First, after reading all the threads on the site I am pretty well set on getting OEM LBJs. But, and I am not trying to start a fight, just a conversation-
How do you square all the above with the Takata mess? I mean, taking for granted that all you wrote is true, I would venture to say that the OEM would be even more particular about a safety item like an air bag, right?
A couple ways in general, as I have not researched this specific issue with the airbags:
1. Nobody's perfect. No matter how much engineering rigor you have, there will eventually be a mistake. What you have to look at is the statistical occurrence rate. I guarantee you that OEM's look VERY carefully at this and it affects their sourcing decisions. A company like Takata can't just change their name and reopen. Everyone in the industry knows them, and their reputation is permanently damaged by this (and rightly so it seems!)
To dig deeper into this point, you have to keep in mind that the OEM part for a specific vehicle model is on EVERY single one of those vehicle ever made. If the part needs replacing, then sometime it'll be replaced with OEM, and sometimes with an aftermarket. Then of those aftermarket ones out on, you further split that # between the different aftermarket companies. So what that means is that for pretty much every single component on a vehicle (except for frequent wear items like brake pads, filters, etc.), there are WAY WAY WAY more OEM's out there than aftermarkets, so if you see 5 failures of OEM parts, and 5 failures of an aftermarket part, the failure rate for the aftermarket is WAY higher.
Also, it isn't always that company's fault, it is often a sub-supplier that failed to inform their customers of a problem in time to catch it, or didn't discover the problem until you started getting returns from the field (this is the worst kind, but it does happen). In this case, the company that gets publicly blamed isn't always the one that deserves the blame.
2. The fact that this is big news speaks to my statement that OEM's are actually regulated, financially liable for quality problems, and liable to the consumer via their reputation. I bet there isn't really an "aftermarket" industry for airbags because they are safety critical components. It would be WAY too expensive for an aftermarket company to actually develop independent airbags for different car models and up to safety standards, and if they did, there is probably a law against using non-approved airbags in vehicles (I mean Cali requires approved CAT's to be used, purely environmental concern, not safety). If they really did cover it up, then there will be a huge class action lawsuit.
To your point, safety critical components absolutely are held to a higher standard. My company makes some safety critical parts, and they require alot more testing in qualification, SPC throughout life, and higher requirements for qualifying any changes to the product, all on top of sometimes higher precision and tighter tolerance.
Europe and NA have some laws on this stuff, but all the major companies meet industry standards which though they may not be legally required, if it came to a lawsuit, especially civil, industry standard is held up as the bar for negligence and culpability.
Another out for aftermarkets is that they can just label the part as "for off-road use only" and sell it without any liability or adherence to any rules or laws.
On the other hand, if an aftermarket company has a quality problem, because of the stats described in my first point, there are fewer of them out there, and there's not as much brand identity. For the majority of the aftermarket companies, they are just buying the product from an un-nammed company and branding it under their badge, so if they have a quality problem, they can either change suppliers without notice, or just fold the name and re-open it under a new name.
3. On components like an airbag, they get used so infrequently, that it can be very difficult to generate the statistics you'd normally like to have before calling ti "qualified". Similarly, for expensive components, it can be very difficult to generate high statistical confidence without it costing ridiculous amounts of money. I don't know the actual cost of an airbag when you work in the labor and materials, as well as all the testing and overhead costs, but I don't think they're that cheap. My company's parts are relatively cheap (between $5-20 for labor and materials), and we test hundreds for qualification, and by the time we launch them, we have made (and then scrapped) thousands of them, not to mention the cost of all the machinery we had to make or modify,a nd the cost of the testing itself (not cheap!). It is very difficult to prove out complex designs at a price point that makes it feasible. That is why 6-sigma is so popular, but you have to be very good at 6-sigma to be able to effectively draw conclusions from small sample sizes, and I guarantee you that a jury in a civil or criminal case won't understand if the stats are BS, or sound.
So all that said, that isn't justification for excusing poor performance. Poor performance from any company isn't acceptable. My point is that poor performance is less likely to come from an OEM supplier than from an aftermarket company (that's how you win an OEM contract after all), and there is alot more oversight of an OEM supplier than of an aftermarket company from both the OES's customer and from government and industry organizations.
And no worries on the question, it's a valid question. I'm not loyal to Toyota or anything, I'm an engineer, so I just hate seeing statistics abused by politicians and others that don't understand them (or that do understand, but intentionally warp them), and I hate seeing people just rip on a company that makes a product we want just because they have made some mistakes, or excuse a company that doesn't stack up on quality. There's negligence (which it sounds like may be at play in the Takata case), and then there's pushing the envelope of both technology and cost, both of which are good for the consumer. We have to take the bad with the good.