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www.CAPAcertified.org 1
When When Quality Quality CountsCounts
Not all Aftermarket Not all Aftermarket Parts are Created Parts are Created
EqualEqual
Not all Aftermarket Not all Aftermarket Parts are Created Parts are Created
EqualEqual
CAPA Update for the CCIF
Who We Are
Why CAPA
Program Review
CAPA’s Success
CAPA Responds
Aftermarket Parts Reform: The Real Future
Mission Statement
CAPA is a non-profit, third party independent standard setting organization whose goal is to ensure that the market has a high quality, fairly priced alternative to expensive car company parts.
How We Got Here
1970’s car companies stopped changing model designs each year
Independents began to produce alternative parts -- Like mechanical part competitors in the 20’s and 30’s
Collision repairers used these parts in record numbers
How We Got Here
After repair shops created the market, insurance companies started including competitive parts on estimates
Then collision repairers started to complain about safety and quality
The insurance industry responded by creating CAPA in 1987
Why CAPA?
To protect American consumers from a car company parts monopoly and poor quality parts
Car companies spend millions of dollars to discredit aftermarket parts, scare consumers, co-opt body shops and intimidate state legislatures into protecting their monopolyNot stepping in and working to break this monopoly will only lead to higher car repair costs and higher insurance premiums.
What Happens in a Car Parts Monopoly?
A 1994 Ford Taurus hood A 1994 Ford Taurus hood costs almost $400 + $350 to costs almost $400 + $350 to install and refinish it.install and refinish it.
$400
$250
$0
$50
$100
$150
$200
$250
$300
$350
$400
A TV/VCR costs around $250 and A TV/VCR costs around $250 and it plugs in for immediate use.it plugs in for immediate use.
Consumers Know There Is Something Wrong When:
$600 will buy a Pentium 4 computer with color printer, 17” color monitor yet they have to add $300 to get a sheet metal quarter panel from Ford for $900$500 buys a new refrigerator or a Chrysler hood
Questions to Ask About a Part Quality Certification Program
1. Are the parts individually certified for quality?
2. What are the credentials of the certifier?
3. Is a fully accredited, independent test lab part of the process?
4. Is the certification process transparent and subject to public comment?
5. Does the program have clear and precise standards?
Questions to Ask About a Part Quality Certification Program
6. Are the standards available to the public?
7. Is there a mechanism for consumers, repairers and other affected parties to be involved in the standard setting process?
8. Who oversees the development of the standards?
9. Are the parts continually inspected after initial certification?
10. Is the certifier involved in the marketing, sale or distribution of the product?
www.CAPAcertified.org 10
Does distributor listing govern CAPA certification?
Only CAPA determines certification
Neither distributors or insurers can decide if a part is to be listed as certified.
Distributors could list part as a CAPA certified part, but only the presence of the CAPA seal actually confirms certification.
CAPA: Answering the Questions
Step 1:FACTORY APPROVAL
A detailed review and audit of the factory and manufacturing processes
Inspection, quality control and operating processes are critically reviewed
An independent body determines whether the quality processes and factory each meet CAPA’s 60+ point quality requirements
Product Quality Certification vs. System Certification
CAPA = QS, Product Certification
& Continuous Inspection
Product
Certification
QS 9000
ISO
Why Factory Approval (Process Certification) is not enough for CAPA
CAPA led the way in process certification by developing and requiring a factory approval process well before the popularity of ISO.In mid 90’s CAPA eliminated facility audits in lieu of QS certification. Within 1 year CAPA was forced to reinstate facility audits.Car companies have had similar problems, so they too are moving away from QS and migrating to TS 16949 which includes more control over the product.
