Malaysian Vehicle Assessment Programme PROTON – A 4

Transcription

MER 09/2009
MIROS Evaluation Report
Malaysian Vehicle Assessment Programme
PROTON
– A 4-Star MPV in Safety
HICOM Industrial Estate, Batu Tiga, Shah Alam, Selangor, Malaysia
Aqbal Hafeez Ariffin
Zulhaidi Mohd Jawi
Yahaya Ahmad
Mohd Syazwan Solah
Fazli Yusof
PROTON EXORA – A 4-star MPV in Safety
MER 09/2009
PROTON
– A 4-Star MPV in Safety
Zulhaidi Mohd Jawi
Yahaya Ahmad
Mohd Syazwan Solah
Fazli Yusof
i
MIROS © 2009 All Rights Reserved
Published by:
Malaysian Institute of Road Safety Research (MIROS)
Lot 125-135, Jalan TKS 1, Taman Kajang Sentral,
43000 Kajang, Selangor Darul Ehsan.
Perpustakaan Negara Malaysia
Cataloguing-in-Publication Data
Malaysian vehicle assessment programme Proton Exora : a 4-star
MPV in safety : HICOM Industrial Estate, Batu Tiga, Shah Alam, Selangor,
Malaysia / Aqbal Hafeez Ariffin ... [et al.].
(MIROS evaluation report)
ISBN 978-983-44643-6-3
1. Automobiles--Crashworthiness. I. Aqbal Hafeez Ariffin. II. Siri.
629.231
For citation purposes
Aqbal Hafeez A, Zulhaidi M J, Yahaya A, Mohd Syazwan S & Fazli Y (2009), Malaysian
Vehicle Assessment Programme PROTON EZORA – A 4-Star MPV in Safety, MER
09/2009, Kuala Lumpur: Malaysian Institute of Road Safety Research.
Printed by: Publications Unit, MIROS
Typeface : Book Antiqua
Size
: 11 pt / 15 pt
DISCLAIMER
The information contained in the report is restricted and/or privileged information and is
intended only for authorized screening and/or confidential presentation of MIROS’s discretion.
This report should not be disseminated, modified, copied/plagiarized or action taken in reliance
upon it, unless permitted by MIROS. None of the materials provided in this report may be used,
reproduced or transmitted, in any form or by any means, electronic or mechanical, including
recording or the use of any information storage and retrieval system, without written permission
from MIROS. Any conclusion and opinions in this report may be subject to reevaluation in the
event of any forthcoming additional information or investigations. MIROS declares that all the
inquiries which MIROS believes are necessary and appropriate and that nothing significance
which MIROS regards as relevant have, to MIROS knowledge, been withheld from the report.
Contents
Page
List of Table
v
List of Figure
vii
List of Plates
vii
List of Abbreviation and Acronyms
ix
Acknowledgements
x
Abstract
xi
1. Introduction
1
2. Objective
2
3. Assessment Background
2
4. Assessment Criteria and Evaluation Approach
5
5. PROTON EXORA at a Glance
8
6. Implementation of MyVAP
11
7. Result Discussion
14
8. Evaluation of the Assessment Scheme 15
9. Conclusion
17
References
18
Appendix
19
iii
List of Tables
Tables
Page
Table 4-1
Point distribution for evaluated Pillars
11
Table 4-2
MIROS safety recognition according to range of scores
11
Table 4-3
QS-9000 elements
12
Table 5-1
Technical specifications and vehicle features
15
Table A-1
Haddon Matrix for 2006-2010 Road Safety Plan
(Radin Umar, 2007)
v
24
List of Figures
Figures
Page
Figure 4-1
Phases of a crash event
9
Figure 4-2
MyVAP assessment items
10
Figure 5-1
EXORA body structure – High Tensile Steel Cage (red),
Side Impact Bars (green) and Hydro Forming
Sub-Frame (orange)
14
Figure 6-1
Assessment team organization chart
16
Figure 7-1
4-star rated PROTON EXORA
20
vi
List of Plates
Plates
Page
Plate 3-1
Example of EuroNCAP crash test involving
Hyundai i20 (Source: euroncap.com)
Plate 5-1
The first entirely “Malaysian Made” MPV – PROTON
EXORA
Plate 6-1
Discussion between MIROS and PROTON
representatives on Passive Safety
17
Plate 6-2
Test report evaluation process
17
Plate 6-3
PROTON’s R&D-HTP General Manager,
YM Tengku Azizan Tengku Ahmad, signing
the Audit Result letter
vii
8
13
18
List of Abbreviations and Acronyms
ABS
ADR
BCM
CAMPRO
CBU
CKD
COP
CRASE
DOHC
EBD
MIROS
MOT
MPV
MyVAP
NCAP
ODB
PERODUA
PROTON
RMK-9
JKJR
JPJ
SOP
SUV
TSP
UNECE
VKT
VSB
VTA
Anti-lock Braking System
Australian Design Rules
Body Control Module
Cam Profile (PROTON’s Engine)
Complete Built Unit
Complete Knock Down
Conformity of Production
Crash Safety Engineering Unit of MIROS
Double Overhead Cam
Electronic Braking Distribution
Malaysian Institute of Road Safety Research
Ministry of Transport
Multi-Purpose Vehicle
New Car Assessment Programme
(e.g. US-NCAP for USA, Euro NCAP for Europe, ANCAP for
Australia)
Offset Deformable Barrier
Perusahaan Otomobil Kedua Berhad
Perusahaan Otomobil Nasional Sdn. Bhd.
