Incident: Rolls-Royce Trent 900 Engine Failure on Qantas A380 Jet

Published Date: 2013-06-27

Postmortem Analysis
Timeline 1. The software failure incident involving Rolls-Royce's Trent 900 engine on a Qantas A380 jet occurred in November 2010 as mentioned in Article [19430]. Therefore, the software failure incident happened in November 2010.
System unknown
Responsible Organization 1. Rolls-Royce - The software failure incident was caused by faulty manufacturing processes at Rolls-Royce's Hucknall plant, where components did not conform to design standards, leading to an engine blowout on a Qantas A380 jet [19430].
Impacted Organization 1. Qantas airline [19430]
Software Causes 1. Unknown
Non-software Causes 1. Faulty manufacturing processes at Rolls-Royce's Hucknall plant in Nottingham [Article 19430] 2. Components manufactured at the plant failed to conform to design standards [Article 19430] 3. Ambiguities within the manufacturer's procedures and non-adherence by manufacturing staff to those procedures [Article 19430] 4. Cultural flaws at the Hucknall plant where it was acceptable not to report minor deviations in parts [Article 19430]
Impacts 1. The software failure incident led to an engine blowout on a Qantas A380 jet with more than 450 people on board in 2010, causing severe damage to the aircraft's left wing and resulting in the temporary grounding of Qantas' entire fleet [19430]. 2. Fragments from the engine turbine smashed into walls of several homes beneath the flight path, causing property damage [19430]. 3. The incident resulted in Rolls-Royce agreeing to pay Qantas A$95m (£62m) in a settlement in 2011 [19430].
Preventions 1. Implementing a more rigorous quality control process at the manufacturing plant to ensure components conform to design standards [19430]. 2. Conducting a thorough investigation into potential risks identified by engineers regarding defective parts in the software [19430]. 3. Enforcing adherence to manufacturer's procedures by all manufacturing staff to prevent ambiguities and non-compliance [19430]. 4. Improving cultural practices at the manufacturing plant to encourage reporting of any deviations in parts, no matter how minor [19430]. 5. Enhancing software monitoring and shutdown mechanisms to prevent engine failures in the future [19430].
Fixes 1. Implementing software that would shut down the Trent 900 engine to prevent a repeat occurrence [Article 19430].
References 1. Australian Transport Safety Bureau (ATSB) [Article 19430] 2. Rolls-Royce [Article 19430]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the engine blowout on a Qantas A380 jet in 2010 was specific to Rolls-Royce. The incident was caused by faulty manufacturing processes at Rolls-Royce's Hucknall plant, leading to an engine explosion on the Airbus A380 aircraft [19430]. (b) There is no specific information in the provided article indicating that a similar software failure incident had happened at other organizations or with their products and services.
Phase (Design/Operation) design (a) The software failure incident in the Rolls-Royce engine blowout on a Qantas A380 jet was primarily attributed to design-related factors. The incident was caused by faulty manufacturing processes that led to components not conforming to design standards [19430]. Rolls-Royce knew about these design issues at least three years before the accident but failed to address them adequately. An initial investigation in 2007 did not understand the consequences of using parts that did not match the design specification, and in 2009, a potential risk was identified but not thoroughly investigated [19430]. (b) There is no specific information in the provided article indicating that the software failure incident was due to factors introduced by the operation or misuse of the system.
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the Rolls-Royce engine blowout on a Qantas A380 jet was primarily due to contributing factors that originated from within the system. The failure was attributed to faulty manufacturing processes at Rolls-Royce's Hucknall plant in Nottingham, where components did not conform to design standards [19430]. The ATSB report highlighted that Rolls-Royce missed several chances over a three-year period to fix the problem, indicating internal issues within the company's procedures and manufacturing staff non-adherence to those procedures [19430]. Additionally, the report mentioned cultural flaws at the Hucknall plant, where it was acceptable not to report minor deviations in parts, further emphasizing internal factors contributing to the software failure incident [19430].
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident in this case was not directly related to non-human actions. The incident was primarily caused by faulty manufacturing processes and defective parts in the Trent 900 engines manufactured by Rolls-Royce. The ATSB report highlighted how components manufactured at Rolls-Royce's Hucknall plant failed to conform to design standards, leading to the engine blowout on the Qantas A380 jet [19430]. (b) On the other hand, human actions played a significant role in the software failure incident. Rolls-Royce missed several chances over a three-year period to fix the problem with the Trent 900 engines. The company knew about the defective parts as early as 2007 but failed to address the issue adequately. Additionally, cultural flaws at the Hucknall plant, where it was acceptable not to report minor deviations in parts, contributed to the incident. The ATSB report concluded that the manufacturer's procedures were ambiguous, and manufacturing staff did not adhere to those procedures, leading to missed opportunities to prevent the engine blowout [19430].
