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Interteks Global Automotive CapabilitiesIntertek provides a wide range of testing and research services for automotive relatedindustries, including engines, components, fuels, lubricants, chemicals, engineering and
certification activities. Intertek automotive services are available through our internationservices network and include:
Testing is provided in labs around the world, including Detroit, Grand Rapids, Boston,Pittsburgh, Houston, San Antonio, Minneapolis, Cortland and Shanghai.
n this issue:
Welcome
page
lcome 1
erteks Global Automotive Capabilities 1
erteks FMVT (Failure Mode Verificationsting): A Solution for Warranty Problems 1
MVT Warranty Success Stories 2
ertek Leads the Industry inLSD Testing Service Capabilities 2
ertek Expands Testing Capabilities with
Aquisition of Automotive Research 3
ertek Offers Automotivemarking Services 3
ertek Opens New Automotive Test Lab Shanghai 4
ertek PARC Automotive Testing:oviding World-Class Services to Clients 4
V (End-of-Life Vehicles) Directive 5
ertek Biodiesel Testing Capabilitiesd Extension of Services 5
t Intertek 5
Interteks FMVT (Failure Mode VerificationTesting): A Solution for Warranty ProblemsLooking for a solution to warranty
problems? Then Intertek ETLSEMKO Automotive Groups
patented accelerated stress testing
process, FMVT, may be just what
you need!
Typically, there are two kinds of
warranty problems: 1) A product
problem that made it through the
development process into the field,
and 2) A production problem that
developed after production started.
Our focus is on the first type ofwarranty problem and how the
FMVT process can be used as a
tool to quickly uncover the
cause(s) of the problem. Warranty
problems rooted in the design of
the product are very difficult to
identify. Traditional testing is
based on hypotheses that state
what failure modes should occur
based on historical trends and
under expected service conditions.
Welcome to the first issue of
he Intertek Automotive Update
ewsletter. The Update is a
orum for news, happenings
nd information in the world
f Automotive Testing andngineering. We welcome our
eaders input and participation
n this forum. If you have
uestions to be addressed in a
uture issue, or article suggestions,
lease send inquiries to
AutomotiveAutomotive
A p r i l / M a y 2 0 0 6
tek Automotive Update newsletter, page 1
-Accelerated Stress
Testing
-Automotive
SystemsCertification
-Component
Testing
-Development
-EMC Testing
-Emissions Testing
-Engineering
-Engine Testing
-Failure Analysis
-Fluids Testing
-Fuels Testing
-Lab Outsourcing
-Lubricant Testing
-Materials Analysis
-Performance
Testing
-Powertrain Testing
-Product Evaluation
-Product T
-Program
Managem
& Valida-Supply C
Services
Continued page 2
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However, what happens when non-intuitive failure modes make it into the final product?
Answer:Additional warranty problems.
How can these types of warranty problems be reduced?
Answer: FMVT
FMVT, as a test process, reduces design related warranty issues by identifying non-intui
failure modes. These non-intuitive failure modes are identified by testing the product a
expected service conditions as well as at combinations and levels above and beyond the
expected.
Solving a non-intuitive warranty problem is an attempt to discover something that has n
been seen in this context before. Design the test to provide the most information possi
(FMVT) and keep an open mind for the spark of information that will give a clue to the
problems solution.
Three Step Process to Solving a Warranty Problem:
1) Problem Isolation: Identify the type of warranty problem that exists; a product(design) problem or production problem.This can be done by submitting problem parts for Failure Analysis (FA). FA can determ
there are any production problems causing issues in the design (knit lines, fiber orientat
hardness variations, etc.). Failure Effects Analysis (FEA) can often help with this effort.
2) Proposed Design or Process Change: An FMVT should be set up and conductewith as many stress sources and operational checks as is practical.
The FMVT should be run without any bias towards a predetermined hypothesis.
Run the FMVT and conduct the failure analysis. Compare these results to original FA.
Unbiased hypotheses should be developed and ranked based on all information, not jus
supporting information.
3) Validation of Change: With all information collected, a comparative FMVT isconducted with stress sources limited to those necessary to reproduce the correct
failure modes at levels that will be quick and repeatable.