Rancangan Malaysia Ke-9 (9th Malaysian Plan)
Road Safety Department
Road Transport Department
Standard Operating Procedure
Sports Utility Vehicle
Technical Service Provider
United Nations Economic Commission for Europe
Vehicle-Kilometre Travelled
Vehicle Safety and Biomechanics Research Centre of MIROS
Vehicle Type Approval
viii
Acknowledgements
This assessment would not have been possible without the considerable
support and cooperation, as well as enthusiasm of many talented people, who
have played a part, directly or indirectly, throughout the event. The authors
would like to express their sincere gratitude to the following individuals.
Perusahaan Otomobil Nasional Sdn. Bhd. (PROTON)
• Dato’ Mohd Nadzmi Mohd Salleh
Chairman
• Dato’ Haji Syed Zainal Abidin Syed Mohamed Tahir Managing Director
• Tuan Ir. Haji Tajul Zahari Abu Bakar
Director of
Engineering Division
• YM Tengku Azizan Tengku Ahmad
General Manager,
R&D & HTP,
Engineering Division
• PROTON Engineering (R&D) and Production & Quality Divisions
Malaysian Institute of Road Safety Research (MIROS)
• Prof. Dr. Ahmad Farhan Mohd Sadullah
Director General
• Assoc. Prof. Dr. Wong Shaw Voon
Director of VSB cum
Audit Advisor
• Khairil Anwar Abu Kassim
CRASE Unit Head
cum Lead Auditor
• PROTON EXORA Safety Assessment Team
Members
Crash Safety
Engineering Unit
• Publications and Knowledge Management Unit
ix
Abstract
Malaysian Vehicle Assesment Programme (MyVAP) was developed by the
Malaysian Institute of Road Safety Research (MIROS) to improve vehicle
safety level in Malaysia. This assesment is conducted to increase awareness
among local road user regarding vehicle safety, particularly in acquiring
roadworthy and crashworthy vehicles. Currently, MyVAp is conducted
according to non-destructive methods as opposed to similar programme in
several other countries whereby destructive tests are performed to evaluate
vehicle crashworthiness. Hence, with the cooperation of PROTON, MyVAP
performed its first assessment on PROTON's latest model, PROTON EXORA.
This report will explore the overall assessment process in terms of its
relevancy and motivation, the process involved throughoout the programme,
and finally, discussion of this first assessment and future enhancement. It
also functions as a reference for general public with regard to this assessment
and the results for PROTON EXORA. MyVAP for PROTON EXORA has
successfully achieved its main objective of evaluating safety performance
of PROTON EXORA which covered: (1) safety of product used (compliance
to the United Nations of Economic Commission (UNECE) regulations;) (2)
passive safety level of the tested EXORA: (3) provision of active safety system;
and (4) conformity of production. The assesment was an excelent initiative
between MIROS and PROTON towards educating motoring consumers on
the importance of safety. Improvements of road safety in Malaysia particulary
in vehicle safety segment will always be uncertain without such initiative.
The final result of assessment proves that PROTON EXPRA deserves to be
awarded the title of "MIROS Safety Companion" for achieving 4-star rating
out of a total of five stars.
xi
1.
Introduction
MyVAP, the acronym for Malaysian Vehicle Assessment Programme, was
created by MIROS to improve vehicle safety situation level in Malaysia.
This assessment is conducted to increase awareness among local road users
with regard to vehicle safety, specifically in acquiring roadworthy and
crashworthy vehicles. MyVAP at this moment is conducted according to
non-destructive methods as opposed to similar programme in many other
countries whereby several destructive crash tests are performed to evaluate
vehicle crashworthiness.
There is no doubt that vehicle regulations have strong influence on safety.
However, new introduction in the policy to improve vehicle safety will
definitely involve complex technical, social and financial considerations.
Conclusive consumer information will be the best solution to drive vehicle
safety at the moment as this will also motivate vehicle manufacturers to
improve their product thus creates healthy competition. MIROS believes this
effort will be able to pave the way for new vehicle safety era in Malaysia, which
at the same time, provide our consumers with value-for-money products.
PROTON, one of the national car makers, is the first to offer its brand new
th
MPV th
to be evaluated
and thus has enabled MyVAP to be launched. The MPV,
PROTON EXORA, is also claimed to be the first MPV ever fully-developed
in the country. The assessment was conducted in a two-day programme
on 15 and 16 June 2009, about two months after EXORA was officially
launched and made available in the local market. The auditing team consisted
of a team of engineers from MIROS, namely members of the Crash Safety
Engineering Unit (CRASE). PROTON as the audited party was represented
by its management personnel and engineers.
