Australian Vehicle Certification System

1. Australian Vehicle Certification System Presented By: Umesh Shamdasani Section Head, Light Vehicle Certification Department of Infrastructure & Regional Development

2. Global Automotive Industry • Manufacturing; • 50 countries • 80 million/yr • Employment; • > 8 million people • 5% of worlds mfg employment • R&D investment; • > ε80 billion ($110 billion)

3. Australia; part of global industry New light vehicle sales in Australia; 20 source countries >60 brands 350 models 1,000,000 sales in 2011 <1.5% global production

4. 2011 data for Australia 2010 data for USA, Canada and UK Competitiveness of global markets

5. Local Industry/Imports

6. Market Segmentation by Marque

7. Market Segmentation by Vehicle Type

8. Market Segmentation by Buyer Type

9. The ADRs: Coverage • The ADRs cover the full array of on road vehicles • There are currently 62ADRs • 54 are safety related • 5 are emissions/energy related (indirectly safety) • 3 are primarily anti-theft related (indirectly safety) • The Safety ADRs cover a diverse range of matters • Such as braking, lighting, door latches and hinges, seat belts and anchorages, instrumentation, mirrors, front underrun protection for heavy vehicles and occupant protection

10. The international context • Australia is harmonising with international vehicle regulations (UN Regulations, Global Technical Regulations), where reasonable to do so • The vehicle industry is global • Over 85% of vehicles are imported and Australia constitutes about 1% of the global vehicle market • Australia participates actively in the development of international vehicle regulations • International vehicle regulation provides for improvements in vehicle safety at the lowest cost, leading to a younger vehicle fleet than otherwise

11. The ADR Program • Recent work includes: • ISOFIX child restraint anchorages • Advanced seat belt reminders • Current work: • Australia is leading development of a Global Technical Regulation on Pole Side Impact (leading to side curtain airbags/thorax protection) • Regulatory Impact Statements(RISs) are being developing on: Brake Assist Systems for light passenger and light commercial vehicles; ABS for heavy vehicles and trailers; ESC for light commercial vehicles • Work in the near future: • Development of a RIS on ABS for motorcycles • Development of RISs for Lane Departure Warning Systems and Advanced Emergency Braking Systems for heavy vehicles

12. Regulatory Background • The Motor Vehicle Standards Act 1989 requires that all road vehicles supplied to the Australian market must comply with all the applicable Australian Design Rules (ADRs) and must be fitted with an Identification Plate (commonly called a Compliance Plate).

13. Australian Certification System • Unlike the European market the manufacturer operates without supervision. • Unlike the USA market vehicles are not purchased for post market compliance testing. • We use the audit process to confirm that the vehicles are compliant.

14. Certification Option • Full Volume Scheme • Low Volume Scheme • Ultra Low Volume Scheme

15. Type Approval system • Identification Plate Approval -ECE approvals for individual ADRs are considered acceptable • Single Uniform Type Inspection • Audits -Verification through design, conformity of production, and test facility inspection audits

16. Current State - Certifying and Importing a vehicle (and supporting processes) Full Certification Manufacturer Registration (Off system*) Type Certification (RVCS) Imports (IVAS) Audit and Compliance (Off system) Full Volume (new) Applications for full certification Manufacturer Registration (Off system*) Type Certification (RVCS SEVS) Imports (IVAS) Vehicle Certification (Off system) Audit and Compliance (Off system) Low Volume (new) Applications for concessions against evidence requirements RAW Certification (RAWS) Imports (RAWS<-> IVAS, SEVS) Vehicle Certification (RAWS) Audit and Compliance (RAWS [VIC], Off System) RAWS (used) Client Registration (Off system*) Imports (IVAS) Vehicle Certification (Off system) Audit and Compliance (Off System) Applications for concessions against the standards Imports (new and used) Add Vehicle (SEVS) SEVS Register (new and used) Supporting systems and Processes : FMS (SAP) EDRMS (TRIM) Web Publishing Interfaces to third parties ++XLS and Access DB Recalls and Safety Investigations Recall and Safety Investigations (new and used) * Paper based process; entered into RVCS/IVAS

17. Identification Plate Approval Vehicle Manufacturer SE Forms VSS Discussion Items Arranges Own Testing Auditors Test Facility COP TFI