FMVTWarranty Success Stories1. Exhaust System Catalytic Converter Support BracketThe product was failing on the test track at 50,000 miles, which was a potential warrant
issue if carried into production. Our client utilized FMVT to quickly evaluate two de
revisions to correct the problem.
The result? FMVT replicated the 50,000 mile test track failure in 180 minutes.The lower cost of the two design revisions was proven viable by FMVT and laterran 150,000 miles on the test track without failure.
2. Automotive Interior Cockpit ModuleAn FMVTwas conducted on an entire cockpit module, including instrument panel, pe
hood release, HVAC outlets and power steering.
The result? 62 potential failure modes were found in just 14 hours of testing.41 of the 62 would likely not have been identified through conventional test methEight of these failure modes had warranty or service bulletin history.
3. Interior Cup HolderThis product had been thoroughly tested using conventional testing. The samples passe
with no failures.
The product was then tested using FMVT.
The result? 7 failure modes, 2 of which were significant warranty concerns.
To discuss how FMVT can resolve a specific warranty issue, or learn more about the
process, contact us at 1-800-888-3737 or [email protected]
Interteks FMVT (Failure Mode Verification Testing): A Solution for Warranty Problems Continued from
ntertek Leads thendustry in ULSDTesting ServiceCapabilitiesntertek Caleb Bretts laboratory network
n the United States have the competitive
dge in the ULSD (Ultra Low Sulphur
Diesel) Testing Services arena and are
prepared to support the forthcomingULSD transition in the diesel fuel supply
hain. We have worked diligently for the
past eighteen months participating in the
alidation processes with EPA to ensure
he diesel market, including producers,
pipeline/terminals, importers and
etailers, can effectively implement quality
oversight programs regardless of regional
placement. Currently 19 laboratories
have validated Sulfur Testing methods,
with two additional sites pending
validation. Included in the 19 sites areacilities located in the Canada and in
Puerto Rico. Sampling kits are available
or non-urgent analyses to service those
lients in remote regions. These kits
will be available online or by direct
order from the closest Intertek Caleb
Brett participating laboratory.
Additionally, Intertek is actively partici-
pating in industry events including the
OPIS ULSD Summit, the ongoing EPA
ound robin program, and are holding
nformational workshops to educate thelients relative to the industry changes
nd progress of the ULSD transition.
The closest date of responding at this
point in the transition is June 1, 2006
where refiners and pipeline/terminal
operators will be required to perform
ulfur testing on production products
nsuring contamination issues have been
minimized to a point allowing ULSD
ulfur levels at the retail point to be
delivered at
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ntertek Expands Testing Capabilities with thequisition of Automotive Researchtomotive Research (AR), in San Antonio, TX, was acquired by Intertek in October, 2005.unded in 1953, the early days of the company were focused on tire testing. AR eventuallypanded into testing vehicles and engines (and their components) as well as testing fuels andbricants using vehicles, engines, analytical instruments and bench rigs. AR was privatelywned until 1973 when the company was sold to EG&G. EG&G changed its name torkinElmer in 1998 after acquiring the PerkinElmer Analytical Instruments Division.
urrently, ARs primary testing focus is on fuel and lubricant qualification. Have you ever
oked on a quart of oil and noticed the American Petroleum Institutes (API) doughnutal? In order for a lubricant manufacturer to use that seal, the oil they are qualifying mustss a battery of tests. These tests are only offered at two independent laboratories in thenited States, AR being one of them. The cost to qualify a gasoline engine oil is $150,000;ple that figure for a diesel engine oil. What tools and equipment does AR use to qualifyose oils? AR has roughly 40 dynamometer based engine test stands that dedicated to the task, as well as an 8,000 square foot chemistry lab thatrforms over 25,000 analytical and bench qualification tests per month.
addition to the fuel and lubricant qualification business, AR has severalher testing areas including:
An automatic transmission fluid test lab that houses roughly 20 benchrigs that are used to qualify automatic transmission fluids.
A vehicle fuel systems and components lab which houses a variety of test rigs,environmental chambers, and SHEDs (sealed housing for evaporative determination).The primary focus of this lab is to test the integrity of vehicle fuel systems and componentsand the tendency of those systems and components to emit (permeate) hydrocarbons (fueln a gaseous state).