This report explains the entire process including the motivation behind the
assessment, structure of the MyVAP scheme, assessment result as well as
recommendations to strengthen the scheme as this was the first time it was ever
applied in Malaysia. It is hoped that MyVAP will become a successful tool to
enhance our road safety agenda that could match with other accomplishment
by Malaysia in many other fields.
1
2.
Objective
The main objective of this report is to recapitulate and evaluate the historic
event in the Malaysian automotive industry as a team of engineers from
MIROS in June 2009 had assessed the safety level of PROTON EXORA by
means of the MyVAP non-destructive assessment scheme. The whole report
will scrutinize the overall assessment in terms of its relevancy and motivation,
the process and at the end, an overall discussion of this first assessment and
future enhancement. This report also functions as a reference for the general
public regarding this assessment and the results for PROTON EXORA.
3.
Assessment Background
The Ministry of Transport (MOT) published “The Road Safety Plan 2006 –
2010” (Road Safety Plan or the plan) in 2006 as the foundation to achieve
several targets in the period of theth9 Malaysian Plan (RMK-9). The plan
was prepared and is monitored by the Road Safety Department (JKJR) –
departmentunder the Ministry of Transport. The plan has identified nine
strategies that included education, engineering and enforcement as the
intervention basis. The plan’s accomplishments at the end of the RMK9 period will be gauged by the achievements in these three internationally
recognised safety indices:
1.
2.
3.
2 deaths per 10 000 vehicles;
10 deaths per 100 000 population; and
10 deaths per 1 billion vehicle-kilometre travelled (VKT).
The establishment of the Malaysian Institute of Road Safety Research
(MIROS) in 2007 exemplifies the commitment of the government to enhance
road safety in the country, namely via evidence-based research. One of the
institute’s responsibilities, among others, is to realize the soon-to-end Road
Safety Plan. Radin Umar (2007), who was the first MIROS Director-General,
had summarised the intervention elements from the plan in a Haddon matrix
(Table A-1 in Appendix A). The matrix, which is divided into road, vehicle
and human intervention basis, also presents road accident in a chronological
point of view – pre-, during and post-crash.
Vehicle safety has been identified as one of the niche areas in vehicle’s preaccident intervention, which corresponds to the plan’s Strategy No. 3 –
Enhance and Complement Engineering Initiatives. MIROS, through one of
its research wings, the Vehicle Safety and Biomechanics Research Centre
(VSB), has initiated a preliminary effort to realise this specific objective. In
addition, the groundwork and execution of this specific cluster’s objectives
has been carried out by one of VSB’s units – the Crash Safety Engineering
Unit or CRASE.
2
The status quo of Malaysia’s vehicle regulations is yet to reach satisfactory
level, especially if compared to the situation in developed countries. The
weak points can be identified in many of the related regulations, including
Vehicle Type Approval (VTA) that has a lot of gaps to be improved. Malaysia
has recently been accepted as one of signatory members of the United Nations
Economic Commission for Europe (UNECE) for the transport sector, where
vehicle technical requirements are discussed for harmonization purposes.
However, the adoption process of more than a hundred regulations into
Malaysia’s domestic legislation still has a long way to go. Nevertheless, the
progression in the legal requirements at the moment, which for the most part
is conducted by the brand new Automotive Engineering Division of Road
Transport Department (JPJ), is indicating a positive development.
MIROS, a close partner to JPJ in the subject matter, also has another plan. The
initiative, which for the time being goes by the name of Malaysian Vehicle
Safety Assessment Programme (MyVAP), is a complement to the prevailing
vehicle regulations and acts as a “booster” towards the provision of safe
vehicles in the local market. MyVAP basically is adopting the gist of the New
Car Assessment Programme (NCAP) – a car crashworthiness rating scheme
that was first introduced in the United States (US NCAP) and later on, put
into practice in other regions such as Australia (ANCAP) and Europe (Euro
NCAP). NCAP in these countries is primarily dedicated to educating the
consumers, whereby it helps them in choosing the best car with regards to
vehicle crashworthiness. This is because NCAP requirements will always
be superseded by existing legislations that inevitably have to compromise
with trade and economic barriers. It is hoped that MyVAP will be at par with
NCAP in the future, but a down to earth approach that suits the domestic
automotive atmosphere will be the utmost consideration in MyVAP.
How NCAP is implemented and how will MyVAP be different from NCAP?
NCAP assessment to a certain extent is fairly “robust” especially for vehicle
manufacturers since the results of destructive crash tests, which assess vehicle
crashworthiness in several collision configurations, will be made public. The
test programme basically consists of frontal impact, side and pole impact, and
pedestrian protection. However, the test procedures and configurations vary
between NCAPs (Plate 3-1). The test results will eventually be presented in
star-rating scheme e.g. 5 stars will be the best possible score in Euro NCAP.
