Incident: Improperly Applied Spot Welds in Subaru Vehicles Impact Safety

Published Date: 2019-07-17

Postmortem Analysis
Timeline 1. The software failure incident involving missing spot welds on the 2019 Legacy sedan and 2019 Outback crossover occurred between May 31 and June 6, 2019 [Article 87787].
System Unknown
Responsible Organization 1. The software failure incident in this case was not caused by any specific entity, but rather by a manufacturing defect related to spot welds on Subaru vehicles [87787].
Impacted Organization 1. Owners of the 2019 Legacy sedan and 2019 Outback crossover vehicles from Subaru were impacted by the software failure incident [87787].
Software Causes Unknown
Non-software Causes 1. Improperly applied spot welds due to a spot-welder tip that may have been cleaned and reshaped incorrectly [Article 87787].
Impacts 1. Reduction in overall body strength of the affected vehicles, potentially increasing the risk of injury in a crash [87787].
Preventions 1. Implementing stricter quality control measures during the manufacturing process to ensure proper spot weld application [87787]. 2. Regularly monitoring and maintaining the spot-welding equipment to prevent issues arising from improper cleaning and reshaping of spot-welder tips [87787]. 3. Conducting thorough inspections and testing of vehicles before they are released to consumers to catch any defects or weaknesses in the body structure [87787].
Fixes 1. Properly cleaning and reshaping the spot-welder tip to ensure correct application of spot welds [87787].
References 1. Documents filed with NHTSA [Article 87787]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident has happened again at one_organization: Subaru has faced a similar recall issue with missing spot welds on its vehicles before. Last year, Subaru recalled Ascent SUVs for missing spot welds on the B-pillar, and now they have issued a recall for Legacy sedans and Outback crossovers due to improperly applied spot welds [87787]. (b) The software failure incident has happened again at multiple_organization: There is no information in the provided article to suggest that this specific software failure incident has occurred at multiple organizations.
Phase (Design/Operation) unknown The articles do not mention any software failure incident related to the development phases (design or operation). Therefore, it is unknown whether the reported recall by Subaru was related to a software failure incident in the design or operation phases.
Boundary (Internal/External) within_system The software failure incident described in the article is within_system. The issue with the spot welds on the Subaru vehicles was due to improperly applied welds caused by a spot-welder tip that may have been cleaned and reshaped incorrectly [Article 87787]. This internal manufacturing process error led to a reduction in overall body strength, increasing the risk of injury in a crash. The problem was discovered at Subaru's US production plant, indicating that the contributing factors originated from within the system.
Nature (Human/Non-human) human_actions (a) The software failure incident in this case is not related to non-human actions but rather to human actions. The issue stemmed from spot welds located below the cowl panel that may have been improperly applied due to a spot-welder tip that was cleaned and reshaped incorrectly [Article 87787]. This indicates that the failure was a result of human actions introducing contributing factors that led to the defect in the vehicles.
Dimension (Hardware/Software) hardware (a) The software failure incident in the articles is not related to hardware issues but rather to improper spot welds on the vehicles. The issue stemmed from spot welds below the cowl panel that were improperly applied due to a spot-welder tip that may have been cleaned and reshaped incorrectly. This led to bad welds that could reduce the overall body strength of the vehicles, increasing the risk of injury in a crash [87787]. (b) The software failure incident in the articles is related to software issues. Subaru discovered the problem at its US production plant after an abnormal noise was heard from the duct area, leading to the identification of improperly applied spot welds. The root cause was found by Subaru's supplier, and the issue was traced back to the spot-welder tip being cleaned and reshaped incorrectly, resulting in the defective welds [87787].
Objective (Malicious/Non-malicious) unknown The articles do not mention any software failure incident related to a malicious or non-malicious objective. Therefore, the information regarding the objective of the software failure incident is unknown.
Intent (Poor/Accidental Decisions) unknown The articles do not mention any software failure incident related to poor decisions or accidental decisions. Therefore, the intent of the software failure incident in this case is unknown.
Capability (Incompetence/Accidental) unknown The articles do not mention any software failure incident related to development incompetence or accidental factors. Therefore, the information related to these specific types of software failure incidents is unknown in this context.
Duration unknown The articles do not mention any software failure incident related to the Subaru recall for missing spot welds on the 2019 Legacy sedan and 2019 Outback crossover vehicles. Therefore, the duration of the software failure incident being permanent or temporary is unknown.
Behaviour value, other (a) crash: The articles do not mention any software failure incident related to a crash. (b) omission: The articles do not mention any software failure incident related to omission. (c) timing: The articles do not mention any software failure incident related to timing. (d) value: The software failure incident mentioned in the articles is related to a defect in the spot welds of Subaru vehicles, which could lead to a reduction in overall body strength, increasing the risk of injury in a crash. This aligns with a failure due to the system performing its intended functions incorrectly [87787]. (e) byzantine: The articles do not mention any software failure incident related to a byzantine behavior. (f) other: The software failure incident described in the articles involves a defect in the spot welds of Subaru vehicles, which could potentially lead to safety issues in the event of a crash. This could be categorized as a failure due to a flaw in the manufacturing process, impacting the structural integrity of the vehicles [87787].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence no_consequence, unknown The articles do not mention any software failure incident or consequences related to software failure. Therefore, the answer to the question is 'unknown'.
Domain manufacturing (a) The failed system was not related to the production and distribution of information. (b) The failed system was not related to transportation. (c) The failed system was not related to extracting materials from Earth. (d) The failed system was not related to exchanging money for products. (e) The failed system was not related to creating the built environment. (f) The failed system was related to manufacturing as Subaru issued a recall for 2,107 examples of the 2019 Legacy sedan and 2019 Outback crossover due to improperly applied spot welds, which could reduce overall body strength and increase the risk of injury in a crash [Article 87787]. (g) The failed system was not related to utilities. (h) The failed system was not related to finance. (i) The failed system was not related to education, research, or space exploration. (j) The failed system was not related to the health industry. (k) The failed system was not related to the entertainment industry. (l) The failed system was not related to the government sector. (m) The failed system was not related to any other industry.

Sources

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