18. Road Vehicle Certification System • An electronic database system managed by VSS. • Allows companies to send their vehicle details and test data using Internet -company can check and validate information before sending information. • Allows companies to check the status of their applications • The public can also view all approvals granted and approved vehicle specifications on our Web site

27. Statistics – New Model IPAs issued

28. Statistics – New Model IPAs issued for Light Vehicles, Heavy Vehicles & Trailers

29. Statistics – IPAs issued to Manufacturers from Emerging Markets

30. Single Uniform Type Inspection • Visual Inspection of a representative vehicle • Any non conformances have to be fixed • Road Vehicle Data electronically transmitted to the registering authorities • Applies to all vehicles up to 4.5 tonnes GVM

31. What are the audit’s objectives? • To ensure that : • The testing was conducted correctly – Test Facility Inspection • Any changes made since testing do not affect compliance with the ADRs – Design Audit • That all variants in production for the Australian market are covered by the approved design – COP audit • Therefore all vehicles supplied to the Australian market comply with Australian Design Rules (ADRs) and conform to the Compliance Plate Approval.

32. History of Audits • Audits started in January 1985 • Audits are mandatory • All suppliers to the Australia market, including those based overseas are subject to an audit • Audits apply to all production, design and test facilities regardless of vehicle size or production volume

33. Audit Methodology • Risk based scheduling of audits. • Linking of test facility, design facility and COP audit. • Examination of Variant Evidence matrix before the audit to establish that all the variants which can be produced for the Australian market are covered in the Approval. • Focus on compliance issues rather than quality management system adoption.

34. Risk based assessment Production facilities ranked by risk based on : 1. Sales volume in category 2. Time since last audit 3. Other information such as certification concerns, recall issues, SUTI performance

35. Risk assessment process • Vehicles with high sales penetration in their area will get a high sales risk rating • Production facilities producing a large range of vehicles will get a high sales risk rating • Production facilities located in emerging markets will get a high risk rating. • Certification concerns, recall issues, SUTI performance will all contribute to the “information” risk.

36. Audit Scheduling • In each market (Japan, Australia, Other) the highest risk rating production facilities will be chosen. • Only one production facility will be chosen for any one manufacturer in any one vehicle category in one year. • Once the Production Facilities are selected, related Test and Design facilities will be identified.

37. Variant Matrix • The intention of the variant matrix is to establish that all the variants which can be produced for the Australian market are covered in the Approval. • This matrix is submitted by manufacturers prior to the audit.

38. Test Facility Inspection • Test Facility Inspection - establish design tested - equipment and its calibration - test procedure and staff qualifications • Accept the test reports from test facilities accredited by certification bodies who are members of ILAC without VSS conducting a test facility inspection. • 50 countries are part of ILAC arrangement including USA, Japan, China, India and most European countries.

39. Areas covered in a COP audit • Quality management system overview • Engineering and test documentation • Purchasing and Supplier Quality Assurance • Manufacturing procedures • Material control and storage • Assembly plant inspection • Tool and gauge calibration and control

40. How long would an audit take? • One day for a Test Facility Inspection (TFI) • based on 1 or 2 ADRs • One day for design audit • Two or three days for a Conformity of Production (COP) audit • depends on the size of the facility • based on 2 or 3 ADRs • An agreed audit agenda is used for the audit

41. Audit Frequency & Classification • Audit frequency is 1-5 years depending on the risk rating allocation and the history of last audit. • Audit findings are classified into - NC : Non conformances - AC : Area of Concern - OI : Opportunity for Improvement • Audit with NC finding is classified as unsatisfactory audit

42. Unsatisfactory audits • The options open to the Administrator include : • stop supply to the Australian market • approvals being varied to include additional conditions (eg outside inspection) • Companies to submit full test reports

43. Audit Statistics

44. Suggestions/Recommendations for Local Industry • Manufacturers are proactive and have the right intentions to produce complying vehicles. However, suggested areas of improvement are: - Open communication between manufacturers and overseas regulatory bodies to improve knowledge of regulations. - Consider designing vehicles with better margin of safety. • Aim to find long term robust solutions instead of quick short term solutions to problems encountered in the field. • Better documentation control for test reports and certification documents. • Develop robust procedures for safety recall.

45. Australian Certification System • Any questions • Thank you for your patience.