This perhaps would be handy for customers to interpret the test results as the
technical terms might not be easy to understand.
The current scheme of MyVAP, on the other hand, will not involve destructive
tests at all. Instead, it will only assess the process of development and
production of a specific car model, for which the details can be found in the
following chapters. Several in-house workshops had been conducted in 2008
involving representatives from the national car manufacturers – PROTON
3
and PERODUA. The process eventually produced the anticipated outcome – a
matrix of non-destructive assessment elements. MyVAP assessment also uses a
star rating scheme but the implementation as of today differs from approach by
NCAP. MyVAP at the moment is an option for car manufacturers, assemblers
(CKD) as well as traders (CBU) to obtain safety recognition from MIROS for their
specific model.
Can MyVAP benefit the customers as what NCAP has achieved today? In
reality, NCAP cannot escape from criticisms due to certain limitations in its
test procedures and results. NCAP, whose original intention is to educate
consumers, is also an excellent selling point in car advertising which benefits car
manufacturers. Another argument is that NCAP by no means could reflect the
many possibilities for a road accident to occur. The different categories according
to vehicle mass and body shape made it impossible to compare the outcome of
a collision between two vehicles of different categories with similar rating e.g.
the outcome of a small family car versus a large SUV with both are rated 5-stars
in a frontal collision. Furthermore, there are also fears that cars will be built with
stronger frontal structure that in turn will cause more damages and injuries in
minor collision (SWOV, 2007).
Nevertheless, NCAP by virtue of its stricter requirements has inspired
manufacturers to build safer cars either to sustain their reputation or at the same
time gaining good impression by customers. As a result, NCAP has increased
the population of high quality vehicles on the road. A study by Lie and Tingvall
(2002) had found that cars rated three to four stars are 30% safer in car-to-car
collision compared to two-star or non-NCAP rated cars. And even though NCAP
has not yet proven as the best tool to gauge the overall vehicle safety, there are
lot of improvement can be seen at least to car manufacturers to provide quality
products that worth buying. In short, MyVAP can be considered as taking the
baby steps towards the same motivation as NCAP in educating consumers as
well as complementing the domestic vehicle legislations.
Plate 3-1Example of Euro NCAP crash test involving Hyundai i20
(Source: http://www.euroncap.com/results/hyundai/
i20/359.aspx Accessed July 2009)
4
4.
Assessment Criteria and Evaluation Approach
A road accident can be divided into three phases: pre-, in-, and post-crash. In
order for a vehicle to be declared as “safe”, it needs to provide the features that are
capable of assisting in collision avoidance during the pre-crash phase, mitigating
the injury during in-crash phase and providing easy access to vehicle during the
post-crash phase (Figure 4-1).
Active Safety
Crash
Crash Probability
Normal
Driving
Information-/
Warning Systems
Assistance
Systems
Pre-crash,
reversible
Protection
Systems
Crash Systems
for minimal
crash
Collision Avoidance & Collision Mitigation
Assistant
Passive Safety
PRE-SAFE
Assistant, Warning
Irreversible Safety
Systems
(soft level)
Irreversible Safety
Systems
(hard level)
Occupant Protection
Irreversible Protection
Assistant, reversible Protection
Safety Systems
after crash
Rescue
Rescue
Figure 4-1 Phases of a crash event (Source: Vera Lauer)
Safety regulations are drafted to ensure that safety measures will be highly
considered during vehicle development and mass production. It is very important
to develop safer vehicles that provide “self protection” to vehicle occupants since
human deficiencies while operating vehicle can lead to catastrophic incidents. A
good driver can also make mistakes while driving, and thus we need a vehicle
which can assist driving to avoid accidents from happening and also provide
considerable protection to all occupants during an accident. MyVAP assessment
is, thus, based on four key pillars with regards to vehicle safety – UNECE
Regulations, Passive Safety, Active Safety and Conformity of Production (Figure
4-2).
Compliance to the latest amendment in relation UNECE regulations will get
the best possible score for each item; either in terms of products (component)
or vehicle systems. However, other standards and regulations will also be
considered to receive mark according to the pre-determined score definition.
The process of evaluating this pillar includes verifying authentic certificates, test
reports and related documents. There are 46 regulations that have been identified
at the end of the process related to the development of PROTON EXORA.
The level of passive safety relies on secondary data provided from the crash
centre where the PROTON EXORA had been tested in a full-scale crash test. It
is also to be noted that the elements in the previous pillar (UNECE regulation)
also cover passive safety. However, the assessment of passive safety here is much
more "strict" as its frontal and side impact test results are based on Euro Ncap
Protocol 4. Pasive safety evaluations is based on the following items – high speed
crash (frontal and side), child restraint, pedestrian safety and rollover.
