QN24509 – Incorrect Components in Air Bag Inflator – Key Safety Systems

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-011
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Key Safety Systems, Inc. – (DBA Joyson)
Submission Date : FEB 21, 2022
NHTSA Recall No. : 22E-011
Manufacturer Recall No. : QN24509
Manufacturer Information :
Manufacturer Name : Key Safety Systems, Inc. – (DBA
Joyson)
Address : 2025 Harmon Road
Auburn Hills MI 48326
Company phone : 475 6111
Population :
Number of potentially involved : 15
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Curtain Airbag inflator
Model : ACI-2E
Part No. : 2557843AA 2553433AC
Size : NR
Function : Restraint
Descriptive Information : The ACI-2e is a Hybrid inflator manufactured by a Joyson Safety System inflator
facility. On February 8, 2022, in a quality check performed in the ordinary course,
an inflator was discovered with a missing component. Further review of
production data prompted by this discovery identified a number of previously
produced inflators which may contain duplicate or missing components.
Production Dates : JAN 01, 2021 – FEB 08, 2022
Description of Defect :
Description of the Defect : The subject inflators may have been released with duplicate or missing
components, with a potential negative impact on restraint performance in the
event of a crash
FMVSS 1 : 214 – Side impact protection
FMVSS 2 : NR
Description of the Safety Risk : Reduction in the airbag’s restraint performance may increase the risk of
occupant injury in a crash
Description of the Cause : 1.) It was discovered that if the production process was interrupted at a
specific point, vacuum could be lost resulting in release of a subcomponent,
leading either to the absence of that component or, in some instances, the
introduction of a second iteration of that component.
2.) The vision system intended to detect the presence or absence of
Part 573 Safety Recall Report 22E-011 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
relevant internal components failed to identify the issue, allowing the inflator
to complete assembly with missing components.
Identification of Any Warning
that can Occur :
The condition addressed is not apparent in advance of airbag deployment
(except through a review of manufacturing data).
Involved Components :
Component Name : ACI-2e Inflator
Component Description : Hybrid Curtain Airbag Inflator
Component Part Number : 2557843 AA 2553433AC
Supplier Identification :
Component Manufacturer
Name : Joyson Safety System
Address : 2500 Innovation Dr
Auburn Hills Michigan 48326
Country : United States
Chronology :
On February 7th, 2022 the LVDT sensor tip used to verify propellent fill height was discovered to be missing by
a routine line maintenance check. By review of production data (specifically, component weight data at
relevant points in the assembly process), inflators were identified that may contain duplicate or missing
components. On [date], it was determined through simulation testing that this could have an adverse impact
on the field performance of affected components. On February 17, 2022, it was confirmed that affected
components were incorporated in vehicles in the field.
Description of Remedy :
Description of Remedy Program : JSS will provide a new Curtain Airbag module to OEMs as necessary to
replace suspect units
How Remedy Component Differs
from Recalled Component :
New parts will be made on the production line after the PLC updates have
been made
Part 573 Safety Recall Report 22E-011 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition
was Corrected in Production :
The PLC Program was changed on February 10, 2022 to allow specific
production stations to reject components if the station cycle is interrupted
at any time before the machine process has completed. Stations were
tested to ensure parts were rejected by introducing different scenarios
that would simulate a process interruption. Also, additional weight
validation was added to ensure detection.
The assembly verification camera for the relevant station was re-trained to
improve the detection of missing components.
Recall Schedule :
Description of Recall Schedule : Recall managed by OEM’s
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : General Motors LLC
Address : 29247 Louis Chevrolet Rd, Floor 2
Warren MI 48093
Country : US
Company Phone : NR
Name : Tesla, Inc.
Address : 3500 Deer Creek Road
Palo Alto CA 94304
Country : US
Company Phone : NR
* NR – Not Reported