Step 2:PART APPROVAL AND CERTIFICATION
Only after the factory has been approved can individual parts be submitted for certificationPart Approval is a Multi-Step Process
When All Criteria are Met: Part Certified and Seal Affixed
Checking Fixture is Approved
Part Properties are Tested & Approved
Part Passes Vehicle Test Fit
Checking Fixture Approved
Holes: Properly placed
Bodylines: Exactly
match car company
Datum Points: Set at all
critical areas
Mating Components:
Checked against part
Flush: Matches Master
Gap: Matches master
Part Properties are Tested
Material composition Coating performance Thickness Corrosion Mechanical properties Form and fit Paint adhesion
Appearance Adhesive and weld
integrity Fasteners\Hardware Quality Control
procedures Identifying markings
Test procedures are based on nationally recognized tests such as ASTM and SAE
Hood - Inner Skin Identified for Testing Welds, Weldments, Adhesives
Part Properties are Tested
Complete destructive testing ensures comparability with car company service parts
Part Properties are Tested
Initiated April 1999
Dedicated Vehicle Test Fit Facility
Collision repair professionals perform tests
Part Passes Vehicle Test Fit
As of December 31, 2001 all CAPA parts have a vehicle test fit or equivalent
CAR COMPANY SERVICE PART QUALITY STUDY
OVERALL RESULTS(1,907 PARTS)
Passed CAPA Fitand Appearance
Requirements50% (953)
Failed CAPA Fitand Appearance
Requirements50% (954)
CAPA Test Fit Results
1,907 Car Company Parts Tested.50% (954) failed CAPA fit and appearance requirements.
Car Company Quality
Car Company # Tested % Failed
General Motors 467 65%
Ford 440 60%
Chrysler 295 47%
Nissan 141 41%
Toyota 236 39%
Honda 227 27%
What Does this Analysis Tell Us?
CAPA Parts are equal or BETTER than their car company counterparts !!
Pass 100%
Pass 50%
Fail
50%
When compared to car company parts in the market, 100% of CAPA parts meet standards and only 50% of
the car company parts meet the standards
Percent Car Company Service Parts Meeting CAPA
Standards
Percent of Parts introduced as CAPA that meet CAPA
Standards
The CAPA Quality Seal: The Final Step in Part Certification
Tamper Proof Design
Two Parts
Top part stays on part
Bottom part provides proof that a CAPA part has been used
Bar coded for ease of tracking
Each and every part has a unique number
CAPA Part TrackingEasy & Available to All
CAPA Part Tracking
One Seal Number Can: Confirm part certification.Provide part history.Identify lot, manufacturer and application. CAPA’s parts database maintains all testing and inspection information on all parts in the program.Bottom tab of the seal affixed to repair order or estimate provides permanent tracking of the part.
Quality Systems Audits twice per year.Dimensional, Appearance, and Quality Control records inspections on 70 - 80% of lots.Random material testing, Vehicle Test Fits and studies.Complaint investigations.Annual Fixture and Weld Jig Verification.Trend analysis on manufacturer, part number and other critical program elements.
Step 3: REGULAR RE-INSPECTION AND MONITORING
Step 4: MARKETPLACE QUALITY MONITORING
Complaint Program: Providing users with the opportunity for quality input.
Decertification Program: Keeping problem parts out of the market.
Recall Program: Removing poor quality parts from distributor shelves.
CAPA Encourages Complaints
1-800-505-CAPA
www.CAPAcertified.org
Written Form: Thousands distributed annually
1,000,000
2,500,000
4,000,000
5,500,000
7,000,000
8,500,000
10,000,000
11,500,000
13,000,000
14,500,000
16,000,000
17,500,000
Complaints Received 1995-2002
00.05%
16,771,089 Parts Certified
Percentage of Valid Complaints to Seals Applied
0
0.0001
0.0002
0.0003
0.0004
0.0005
0.0006
1994 1996 1998 2000 2002
CAPA’s Success: What CAPA has Accomplished
Accredited by the American National Standards Institute (ANSI), as a standard developer.Developed specific, enforceable, effective standards for metal and plastic body parts and lighting.