5
UNECE
Regulations
Passive
Safety
MyVAP
Active
Safety
Conformity
of
Production
Figure 4-2 MyVAP assessment items
Provision of more accident avoidance mechanisms, which can assist driving
or “take over” vehicle control in certain situations, is hoped to become a main
consideration by car makers to be fitted as “standard” rather than to be “priced”
unnecessarily. Active safety is divided into three groups – Braking, Handling
and Stability; Warning, Visibility and Conspicuity; and Others (declaration base).
As of now, the assessment can be considered as “straightforward” based on
the existence and functionality of declared active safety features. Still, for this
very first MyVAP assessment, PROTON engineers had invited some of MIROS
auditors to personally experience the functionality of the vehicle active safety
features (hard braking, ABS effects etc.) at its proving ground.
Conformity of Production (COP) assesses the production of PROTON EXORA
in its assembly line whereby this pillar is in fact supporting the evidence
of conforming to UNECE regulations. According to UNECE regulations
requirement, conformity of production is compulsory and non-compliance will
result in withdrawal of the granted approval. Therefore, MIROS views COP as
an important criteria in producing safe vehicles.
All pillars will contribute 1 point each, except for passive safety with has 2 points
(Table 4-1), which makes total assessment score of 5 points. In order to determine
the number of stars, the actual score will be matched with the score range as
explained in Table 4-2. In addition, any model which is able to score 3 or 4 stars
6
will be recognised as “MIROS Safety Companion” car while models which are
rated 5-star according to the assessment scheme will be recognised as ”MIROS
Safety Champion”.
Table 4-1 Point distribution for evaluated Pillars
1
2
3
4
Pillar
Compliance to UNECE Regulations
Passive Safety Performance
Active Safety Equipment
Conformity of Production
TOTAL
Point
1.0
2.0
1.0
1.0
5.0
Table 4-2 MIROS safety recognition according to range
of scores
Points (in range)
4.50 - 5.00
3.75 - 4.49
3.00 - 3.74
2.00 - 2.99
1.25 - 1.99
Stars





MyVAP also considers QS-9000 as one of the assessment basis. QS-9000 is the
name given to the Quality System Requirements of the automotive industry
which was developed by Chrysler, Ford, General Motors and major truck
manufacturers and issued in late 1994. The goal for Quality System Requirements
QS-9000 is the development of fundamental quality systems that provide for
continuous improvement, emphasize defect prevention and reduce variation. In
order to obtain QS-9000 certification, a company must first prepare its staff for
the challenge that awaits them. Each employee will have responsibilities under
QS-9000. QS-9000 based elements are provided in Table 4-3. Based on these
elements, the MIROS team set-up its own audit guidelines and specifications that
were divided into two main parts – assessment on documents and on-site audit.
The method of assessing the compliance of the safety product and system
according to UNECE regulations or other standards and regulations involves
reviewing relevant documents. This will include engaging authentic certificates,
test reports and necessary documents for each regulation applied. During
the session, the audit team will work in several distinct groups to review and
validate all necessary documents that would be provided by the audited party.
The working groups would be facilitated by the personnel whom are responsible
for the documents and present explanations in respect to the assessment needed.
7
On-site assessment audits the production capability and performance of a factory
to ensure that only products that pass the required inspections and tests can be
installed in a complete vehicle. During the session, the audit team will visit the
production factory to verify the implementation. There are several safety items
that had been identified such as steering wheel, air bag and others. However,
only some of them will be chosen on the assessment day. Basically, the on-site
assessment is to validate the documents provided earlier in the process with
the production document to ensure the production line complies with the latest
amendments in the design. In addition to that, the audit team will also assess
the standard operation procedure (SOP), system verification, product traceability
and conformity of production (COP).
Table 4-3 QS-9000 elements
QS-9000 Elements
Management Responsibility
Inspection, measuring and test equipment
Quality System
Inspection and test status
Contract Review
Nonconforming product
Design Control
Corrective and preventive action
Document and Data Control
Handling, storage, packaging, preservation and delivery
Purchasing
Control of quality records
Control of Customer Owned Products
Internal quality audits
Product Identification and Traceability
Training
Process Control
Servicing
Inspection and Testing
Statistical techniques
5.
PROTON EXORA at a Glance
PROTON EXORA is the first locally developed and manufactured MPV in
Malaysia (Plate 5-1), and is available as of today in two variants – 1.6 litre automatic
high-line and a 1.6 litre automatic medium-line. It can fit seven adults (up to
188cm height) and for more room, the second and third rows can be arranged
and folded in six different ways, including completely flat. It is equipped with
intelligent electronic Body Control Module (BCM), where all basic or standard
body functions of a car are controlled by one integrated control module, hence,
offering value added features to customers.