An engine and engine component testing lab. In this lab, nine dynamometer based enginetest stands are used to test engines and engine components provided by the gasoline anddiesel engine manufacturers and their suppliers.
addition to the various testing areas, AR has an extensive support infrastructure that helpskeep the 24/7/365 operation going. This infrastructure includes:
Engine Build - Engine block and cylinder head build areas.
Rating Department - Visual rating of engine parts.
Metrology Lab - Performs measurements required for engine blueprinting.Equipment includes dimensional gauges, roundness, flatness, surface finish, hardness,coordinate measurement machine and weight scales.
Calibration Lab - Performs instrument calibrations for all of ARs labs.
Project Engineering- Performs engineering for new test stand installations andconversions, and design of test rigs.
Instrumentation Shop - Engineering and technician support for all test stand andengine electrical/electronic controls.
Electric, Welding, Machine, Plumbing and Construction Shops - Performs testcell conversion, installation and repair.
Information Systems - Provides support for test cell automation, database operations,test process automation and customer data communication.
Photographic Services - Complete digital imaging using photo booths, in-lab shootingand borescope photography.
Client Services - Performs data retrieval, test report generation and transmissionto customer.
Parts Stock- Maintains an inventory of spare parts for engines and test cells.
Fuel Handling- Over 300,000 gallons of fuel tank storage.
sitors are always welcome at AR, please contact us at 210-684-2310 to arrange a tour.
r more information, seewww.ar.intertek-cb.com or email [email protected]
Intertek OffersAutomotivee-marking Services
Intertek has four locations in North
America offering e-marking services to
the automotive industry, including
Boston, MA and Minneapolis, MN for
EMC testing and Cortland, NY and
Grand Rapids, MI for lamp componen
testing. These labs have been accepted
Technical Service Suppliers (TSS) to th
Vehicle Certification Agency (VCA),
allowing Intertek to certify automotive
components for sale in Europe.
As a Technical Service Supplier, Interte
can provide all the necessary informatio
for assessment, documentation, testing
and reporting. This enables theApprovals Authority to issue relevant
Type Approval Certificates to the
applicant through the Technical Service
Supplier rather than it being directly
involved. This makes the whole
process of obtaining an e-mark on an
automotive component more efficient
and cost effective.
Type approval is the confirmation that
production samples of a design will mespecified performance standards.
Automotive EC Directives and ECE
Regulations require third party
approval - testing, certification and
production conformity assessment
by an independent body. Each Member
State is required to appoint an Approva
Authority to issue the approvals and
a Technical Service to carry out the
testing to the Directives and Regulation
An approval issued by one Authority
will be accepted in all the Member Stat
VCA is the designated UK Approval
Authority and Technical Service for all
type approvals to automotive EC
Directives and ECE Regulations.
For more information, contact
Linda Hall at 800-888-3787 or
tek Automotive Update newsletter, page 3
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Intertek PARC Automotive Testing:Providing World-Class Services to ClientsOnce considered Gulf Oil Corporations premier Automotive Testing facility, Intertek P
Automotive Testing (ATS) continues today as one of the leading INDEPENDENT statthe-art Testing Facilities available world-wide. Since 1986, PARC ATS has provided tesservices to major oil companies, leading OEMs and lube oil and additive manufacturers
Our employees have the technical expertise and skills required to meet the quality testindemands of our customers. In February 2003, PARC ATS was ISO 17025 Certified anremains accredited today.
Intertek PARCs ATS facility consists of 29,000 square feet with 50,000 gallons of fuelstorage capacity. The main test area contains twenty individual testing cells and supportfacilities. A central control corridor features individual centers consisting of data logginand computer controls for operation of each testing area. Electrical and water brakedynamometers are available from 5 H.P. to more than 500 H.P.
A four-lane programmed road simulator is available for performance testing of passengecars or light trucks. The chassis dynamometers are large roll-type units, or a rolling roa
A remote-controlled mechanical inertia system and an air blower are used to simulate roload test conditions.
