The purpose of this internal analysis is to synthesize the available information regarding the defect's nature, scope, and potential impact. The findings herein are intended to inform strategic decision-making across key business functions, including safety compliance, operational logistics, and brand management, ensuring a coordinated and effective corporate response. 2.0 Defect Characterization A precise definition of a product defect is strategically fundamental. A clear technical understanding forms the basis for developing an effective engineering response, communicating accurately with regulatory bodies like the NHTSA, and mitigating potential legal and financial exposure. The issue at the core of this recall involves a specific structural component failure within the vehicle's cabin, with a technical breakdown as follows: • Component: The specific part identified as faulty is the height-adjust pivot bolt located in the front driver and passenger seats. • Failure Mode: The nature of the defect is a critical lapse in assembly and quality control, where the bolt may be loose or completely dislodged from the seat frame. • Quality Control Assessment: The presence of a loose structural bolt on a new vehicle represents a significant quality control failure. As noted in the source material, such a defect "simply shouldn't happen" and points to a critical lapse in manufacturing or inspection protocols. This specific technical failure has a widespread impact, affecting a significant number of recently produced vehicles. 3.0 Scope and Scale of the Recall Quantifying the scope of a recall is essential for strategic planning. These metrics directly inform logistical requirements for the service campaign, guide financial provisioning for repair costs, shape the customer communication strategy, and ultimately define the overall magnitude of the business impact. The core statistics for this recall, as documented by the NHTSA and Ford, are presented below.

13 min
10/31/2025

Honda's Family Haulers Under Fire: Feds Investigate Over 500,000 Odyssey and Pilot Models for Major Safety Flaws

Honda's Family Haulers Under Fire: Feds Investigate Over 500,000 Odyssey and Pilot Models for Major Safety Flaws Introduction: The Unsettling Truth Behind a Trusted Family Brand For decades, the Honda brand has been synonymous with reliability and trust, a go-to choice for families seeking safe, dependable transportation. Vehicles like the Honda Odyssey minivan and the Pilot SUV are staples in suburban driveways, purchased with the expectation that they will protect the people that matter most. It’s a reputation built on years of engineering and customer satisfaction. That well-earned trust is now facing a serious challenge. The National Highway Traffic Safety Administration (NHTSA) has announced two official investigations into more than 583,000 of these popular family vehicles for significant safety concerns. While these are not yet recalls, they represent a critical development that every Odyssey and Pilot owner needs to understand, as the issues involve fundamental safety systems: airbags and seat belts. 1. A Safety Feature That's Dangerously Proactive: The Odyssey's Airbag Issue The first investigation centers on a deeply alarming problem: the inadvertent deployment of side airbags in 2018-2022 Honda Odysseys. According to complaints filed with the NHTSA, these airbags can deploy suddenly and without warning while the vehicle is in motion. In some cases, the trigger was as common as driving over a pothole. This potential issue, which could affect 441,002 vehicles, is particularly troubling for a model that has been Honda's most recalled vehicle over the past decade. The NHTSA has already received 18 complaints, including two reports of injuries. The agency's official statement underscores the severity of the risk: The complaints allege that the inadvertent deployments occurred while the vehicle was in motion. Consumers allege no warning prior to air bag deployment. Some allegations state that the deployment(s) occurred after traveling over a pothole or similar roadway feature. Inadvertent deployment of air bags while a vehicle is in motion can lead to injury of vehicle occupants or driver distraction, which may result in a collision. This is a profoundly concerning development. A safety feature designed to save lives in a collision is potentially causing the very distraction and