8
Figure 5-1 The first entirely “Malaysian Made” MPV – PROTON EXORA
PROTON EXORA is powered by the 1.6 CAMPRO CPS engine with 125 hp (or
92kW at 6500 rpm), 150Nm (at 4500 rpm) torque, and 88.0bhp/ton (at 1422kg)
power over weight ratio. The body structure is designed to meet various impact
tests which comply with internationally recognised standards. Some of the tests
complied to are: ECE R94 equivalent to ADR73/00 for 40% Offset Deformable
Barrier (ODB), ECE R95 equivalent to ADR72/00 for dynamic side impact,
ADR69/00 for full frontal and 2003/102/ECE-Phase II for pedestrian protection.
Its body strength is optimised through extensive application of High Tensile Steel
Cage, side impact bars on all doors for side impact protection and Hydro Forming
Sub-frame Technology for better load impact distribution (Figure 5-1). PROTON
EXORA is also equipped with dual front SRS airbags, and pyrotechnic seatbelts
with pretensioners which come standard for all models. The vehicle is fitted with
Antilock Braking System (ABS) and Electronic Braking Force Distribution (EBD),
and for safety purposes, the hazard light will be automatically activated during
sudden braking at speed surpassing 96km/h. Table 5-1 summarises technical
specifications and features of PROTON EXORA.
Figure 5-1 EXORA body structure – High Tensile Steel Cage (red), Side
Impact Bars (green) and Hydro Forming Sub-Frame (orange)
9
Figure 5-1 Technical specifications and vehicle features
1.6 AT (M-LINE)
Engine
Performance
Chassis
Dimensions
&
weight
Safety
&
security
Other
Feature
1.6 AT (H-LINE)
Model
CamPro CPS 4 Cylinder, DOCH16V
Maximum Output (hp[kW]/rpm
125hp [93 kW]/6,500 rpm
Maximum Torque (Nm/rpm)
150 Nm / 4,500 rpm
Fuel Tank Capacity (I)
55
Maximum Speed (km/h)
165
Acceleration 0-100km/h (sec)
15.5
Power Steering
Hydraulic
Suspension - Front/Rear
MacPherson Strut / Torsion Beam
Brake - Front/Rear
Ventilated Disc / Drum
Tyres & Rims
195/65 R15, Alloy
Overall Lenght x Width x Height (mm)
4592 x 1809 x 1691
Wheelbase (mm)
2730
Kerb Weight
1422
1442
Dual Aorbags witg zPre-tensioner Seat Belt
√
√
Anti-Lock Braking System with EBD + Back
Up EBD (BEBD)
√
√
Immobilizer System
√
√
Central Door Lock Alarm System & Keyless
Remote Entry
√
√
Reverse Sennsors
√
√
Radio with CD, MP3 Player, WMA, Blutooth
√
√
Front & Rear Power Window
√
√
Electric-Remote Sida Window
√
√
Driver's seat Height Adjuster
√
√
Steering Wheel with Audio Switches
√
√
Seat & Door Trim Finishing
Fabric
Leather
Front Fog Lamps
-
√
Rear Spoiler
-
√
Rear Seat Armrest
-
√
Cruise Control
-
√
Navigation System
-
√
DVD/LCD Monitor with SD/MMC Slot & USB
Port
-
√
Tinted Glass
-
√
* All information and graphic presentations in this chapter are provided by PROTON.
10
6.
Implementation of MyVAP
During the two-day safety assessment period, MIROS was represented by a team
of auditors from the CRASE Unit of Vehicle Safety and Biomechanics Research
Centre (VSB). The team, which was supervised by an Audit Advisor and Lead
Auditor, consisted of four groups with two assigned auditors for each, as well as
an assistant auditor to support the whole team. The groups were responsible to
assess all four pillars, namely: Passive Safety, Active Safety, UNECE Regulations’
Compliance and Production Confirmation. Figure 6-1 depicts the organisation
chart of the team.
Director General of MIROS
Prof Dr Ahmad Farhan Mohd Sadullah
Director of VSB cum Audit Advisor
Assoc Prof Dr Wong Shaw Voon
Lead Auditor
Khairil Anwar Abu Kassim
Passive Safety
Yahaya Ahmad (GL)
Noor Faradila Paiman
Active Safety
Zulhaidi Mohd Jawi (GL)
Mohd Hafzi Md Isa
Production Confirmation
Azhar Hamzah (GL)
Mohd Syazwan Solah
UNECE Regulations'
Compliance
Mohd Khairudin Rahman (GL)
Assistant Auditor
Fazli Yusof
* GL = Group Leader
Figure 6-1 Assessment team organization chart
Day one started with an opening meeting between MIROS and PROTON
where the overall assessment procedures were presented by the Lead Auditor
to PROTON representatives and the tentative schedule for the event was later
discussed and finalised. During the meeting, groups of four consisting of
assigned members from both parties were formed to assess the EXORA safety
performance based on the first three pillars, which exclude Conformity of
Production. The three pillars that were assessed are Passive Safety (including
UNECE Regulations for Passive Safety) (Plate 6-1), Active Safety (including
UNECE Regulations for Braking and Running Gears) and the remaining 46
UNECE Regulations (Lighting and Signalling, General Safety, Pollution, and
11
Noise). During this assessment, related documents such as certificates and test
reports were presented by PROTON’s engineers and were then evaluated by the
MIROS’s auditors (Plate 6-2). The first day ended with conclusion remarks on
first day assessment from leaders of both parties.