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OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-011
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Key Safety Systems, Inc. – (DBA Joyson)
Submission Date : APR 21, 2022
NHTSA Recall No. : 22E-011
Manufacturer Recall No. : QN24509
Manufacturer Information :
Manufacturer Name : Key Safety Systems, Inc. – (DBA
Joyson)
Address : 2025 Harmon Road
Auburn Hills MI 48326
Company phone : 475 6111
Population :
Number of potentially involved : 15
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Curtain Airbag inflator
Model : ACI-2E
Part No. : 2557843AA 2553433AC
Size : NR
Function : Restraint
Descriptive Information : The ACI-2e is a Hybrid inflator manufactured by a Joyson Safety System inflator
facility. On February 8, 2022, in a quality check performed in the ordinary course,
an inflator was discovered with a missing component. Further review of
production data prompted by this discovery identified a number of previously
produced inflators which may contain duplicate or missing components.
Production Dates : JAN 01, 2021 – FEB 08, 2022
Description of Defect :
Description of the Defect : The subject inflators may have been released with duplicate or missing
components, with a potential negative impact on restraint performance in the
event of a crash
FMVSS 1 : 214 – Side impact protection
FMVSS 2 : NR
Description of the Safety Risk : Reduction in the airbag’s restraint performance may increase the risk of
occupant injury in a crash
Description of the Cause : 1.) It was discovered that if the production process was interrupted at a
specific point, vacuum could be lost resulting in release of a subcomponent,
leading either to the absence of that component or, in some instances, the
introduction of a second iteration of that component.
2.) The vision system intended to detect the presence or absence of
Part 573 Safety Recall Report 22E-011 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
relevant internal components failed to identify the issue, allowing the inflator
to complete assembly with missing components.
Identification of Any Warning
that can Occur :
The condition addressed is not apparent in advance of airbag deployment
(except through a review of manufacturing data).
Involved Components :
Component Name : ACI-2e Inflator
Component Description : Hybrid Curtain Airbag Inflator
Component Part Number : 2557843 AA 2553433AC
Supplier Identification :
Component Manufacturer
Name : Joyson Safety System
Address : 2500 Innovation Dr
Auburn Hills Michigan 48326
Country : United States
Chronology :
On February 7th, 2022 the LVDT sensor tip used to verify propellent fill height was discovered to be missing by
a routine line maintenance check. By review of production data (specifically, component weight data at
relevant points in the assembly process), inflators were identified that may contain duplicate or missing
components. On February 10th, 2022, it was determined through simulation testing that this could have an
adverse impact on the field performance of affected components. On February 17, 2022, it was confirmed that
affected components were incorporated in vehicles in the field.
Description of Remedy :
Description of Remedy Program : JSS will provide a new Curtain Airbag module to OEMs as necessary to
replace suspect units
How Remedy Component Differs
from Recalled Component :
New parts will be made on the production line after the PLC updates have
been made
Part 573 Safety Recall Report 22E-011 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition
was Corrected in Production :
The PLC Program was changed on February 10, 2022 to allow specific
production stations to reject components if the station cycle is interrupted
at any time before the machine process has completed. Stations were
tested to ensure parts were rejected by introducing different scenarios
that would simulate a process interruption. Also, additional weight
validation was added to ensure detection.
The assembly verification camera for the relevant station was re-trained to
improve the detection of missing components.
Recall Schedule :
Description of Recall Schedule : Recall managed by OEM’s
JSS Informed the affected OEM’s of action to submit a Defect Investigation
report with NHTSA and were provided a copy of the equipment filing.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Tesla, Inc.
Address : 3500 Deer Creek Road
Palo Alto CA 94304
Country : US
Company Phone : NR
* NR – Not Reported