The test facilities can be altered and/or special test equipment can be designed and instato accommodate specific test conditions to satisfy customers requirements. Examples winclude 2-cycle or 4-cycle engines; 1, 4, 6 or 8 cylinder engines and unique customer teconditions.
Gear Lubricant TestingThe L-33 is a referenced test that evaluates the rust and corrosion inhibiting propertiesof a gear lubricant. The test is run using a DANA Model 30 hypoid differentialhousing assembly.
The L-37 evaluates load carrying capabilities of a lubricant under conditions of low speeand high torque. Also, a referenced test, a DANA Model 60 hypoid differential, can beoperated with either lubrited or non-lubrited gears. This test can be run at standard, lowtemp., high temp. or wet.
Using a DANA Model 44 hypoid rear axle, the L42 test (also a referenced test) is usedto determine the antiscoring properties of gear lubricants under high speed and shockconditions. This test can be run at standard, low temp., high temp. or wet.
The ASTM D5579, or better known as the HTCT (also a referenced stand) evaluates htemperature thermal stability of fluids in a Mack manual transmission. The test can opeuntil failure is reached or to a length of time predetermined by the customer.
The FZG Scuffing test, or ASTM D5182, can be adjusted to meet the requirementsof our customers.
The scuffing test evaluates mildlyadditized industrial gear oils resistanceto scuffing on spur gears. A 13th stage can be added for more robust fluids.
The FZG Micro-Pitting test determinesa lubricants resistance to micro-pittingon spur gears. The FZG Pitting test is used to evaluate resistance to pitting on special sgears.
The FZG High Performance Scuffing testuses a special A-10 spur gear to determinea lubricants ability to resist scuffing.
Gear LubricantScreening TestsThe following three tests are used tostudy lubricants under simulatedhighway conditions.
Low speed/high torque heavy dutytruck axle evaluation
Spalling test using a 150 H.P. or a 250
H.P. electric motor
ntertek Opens NewAutomotive Test Labn Shanghai
To expand its global automotive testing
apabilities, Intertek opened a new
utomotive component and systems
est lab in Shanghai in 2005, the first
ommercial lab of its kind in China.
The new facility, Intertek Automotiveervices, is located in the Pudong Region
of Shanghai, with 40,000 square feet of
vailable space. The lab has initially
ocused on automotive performance
esting, primarily for electronics, audio
nd interior components, including:
Vibration (sine, random, shock)
Thermal Aging (walk-in chambers,drive-in chambers)
Thermal Cycling
Programmable Chamber Exposures Temperature, Humidity
BSR (Buzz, Squeak, Rattle)
n 2006, expansion plans are underway
or the addition of EMC testing.
t is anticipated that three EMC/EMI
hambers (Reverberation chamber,
CISPR 25 chamber, and 3meter/
CISPR 25 combination chamber) will
be operational by May 1, 2006.
ntertek Automotive Services also offersngineering / product development,
program management, technical liaison
nd support with North American
OEMs and suppliers, supply chain
development/supplier audits and
public & on-site training (EMC,
DFMEA, DVP&R, APQP, AST, ISO/
TS 16949). The lab can be contacted at
011 86 21 5031 9089 or e-mailed at
The website iswww.intertek-automotive.com.
tek Automotive Update newsletter, page 4
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ntertek Biodiesel Testing Capabilitiesand Extension of ServicesAs biodiesel production soars in the U.S. and abroad, the Intertek Caleb Brett
division is aligning our service packages, capabilities and support sites to meet
he ever growing changes to the industry. Currently, Intertek Caleb Bretts
aboratory network has six sites supporting full ASTM D6751 testing. We
have worked extensively to ensure the standardization of our method performance
o improve comparative data from production to distribution points. Full
EN 14214 specification testing is available through the Intertek CB Deer ParkTechnical site for producers that will be exporting the biodiesel product abroad.
ntertek Laboratories supporting Biodiesel testing include Deer Park Technical Center
Houston, Texas), New Orleans Technical Center (St. Rose, Louisiana), Carteret,
New Jersey, Chicago, San Franscisco and Hamilton, Ontario. To discuss biodiesel
esting programs, please contact the Laboratory Business Development Group at
[email protected] or our inquiry center at 713.844.3263.