Figure 6-1 Discussion between MIROS and PROTON representatives on
Passive Safety
Figure 6-2 Test report on the evaluation process
12
Reconfirmation of the first day assessment was carried out between MIROS and
PROTON on the second day. Subsequent to the reconfirmation, the Lead Auditor
finalised assessment results for all three pillars. Later, all related documents,
especially technical drawings obtained from the assessment of compliance
to UNECE regulations, were then transferred to the Production Confirmation
group to assess the level of Conformity of Production (COP) at the production
line. Aside from comparing production items to match the technical drawings
provided by manufacturers, the Standard of Procedures (SOP) was also assessed
the actual operation of the operators at the production line. Data gathered at
the production line was then brought into MIROS group discussion for result
calculation. Subsequently, summary of the findings were presented to PROTON
for further discussion to finalize result for each pillars. This was followed by
assessment conclusion and presentation of overall final results to PROTON by
the Lead Auditor. The event ended with a concluding remarks and signing of
Audit Result Letter by Audit Advisor and PROTON’s representative on behalf
of the Director of Engineering Division (Plate 6-3).
Figure 6-3 PROTON’s R&D-HTP General Manager, YM Tengku Azizan
Tengku Ahmad signing the Audit Result letter
13
7.
Result Discussion
PROTON EXORA successfully scored more than half of the dedicated point
for each pillar. On the assessment of the compliance of 46 UNECE regulations,
Exora complied with almost all of the regulations. The product and the system
do meet the regulation with official certification from approved Technical Service
Provider (TSP) and complied with the latest amendments of the regulation.
Apart from the UNECE regulations’ compliance assessment, both passive and
active safety assessments also showed good results. Based on the injury data of
the crash regulation tests provided by PROTON, EXORA performed well on all
categories defined, namely high speed crash which involved frontal and side
impacts, child restraint, pedestrian and rollover. Among all the categories, EXORA
scored excellently on the side impact (45% better than regulation requirement on
structural loading and 35% better than regulation on structural deformation) and
the child restraint evaluation. On the active safety assessment which was divided
into three major areas, EXORA scored reasonably good results with all systems
declared in the brochures proven workable by demonstration at the proving
ground. Last but not least, the conformity of production assessment shows
fair result in which all the products assessed conformed to the latest official
development and based on the observation at the production line it was noticed
that handling and assembly were according to Standard Operating Procedures
(SOP). Overall, PROTON EXORA scored in the 4-star range, which also enabled
this model to be recognised as “MIROS Safety Companion” (Figure 7-1).
Figure 7-1 4-star rated PROTON EXORA
14
8.
Evaluation of the Assessment Scheme
As mentioned earlier, PROTON EXORA Safety Assessment is the first attempt
by MIROS to evaluate vehicles in Malaysia, especially new models in the
market, with the main intention of educating consumers on the subject of vehicle
safety. Both sides (PROTON and MIROS) reaped significant benefits from the
assessment exercise.
For PROTON, they are definitely being acknowledged for their effort not only
in developing the first “Malaysian Made” MPV but also in providing quality
product with regards to vehicle safety. From the sharing session and assessment
results explanation, PROTON received some valuable inputs in the subject matter
for future considerations. For the MIROS side, the audit team also learnt some
new things from this exercise. Even though it was the first assessment, the team
had achieved the main objective of the assessment to rate PROTON EXORA. The
team also acquired a better overall understanding of how vehicles are developed
from the documentation phase till the last process in the production line. It was
indeed a great exposure and valuable experience for the MIROS team.
Despite the fact that this assessment has finally achieved its objectives, there are
several gaps that need to be fulfilled and improved in order to strengthen the
overall assessment scheme:
i.
The current audit checklist and its effectiveness need to be reviewed
in oder to cater for all specific vehicle segments. For example, certain
UNECE regulations are defined as a system rather than individual
product or component, and certain regulations also will not be applicable
with regard to the uniqueness of vehicle built or design. In the example
of PROTON EXORA, which is categorized as a MPV, it uses standard tire
as the spare unit and therefore UNECE R64 is not applicable.
ii.
All relevant regulations in other regions that relate to automotive sector
need to be also reviewed such as EC (European Commission), EEC
(European Economic Community), ADR (Australia Design Rules)
and others, to benchmark and verify the similarity of the content. This can
resolve conflicts involving compliance with several regulations in
developing a vehicle model as well as to provide flexibility in the case of
imported vehicles. Nevertheless, compliance to UNECE regulation
package will be the most relevant in MyVAP scheme as Malaysia is a
signatory member of UNECE WP29.
15
iii.
