The tests were conducted off hours by only need-to-know individuals. The results were frightening. After only a few short years out in the elements, the inflators were compromised. As a consequence more covert actions were taken, mainly the design of remedies and/or replacements. However, due to liability, all of the R&D (research and development) and evidence against plausible deniability was scrapped and erased.
A big factor in the whole ordeal was demand, Takata Corporation had grown… substantially; in 1995 they were making about 650 million a year by 1999 they were projected to make a Billion annually despite being involved in a lesser recall. This was before their big break through, aluminum nitrate, which allowed them to undercut other producers. During the time in question they were supplying a fifth of all cars made with airbags.
The Japanese company was struggling to keep up with demand. Major automakers had started a policy of just-in-time production, to maximize profits by minimizing waste. This means that the deadlines are solid. If any one part is late the production line shuts down completely. Automakers like Toyota and Honda started issuing strict fines for tardiness. 5 digits per minute or a minimum of 600,000 per hour late. The deadlines were so harsh, Takata Corporation could hardly keep