14 min
10/27/2025

The Hypercar and the Screw: A Case Study on the Aston Martin Valkyrie Recall

The Hypercar and the Screw: A Case Study on the Aston Martin Valkyrie Recall In base a 1 fonte The Hypercar and the Screw: A Case Study on the Aston Martin Valkyrie Recall Introduction: The Devil in the Details The Aston Martin Valkyrie is more than just a car; it's a masterpiece of automotive engineering, a hypercar that pushes the boundaries of technology and performance. When a machine this complex and meticulously built is announced, the world takes notice. It's even more surprising, then, when such a vehicle is recalled not for a complex system failure, but for a component so seemingly mundane: a screw. This analysis explores how a tiny, incorrectly sized part can trigger a cascade of critical failures in a multi-million dollar machine, offering a powerful lesson on the absolute importance of quality control. -------------------------------------------------------------------------------- 1.0 The Recall in Numbers: Key Facts The official recall notice, monitored by Germany's Federal Motor Transport Authority (KBA), outlines the essential scope of the issue. Detail Information Make Aston Martin Model Valkyrie Number of Vehicles Affected 137 Production Period 16. 6. 2020 – 23. 12. 2024 Official KBA Reference 15104R Manufacturer Code RA-18-2044 These figures provide the what, who, and when of the recall, but the technical explanation reveals the true severity of the problem. -------------------------------------------------------------------------------- 2.0 The Chain Reaction: How a Small Screw Creates a Big Problem The defect at the heart of the Valkyrie recall demonstrates a classic chain reaction, where a single, small error escalates into a potentially catastrophic system failure. 2.1 The Root Cause: An Issue of Millimeters The point of origin for this multi-million-dollar recall is a fundamental error of dimensioning: the screws used on the fuse box's locking plate were manufactured to be too long. In the tightly packaged architecture of a hypercar, where every gram of weight and cubic centimeter of space is meticulously optimized, there is no tolerance for such a deviation. This seemingly minor discrepancy is the starting point for a series of dangerous consequences. 2.2 The Domino Effect: From Damaged Wires to System Failure The oversized screws set off a dangerous sequence of events, with each stage presenting a greater risk to the vehicle and its occupants. 1. Initial Damage: The excess length of the screws causes them to press into and damage the vehicle's wiring harness. This harness is the nervous system of the car, routing power and data to all critical components and transmitting everything from critical sensor readings to driver control inputs.

11 min
10/27/2025

Case Study Analysis: Ferrari 296 Recall (NHTSA ID: 25V716000)

Case Study Analysis: Ferrari 296 Recall (NHTSA ID: 25V716000) 1.0 Executive Overview This formal case study analyzes the Ferrari North America recall (NHTSA ID: 25V716000), deconstructing the technical defect, potential risks, and prescribed remedy based exclusively on the official filing. The analysis begins with the foundational identification and scope of the recall. 2.0 Recall Identification and Scope The accurate identification of a recall's scope establishes the fundamental parameters of the event, defining the responsible manufacturer, the affected vehicle population, and the component systems involved. These details for recall 25V716000 are as follows: Identifier Details Manufacturer Ferrari North America, Inc. NHTSA ID Number 25V716000 Manufacturer Recall Number RC 93 Affected Components ENGINE AND ENGINE COOLING Affected Vehicles 2025 296 GTS and 296 GTB Potential Number of Units Affected 6 With the specific vehicles and limited number of units identified, the analysis can now focus on the underlying technical problem that necessitated this recall action. 3.0 Technical Problem Analysis The defect's root cause, a failure in assembly-line quality control, highlights a critical vulnerability in the vehicle's engine and cooling system. Ferrari's investigation pinpointed a specific mechanical failure as the source of the defect. The technical defect stems from an assembly process error. The core issue is precisely described as follows: The nut securing the oil filter connection to the turbocharger oil feed pipes was tightened incorrectly and may cause an oil leak. The direct consequence of this defect is a potential oil leak from a critical engine component. This single point of failure introduces a significant vulnerability within the engine and engine cooling system. This oil leak transforms a minor assembly defect into a critical fire hazard. 4.0 Risk Assessment and Safety Implications An assessment of a defect's consequences determines its severity and the required urgency of the response. In this case, the mechanical failure creates a direct and severe risk to vehicle occupants, necessitating an immediate owner directive. The primary risk associated with the potential oil leak is severe. As stated directly in the recall documentation, "An oil leak near a combustible source increases the risk of a fire." This elevates the defect from a potential performance issue to a critical safety hazard. In response to this significant risk, a "Do Not Drive Warning" has been issued to all owners of the affected vehicles. This measure is reserved for defects with a high potential for severe consequences and is a critical step to mitigate the identified fire risk. The directive instructs owners to cease operating their vehicles immediately until a repair can be performed, prioritizing owner safety until the official remedy is implemented. With the immediate risk contained through this directive, the focus shifts to the official remedy required to make the vehicles safe for operation. 5.0 Corrective Action and Remediation Plan The remediation plan for this recall is defined by a clear corrective action, a no-cost provision for owners, and a structured communication strategy. This plan is designed to ensure full compliance and restore vehicle safety. The official remedy is a multi-step process designed to correct the defect: 1. Immediate Owner Action: Owners are advised not to drive their vehicles until they have been repaired. 2. Official Repair Procedure: Ferrari will verify tightness and retighten the attachment nut. 3. Cost to Owner: The remedy will be provided free of charge.

11 min

This podcast is dedicated to Automotive Industry,innovation,research and development,quality and engineering and official vehicle recalls occured. If you want to share with me this passion for cars and engines you're in the right place and I would like to give you a warm welcome.

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Automotive industry Quality and Engineering