The current assessment scheme basically adopted only some features
from the QS-9000 elements, which are more on documentation and onsite production view. Therefore, the adoption of all QS-9000 elements
that are relevantly associated to the automotive industry should be
considered, namely in producing vehicles.
iv.
As mentioned earlier, provision of active safety features by manufacturers
in their vehicles should be looked as “self-motivation” to supply them
as “standard fit” rather than for certain price in model variants
(usually higher end variants). Technology in all areas, be it electric
appliances or communication handhelds, will for some reasons be
depreciated in terms of market value. As this also applies to vehicle
technologies, there is no reason to be rather “late” in making longexisting safety technologies embedded in today’s new models. The
current evaluation item in active safety pillar is fairly lenient and it
is expected to be more comprehensive in the future to suit the progression
in vehicle’s safety-assist technologies.
v.
Last but not least, the destructive test method as executed in NCAP
should be the main aim in MyVAP in the future. This cannot be done
in MyVAP at the moment due to non-availability of test centre and
funding restriction. As such, current MyVAP assessment accepts the test
results done by other technical service providers (tests conducted by
manufacturer during the development process).
16
9.
Conclusion
The MyVAP programme for PROTON EXORA has successfully achieved its main
objective of evaluating safety performance of PROTON EXORA which covered
safety of the product used (compliance to UNECE regulations), passive and
active safety level of tested EXORA and conformity of production. On another
aspect, the assessment was an excellent start between MIROS and PROTON
towards educating motoring consumers on the importance of safety. Without
such initiative, improvements of road safety in Malaysia especially in vehicle
safety segment will always be uncertain.
The final result of the assessment shows that PROTON EXORA deserves
to achieve 4-star rating out of a total of five stars, and be awarded the title of
“MIROS Safety Companion”. This significant achievement proves that
local manufacturer is also capable of producing vehicles with excellent safety
features which complies with internationally accepted standards, as compared
to other internationally well-known manufacturers. Nevertheless, there are
still improvements to be made by PROTON on certain aspect as mentioned in
separate detailed report published exclusively for PROTON’s reference. With
the success of the PROTON EXORA Safety Assessment, it is hoped that more
vehicle manufacturers will come and voluntarily participate in the evaluation in
order to support MyVAP towards safer vehicle – for the consumers as well as the
nation. The willingness of PROTON to participate in the assessment is greatly
appreciated and the excellent achievement is something that all Malaysians can
be proud of.
17
References
Chrysler, Ford & General Motors (1998), Quality system requirements QS-9000
Chrysler Corporation, Ford Motor Company, and General Motors
Corporation.
Chrysler, Ford & General Motors (1998), Internal auditing for QS-9000 module
3 – the audit system, Chrysler Corporation, Ford Motor Company, and
General Motors Corporation.
Lie, A & Tingvall, C (2002), How do Euro NCAP results correlate with reallife injury risks? A paired comparison study of car-to-car crashes., Traffic
Injury Prevention 3:288–293.
Radin Umar, R S 2007. Integrated Approach to Road Safety in Malaysia.
Proceedings of the 7th Malaysian Road Conference 2007, Kuala Lumpur.
Road Safety Department (2006), Road Safety Plan of Malaysia 2006 – 2010, Road
Safety Department, Ministry of Transport, Putrajaya, Malaysia.
SWOV (2007), SWOV fact sheet – Euro NCAP, a safety instrument, SWOV,
Leidschendam, the Netherlands, Accessed on January 2009 from http://
th
www.swov.nl/rapport/Factsheets.
Vera Lauer-Daimler Chrysler AG, The enabling technology for the Introduction
of integrated safety systems, EASIS 6 Framework Programme (undated).
18
Appendix A
Figure A-1 Haddon Matrix for 2006 – 2010 Road Safety Plan (Radin Umar, 2007)
Pre-Crash
Crash
Post-Crash
• Compliance and Cor
rect Use of Active Safety
Features
• Skills of Paramedics and
First Respondents
Human
• Road Safety Education
• Driver Training Program
and Grading of Driving
Institutes
• Automated Enforcement
System
• Publicity Campaign
• Community Based
Programs (VEM, Helmets,
RSE, Belts)
Vehicle
• Type Approval/C&U (e.g.
WP29)
• NCAP Ratings
• Rear Seatbelts
• Passive Safety System
• Crash Compatibility
• Ease of Evacuation
• Evacuation Tools
Environment
• Road Safety Audit
• Blackspot Treatment
• Motorcycle Lanes
• Clear Zones
• Barrier Systems
• Crash Cushion
• Easy Access by First Re
spondent Teams
• Trauma Centre
19
Designed by : Publications Unit, MIROS
Malaysian Institute of Road Safety Research
Lot 125-135, Jalan TKS 1, Taman Kajang Sentral
43000 Kajang, Selangor Darul Ehsan
Tel +603 8924 9200 Fax + 603 8733 2005
Website www.miros.gov.my Email [email protected]

Malaysian Vehicle Assessment Programme PROTON – A 4

Transcription

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