Dimension (Hardware/Software) hardware (a) The software failure incident occurring due to hardware: The incident involving the engine blowout on a Qantas A380 jet was primarily caused by faulty manufacturing processes related to the engine components, specifically the Trent 900 engines manufactured by Rolls-Royce. The ATSB report highlighted that components manufactured at Rolls-Royce's Hucknall plant in Nottingham failed to conform to design standards, leading to the engine explosion [Article 19430]. (b) The software failure incident occurring due to software: The software failure incident was not directly attributed to software issues. However, after the incident, Rolls-Royce introduced software that would shut down a Trent 900 engine to prevent a repeat occurrence. This software implementation was a proactive measure taken by Rolls-Royce to address the hardware-related issues that led to the engine blowout [Article 19430].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident in this case was non-malicious. The incident was related to a faulty manufacturing process at Rolls-Royce's Hucknall plant in Nottingham, which led to components not conforming to design standards and ultimately causing an engine blowout on a Qantas A380 jet [19430]. The failure was attributed to ambiguities within the manufacturer's procedures and non-adherence by manufacturing staff to those procedures, as well as cultural flaws at the plant where it was acceptable not to report minor deviations in parts. This indicates that the failure was not due to malicious intent but rather a result of oversight, lack of thorough investigation, and procedural shortcomings within the company.
Intent (Poor/Accidental Decisions) unknown The software failure incident reported in the provided article [Article 19430] was not related to a software failure but rather to a manufacturing issue with components in Rolls-Royce's Trent 900 engines. Therefore, the incident did not involve poor decisions or accidental decisions related to software.
Capability (Incompetence/Accidental) accidental (a) The software failure incident in this case was not directly related to development incompetence. The incident was primarily caused by faulty manufacturing processes and defective parts in the Trent 900 engines manufactured by Rolls-Royce. The ATSB report highlighted ambiguities within the manufacturer's procedures and non-adherence by manufacturing staff to those procedures as contributing factors to the missed opportunities to address the issue [19430]. (b) The software failure incident can be attributed to accidental factors, such as the initial failure to understand the consequences of using parts that did not match the design specification, the missed opportunities to address the issue due to cultural flaws at the manufacturing plant, and the lack of investigation into the potential risks identified by a Rolls-Royce engineer in 2009. These accidental factors ultimately led to the engine blowout on the Qantas A380 jet in 2010 [19430].
Duration unknown The software failure incident related to the Rolls-Royce engine blowout on a Qantas A380 jet in 2010 was not directly attributed to a software failure. The incident was caused by faulty manufacturing processes and defective parts in the Trent 900 engines [Article 19430]. Therefore, the concept of a permanent or temporary software failure does not apply in this case as the incident was not related to software failure.
Behaviour other (a) crash: The software failure incident in this case did not involve a crash where the system lost state and did not perform any of its intended functions. The incident was related to an engine blowout on a Qantas A380 jet due to faulty manufacturing processes in the engine components [Article 19430]. (b) omission: The software failure incident did not involve omission where the system omitted to perform its intended functions at an instance(s). The incident was more related to a manufacturing defect in the engine components that led to the engine explosion [Article 19430]. (c) timing: The software failure incident was not due to timing issues where the system performed its intended functions too late or too early. The incident was primarily caused by faulty manufacturing processes and the failure to address known issues with the engine components in a timely manner [Article 19430]. (d) value: The software failure incident did not involve a failure due to the system performing its intended functions incorrectly. The incident was not related to software directly but rather to the manufacturing processes of the engine components [Article 19430]. (e) byzantine: The software failure incident did not exhibit behavior characteristic of a byzantine failure where the system behaves erroneously with inconsistent responses and interactions. The incident was more straightforward in terms of the cause being related to faulty manufacturing processes and lack of proper investigation into known risks [Article 19430]. (f) other: The behavior of the software failure incident can be categorized as a manufacturing flaw leading to a critical engine failure on an Airbus A380 jet. The incident highlighted issues with quality control, adherence to procedures, and cultural flaws at the manufacturing plant, rather than a specific software-related failure [Article 19430].

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence no_consequence (a) death: People lost their lives due to the software failure - No mention of any deaths resulting from the software failure incident in the provided article [19430].
Domain transportation, manufacturing The software failure incident reported in the provided article [19430] is related to the manufacturing industry. The incident involved a problem with Rolls-Royce's Trent 900 engines, which are used in aircraft, specifically the Airbus A380 jet. The faulty manufacturing processes at Rolls-Royce's plant led to an engine blowout on a Qantas A380 jet in 2010, highlighting issues with the design and manufacturing of engine components [19430]. The incident resulted in a safety scare for the Airbus A380 jet and led to temporary grounding of Qantas' fleet [19430]. Therefore, the failed system in this case was intended to support the manufacturing industry by providing reliable and safe engines for aircraft.

Sources

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