CAPA’s Success: What CAPA has Accomplished
Dramatically improved the quality of competitive repair parts bearing the CAPA seal.Provided repairers with a means to reduce total losses and therefore repair more cars.Provided a high quality alternative to expensive car company parts.
CAPA’s Success: What CAPA has Accomplished
Secured one of the nation’s most accredited testing laboratories: Entela, Inc., Grand Rapids, MI
ISO/TS-16949 (World Automotive Standard):First accredited and issued first certificate.QS-9000 and Tooling & Equipment Supplement: USA’s leading Registrar.American Association for Laboratory Accreditation in Chemistry, Mechanical, Electrical, Metrology, MetallurgyProduct Certification for Automotive Aftermarket Parts, IT, Medical Devices, Machinery, Furniture, Appliances, Lab Equipment.
CAPA’s Success: What CAPA has Accomplished
Brought collision repairers into the part certification process:
•CAPA’s Board is led by one of the nation’s foremost collision repairers.
•CAPA’s Board and TC include ASA, SCRS and other industry leaders.
CAPA’s Success: Industry-Wide Acceptance of CAPA
Repairers and other parties are now stating that there is a need for a certification program
The ASA, the largest trade association of repairers in the U.S., has endorsed our model bill on a federal level which would require the use of certified parts
CAPA Responds: GM Report on 10 CAPA PartsCAPA regularly tests car company parts and we’ve accumulated significant data on GM parts:
Overall, 65% of 467 GM parts vehicle test fit failed to meet CAPA’s fit and
appearance requirements.GM report implies that all Pontiac Grand
Am hoods are made the same way.GM report did not indicate if their parts
meet their standards.
CAPA Responds:GM ReportGM implies that CAPA parts are inferior because they did not match GM parts or specifications, yet when CAPA reviewed Pontiac Grand Am hoods, we found:
55% Variation in No. of Adhesive Patches
105% Variation in Surface Area Covered
129% Variation in Minimum Weld Size
CAPA Responds:Consumer Reports
CR supports the goals of CAPA.
CR applauds the changes CAPA instituted
CR said CAPA should expand to cover bumper assemblies.
CAPA Responds:CAPA’s Independence
UL stands alone only after 19 years of dependence on the insurance industry. UL gained this independence because regulations require UL standards.
CAPA has suggested similar requirements on a state level and the ASA has proposed federal certification standards.
CAPA is led by one of the nation’s foremost consumer advocates, Jack Gillis.
40
Aftermarket Parts Reform
CAPA has built a strong foundation
There is a tremendous opportunity to embrace and insist on true quality
Each industry segment needs to make a decision regarding CAPA and quality aftermarket parts
Aftermarket Parts Reform: Consumers Support Competition
Center for Auto Safety
Consumer Federation of America
Ralph Nader’s Public Citizen
Consumer’s Union
All are on record in support of CAPA, its goals and/or aftermarket parts
Aftermarket Parts Reform:Collision Repairers Must
Decide that they want to encourage competition.
Decide to use only quality parts.
Reject poor quality.
Look for the CAPA seal.
Aftermarket Parts Reform:Distributors Must
Remember that they have the strongest influence on manufacturers
Decide That Quality Is Really Important
Communicate Decision in Buying Practices
Provide Choice in the Marketplace
Aftermarket Parts Reform:Insurers Must
Develop mechanism that ensures that policy holders get the parts specified.
Monitor the use of parts.
Develop educational programs for staff.
Share importance with policy holders.
Promote your efforts.
Financially support independent certification
The Car Companies win in two ways:
1. They can charge whatever they want for parts.
2. As repair costs escalate and more cars are totaled, consumers are forced back into the market to buy another car.
In addition:
No incentive for car companies to improve quality.
Lack of choice negatively affects all parties.
What Happens Without CAPA?
When When Quality Quality CountsCounts
Insist on Genuine Insist on Genuine CAPA Parts!!CAPA Parts!!