Y.M：To sum things up, quality assurance means building quality from the moment the product is designed. Rather than simply testing and determining whether it passed or failed, we check to see if the design is free of problems to begin with, and if there is a risk of a defect, we investigate the cause and propose a solution. Our role is to work with the Design Department to create systems that meet quality standards.

I.M：Oh, you gave it all away before we had a chance to explain. To put it in concrete terms, if a car door does not open or close smoothly, or if the color of the dashboard is slightly different, you might feel a sense of strangeness, right? If a part comes loose or the engine stops while driving, it could lead to a serious accident.

S.S：We create systems to maintain the quality of automobiles so that things like that do not happen. Even if there are no problems with the parts individually, it would be a big problem if the parts installed in a car start to rattle while driving. In order to eliminate these concerns, we carry out testing and evaluation from the design stage, thoroughly identify any quality risks, and take measures to maintain the highest quality.

Y.M：The systems for maintaining the quality of automobiles is based on the international standards for the automobile industry, "IATF16949". We regularly review our internal quality rules and constantly update them to meet the latest standards.

I.M：The way you said it sounds cool! Having as much information as possible is the key to staying ahead. We are at the forefront of the industry, keeping up with the latest information and reviewing quality rules. It was really tough when we revised nearly 100 rules in a year and a half.

S.S：That was quite a task. In order to prevent confusion among customers and on-site staff, it is also our role to work with the Sales and Development teams, clarify the rules, and improve them so that they are easy to use. We also standardized the criteria for Hiroshima and Yamaguchi Plants.

I.M：For example, even with a record of customer complaint correspondences, if we do not use the same wording, it is impossible to find the data. If we can instantly find out if there have been similar complaints in the past and how they were handled, we can respond quickly.

Y.M：So we have standardized the way we record customer correspondences, making them easier to organize. Systematizing and implementing these daily discoveries also helps improve quality.

S.S：Testing and evaluation is the job that checks quality and performance required in products. In cooperation with other departments, we check whether the precision of molds is maintained. The quality is assured based on the test data.

I.M：I like to perform tests on the Active Grille Shutters (AGS) and the thermostatic chamber we use for testing is my favorite piece of equipment. The AGS is a product that opens and closes using a motor called actuator and it must operate smoothly in any temperature environments. The thermostatic chamber can handle temperatures ranging from -40 to 85 °C. You can reproduce and test the temperature environments in which cars run, from the extreme cold of Russia to the scorching heat of Death Valley.

S.S：ASince the AGS is mounted near the engine, it is essential to test its durability in high-temperature environments. Because plastics have a high coefficient of thermal expansion, when it gets hot, the gaps between the parts disappear and they collide with each other, and if it is repeatedly exposed to sudden changes in temperature, distortion accumulates and causes it to break.

I.M：That is why we always thoroughly test our products under conditions that simulate the worst-case scenario, so that we can understand how they behave.

S.S：The most important thing I learned was the pressure test for sub tanks. When the engine becomes hot, the coolant expands and may overflow from the cooling circuit. The overflow is stored in a sub tank. It stabilizes the pressure within the system.

I.M：The unthinkable happened to a prototype made from a new mold. When we simulated the worst case and tested the product by pressurizing it at high temperatures, it cracked and leaked coolant. It was so unexpected that we had a tough time figuring out how to solve it.

S.S：Even after trying various steps and adjustments, for example, manually adjusting the radius of the tank to avoid stress concentration and increasing the thickness of the plate to improve rigidity, the leak still occurred. I wanted to scream, "Why? Why is it still leaking???"

I.M：Well, you were literally screaming. At that time, you were working with the Design Department to investigate and verify the cause repeatedly, right? We had them redesign the product based on our findings, and we used CAE to perform simulation analysis. Then they built another prototype, and we verified it again. It was an endless process.

S.S：We were really into this together. It was all hands-on deck, with both departments discussing and bringing in all of our expertise and experiences. It was a huge learning experience. When we solved the problem and finally passed the test, we were overjoyed! That sense of accomplishment was something else.

S.S：Well, I talked too much, so I will let Y.T and I.M speak here.

I.M：At first, I was not interested in cars or product structure. But after I learned about the products and tested them, I found them more and more interesting. When I realized the products we create are used in cars I see every day, I thought, "I want to know more!".

S.S：I understand that feeling. After you see how the parts move, which you could not visualize from the drawings, or how a product failed a test, you will really get to know the function of the product.

I.M：Yes, that is when I became hooked. When we test and evaluate a new product, we work with the Design Department to create strategies and learn more through repeated testing. I would like to keep bringing safe and reliable products for automobiles to the world!

Y.M：The quality assurance work covers a wide range, including reviews at the design stage, investigations into in-process defects, and responding to customer complaints, but the issue is that work is dependent on certain people. Rather than relying on individual skills, it is important to create systems that allow anyone to evaluate using data.

I.M：In order to do that, we must create an environment that makes it easy to use data. I want to be able to quickly retrieve data with recorded and accumulated information that can be used as a basis for judgment. If we incorporate AI, I think we will be able to ensure quality more efficiently.

Y.M：Then, everyone will have more time to further improve their skills, and as a result, we should be able to meet more quickly and reliably the quality that our customers are looking for. I hope we can build such a good cycle.