**************************************************************************************************************

OMB Control No.: 2127-0004
Part 573 Safety Recall Report 22E-011
The information contained in this report was submitted pursuant to 49 CFR §573
Manufacturer Name : Key Safety Systems, Inc. – (DBA Joyson)
Submission Date : APR 14, 2022
NHTSA Recall No. : 22E-011
Manufacturer Recall No. : QN24509
Manufacturer Information :
Manufacturer Name : Key Safety Systems, Inc. – (DBA
Joyson)
Address : 2025 Harmon Road
Auburn Hills MI 48326
Company phone : 475 6111
Population :
Number of potentially involved : 15
Estimated percentage with defect : 100 %
Equipment Information :
Brand / Trade 1 : Curtain Airbag inflator
Model : ACI-2E
Part No. : 2557843AA 2553433AC
Size : NR
Function : Restraint
Descriptive Information : The ACI-2e is a Hybrid inflator manufactured by a Joyson Safety System inflator
facility. On February 8, 2022, in a quality check performed in the ordinary course,
an inflator was discovered with a missing component. Further review of
production data prompted by this discovery identified a number of previously
produced inflators which may contain duplicate or missing components.
Production Dates : JAN 01, 2021 – FEB 08, 2022
Description of Defect :
Description of the Defect : The subject inflators may have been released with duplicate or missing
components, with a potential negative impact on restraint performance in the
event of a crash
FMVSS 1 : 214 – Side impact protection
FMVSS 2 : NR
Description of the Safety Risk : Reduction in the airbag’s restraint performance may increase the risk of
occupant injury in a crash
Description of the Cause : 1.) It was discovered that if the production process was interrupted at a
specific point, vacuum could be lost resulting in release of a subcomponent,
leading either to the absence of that component or, in some instances, the
introduction of a second iteration of that component.
2.) The vision system intended to detect the presence or absence of
Part 573 Safety Recall Report 22E-011 Page 2
The information contained in this report was submitted pursuant to 49 CFR §573
relevant internal components failed to identify the issue, allowing the inflator
to complete assembly with missing components.
Identification of Any Warning
that can Occur :
The condition addressed is not apparent in advance of airbag deployment
(except through a review of manufacturing data).
Involved Components :
Component Name : ACI-2e Inflator
Component Description : Hybrid Curtain Airbag Inflator
Component Part Number : 2557843 AA 2553433AC
Supplier Identification :
Component Manufacturer
Name : Joyson Safety System
Address : 2500 Innovation Dr
Auburn Hills Michigan 48326
Country : United States
Chronology :
On February 7th, 2022 the LVDT sensor tip used to verify propellent fill height was discovered to be missing by
a routine line maintenance check. By review of production data (specifically, component weight data at
relevant points in the assembly process), inflators were identified that may contain duplicate or missing
components. On [date], it was determined through simulation testing that this could have an adverse impact
on the field performance of affected components. On February 17, 2022, it was confirmed that affected
components were incorporated in vehicles in the field.
Description of Remedy :
Description of Remedy Program : JSS will provide a new Curtain Airbag module to OEMs as necessary to
replace suspect units
How Remedy Component Differs
from Recalled Component :
New parts will be made on the production line after the PLC updates have
been made
Part 573 Safety Recall Report 22E-011 Page 3
The information contained in this report was submitted pursuant to 49 CFR §573
Identify How/When Recall Condition
was Corrected in Production :
The PLC Program was changed on February 10, 2022 to allow specific
production stations to reject components if the station cycle is interrupted
at any time before the machine process has completed. Stations were
tested to ensure parts were rejected by introducing different scenarios
that would simulate a process interruption. Also, additional weight
validation was added to ensure detection.
The assembly verification camera for the relevant station was re-trained to
improve the detection of missing components.
Recall Schedule :
Description of Recall Schedule : Recall managed by OEM’s
JSS Informed the affected OEM’s of action to submit a Defect Investigation
report with NHTSA and were provided a copy of the equipment filing.
Planned Dealer Notification Date : NR – NR
Planned Owner Notification Date : NR – NR
Purchaser Information :
The following manufacturers purchased this defective/noncompliant equipment for possible use or
installation in new motor vehicles or new items of motor vehicle equipment:
Name : Tesla, Inc.
Address : 3500 Deer Creek Road
Palo Alto CA 94304
Country : US
Company Phone : NR
* NR – Not Reported

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