ELV (End-of-Life Vehicles) DirectiveWhat is the End-of-Life Vehicles Directive?
n September 2000, the European Parliament passed the European UnionEnd-of-Life Vehicles (ELV) Directive, a set of requirements related to the storagend recycling of vehicles after they are no longer in use (Directive 2000/53/ECf the European Parliament and the Council of the European Union). This directiveequires that vehicle manufacturers provide the information needed for dismantlingvehicle, such as details of vehicle components and location of hazardous
ubstances, to authorized recycling facilities.
What Do OEMs and Suppliers Need To Do?
OEMs must comply with the End-of-Life Vehicles (ELV) Directive of theEuropean Union by reporting a great deal of information about materials, partsnd systems that OEMs manufacture and assemble. In order for OEMs to comply
with this directive, it is necessary that the supply chain be engaged as part of theeporting process.
uppliers must report on specific chemicals found in the materials, parts andystems they manufacture and assemble. In its most complete form it requires
material constituent disclosure for all raw materials used in all components andssemblies that comprise a vehicle. To do this, a chain of information must be builtrom the final vehicle assembly all the way back through parts manufacturing to theaw materials.
ELV Compliance Limits Overview:
Lead limits 0.1 % (1,000 ppm)
Mercury limits 0.01 % (1,000 ppm)
Chromium (VI) limits 0.1 % (1,000 ppm)
Cadmium limits 0.01 (100 ppm)
Limits are applied to homogenous material, provided that these substances arenot intentionally introduced, meaning deliberately utilised in the formulationof a material or component where its continued use is desired for the finalproduct to provide a specific characteristic, appearance or quality. Use of recycledmaterials containing a portion of these restricted metals is permitted by not beingconsidered an intentional addition.
Learn more regarding Intertek ELV related services:
http://www.intertek-cb.com/newsitetest/services/ARL/elvcomplianceservices.shtml
L-37 Procedures - 150 H.P. electric mo
Ancillary Services Include:
Computer Programming
Photography (of completed testing resu
Engineering
Report Generation
Certified ratings for all in-house laboratesting procedures as
well as field studies.
Future issues will focus on specific testingareas with more detailed information.
We also plan to introduce you to eachmember of our dedicated staff. Theirexperience and our versatile equipmentpermit independent, confidential, timely,customized and cost-competitive testing.
Visit the PARC website atwww.intertek-cb.com for informationon our services, or contact us at
CONTACT INFORMATIOIntertek plc:
www.intertek.com
Intertek ETL SEMKO:www.intertek-etlsemko.come-mail: [email protected]
Intertek ETL Entela:www.intertek-etlentela.come-mail:[email protected]
Intertek Caleb Brett:www.intertek-cb.come-mail: [email protected]
tek Automotive Update newsletter page 5 2006 Intertek
AutomotiveAutomotive
Intertek PARC Automotive Testing: Continued fromProviding World-Class Services to Clients
About Intertek
Intertek is a leading international
testing, inspection and certification
organization, which assesses custom
products and commodities against a
wide range of safety, regulatory, qu
and performance standards and ce
the management systems of custome
Intertek has over 300 laboratories a
over 15,500 people around the world
is increasingly undertaking outsou
testing work for its customers.
mailto:[email protected]:[email protected]://www.intertek-cb.com/newsitetest/services/ARL/elvcomplianceservices.shtmlhttp://www.intertek-cb.com/newsitetest/services/parc/automotive.shtmlmailto:[email protected]:[email protected]://www.intertek.com/http://www.intertek.com/http://www.intertek-etlsemko.com/mailto:[email protected]://www.intertek-etlentela.com/mailto:[email protected]:[email protected]://www.intertek-cb.com/mailto:[email protected]:[email protected]://www.intertek-cb.com/mailto:[email protected]://www.intertek-etlentela.com/mailto:[email protected]://www.intertek-etlsemko.com/http://www.intertek.com/mailto:[email protected]://www.intertek-cb.com/newsitetest/services/ARL/elvcomplianceservices.shtmlmailto:[email protected]://www.intertek-cb.com/newsitetest/services/parc/automotive.shtml