Incident: Brake Assist System Failure in Toyota and Lexus Hybrid Vehicles

Published Date: 2019-08-15

Postmortem Analysis
Timeline 1. The software failure incident involving the brake assist systems in the 2019 Toyota Prius and RAV4 Hybrid occurred between April and June of 2019 as per the article [88231]. Therefore, the software failure incident happened in April to June 2019.
System 1. Brake assist systems in the 2019 Toyota Prius and RAV4 Hybrid, 2020 Corolla Hybrid, 2019-2020 Prius Prime plug-in hybrid, and various Lexus hybrid models (2019 Lexus LS500, LC500, ES300h, UX250h, LS500h) failed due to a fault in the brake booster [88231].
Responsible Organization 1. Toyota - Toyota was responsible for causing the software failure incident in the 2019 Toyota Prius and RAV4 Hybrid, as well as other affected models, due to a fault in the brake assist systems [88231].
Impacted Organization 1. Owners of the 2019 Toyota Prius and RAV4 Hybrid, 2020 Corolla Hybrid, 2019-2020 Prius Prime plug-in hybrid, and various Lexus hybrid models [88231].
Software Causes 1. The software cause of the failure incident in the Toyota Prius and RAV4 Hybrid recall was traced to a fault in the brake assist systems due to a manufacturing error in the plastic brush holder for the motor brushes, causing an electrical connection to fail [88231].
Non-software Causes 1. Manufacturing error in the plastic brush holder for the motor brushes leading to an electrical connection failure [88231].
Impacts 1. The software failure incident in the 2019 Toyota Prius and RAV4 Hybrid resulted in the deactivation of the Vehicle Stability Control system, leading to potential safety risks for drivers [88231]. 2. The fault in the brake assist systems caused the brake assist to not kick in when required, compromising the braking performance of the affected vehicles [88231]. 3. The failing brake booster pumps, attributed to a manufacturing error in a plastic brush holder, could cause an electrical connection to fail, triggering various dash lights to illuminate for the owners [88231].
Preventions 1. Implementing thorough quality control measures during the manufacturing process to detect and rectify any defects in components like the plastic brush holder for the motor brushes [88231]. 2. Conducting comprehensive testing and validation of the brake assist systems and related software to ensure they meet federal requirements for stability control systems [88231]. 3. Regularly monitoring and analyzing data from the brake assist systems to proactively identify any potential issues or anomalies that could lead to a failure [unknown].
Fixes 1. Owners of the affected vehicles need to stop by a dealership to have a technician inspect the car. If necessary, the technician will install a new brake booster pump at no cost to owners [88231].
References 1. Documents filed by Toyota with the NHTSA [Article 88231]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the brake assist systems in the 2019 Toyota Prius and RAV4 Hybrid is specific to Toyota vehicles. This incident has happened within the same organization, as Toyota has issued a new recall due to a fault in the brake booster affecting multiple models [88231]. (b) There is no information in the provided article about a similar incident happening at other organizations or with their products and services.
Phase (Design/Operation) design, operation (a) The software failure incident related to the design phase is evident in the article as it mentions a fault in the brake assist systems of the 2019 Toyota Prius and RAV4 Hybrid. The issue with the brake booster was traced back to a manufacturing error in a plastic brush holder for the motor brushes, which could cause an electrical connection to fail. This indicates a design flaw introduced during the development phase of the system [88231]. (b) The software failure incident related to the operation phase is highlighted in the article when it states that if the brake booster fails in any of the recalled cars, it deactivates the Vehicle Stability Control system and brake assist will not function as required. This failure due to the operation of the system could lead to safety concerns as the cars do not meet federal requirements for stability control systems when the fault occurs [88231].
Boundary (Internal/External) within_system The software failure incident related to the Toyota Prius and RAV4 Hybrid recall is primarily within_system. The article mentions that the fault in the brake booster pumps was traced back to a plastic brush holder for the motor brushes, which was misshapen due to a manufacturing error, causing an electrical connection to fail [88231]. This indicates that the software failure originated from within the system itself.
Nature (Human/Non-human) human_actions (a) The software failure incident in the Toyota Prius and RAV4 Hybrid recall was not directly attributed to non-human actions. The issue was traced back to a manufacturing error in the brake booster pump, specifically a misshapen plastic brush holder for the motor brushes, which could cause an electrical connection to fail. This indicates a fault in the physical component rather than a non-human action [88231]. (b) The software failure incident in the Toyota Prius and RAV4 Hybrid recall was due to a manufacturing error in the brake booster pump, specifically a misshapen plastic brush holder for the motor brushes, which could cause an electrical connection to fail. This error was introduced during the manufacturing process, which involves human actions such as assembly and quality control. Therefore, the contributing factor to the software failure incident was introduced by human actions [88231].
Dimension (Hardware/Software) hardware (a) The software failure incident in the reported article is related to hardware. The issue with the brake booster pumps in the Toyota Prius and RAV4 Hybrid was traced back to a plastic brush holder for the motor brushes, which was misshapen due to a manufacturing error. This misshapen part caused an electrical connection to fail, leading to the malfunction of the brake assist systems and the deactivation of the Vehicle Stability Control system [88231].
Objective (Malicious/Non-malicious) non-malicious (a) The articles do not mention any malicious intent related to the software failure incident. [88231] (b) The software failure incident in the articles is non-malicious, attributed to a fault in the brake assist systems due to a manufacturing error in the plastic brush holder for the motor brushes. This error causes an electrical connection to fail, leading to the deactivation of the Vehicle Stability Control system and the brake assist not functioning as required. The issue is identified as a defect in the system, not as a deliberate act to harm the vehicles. [88231]
Intent (Poor/Accidental Decisions) unknown The software failure incident related to the brake assist systems in the Toyota vehicles does not directly point to poor decisions or accidental decisions as the intent behind the failure. The article primarily attributes the issue to a manufacturing error in the plastic brush holder for the motor brushes, which may cause an electrical connection to fail, leading to the brake booster pump failure [88231].
Capability (Incompetence/Accidental) accidental (a) The software failure incident related to development incompetence is not explicitly mentioned in the provided article. Therefore, it is unknown whether the failure was due to contributing factors introduced due to lack of professional competence by humans or the development organization. (b) The software failure incident related to an accidental factor is mentioned in the article. The article states that the fault in the brake booster pumps was traced back to a manufacturing error, where a plastic brush holder for the motor brushes may be misshapen due to a manufacturing error, causing an electrical connection to fail. This indicates that the software failure incident was due to contributing factors introduced accidentally [88231].
Duration temporary The software failure incident related to the brake booster issue in the Toyota and Lexus vehicles is more of a temporary nature. The failure is attributed to a manufacturing error in the plastic brush holder for the motor brushes, which may cause an electrical connection to fail. This specific issue is not a permanent failure but rather a temporary one caused by certain circumstances, such as the manufacturing error in the part [88231].
Behaviour crash (a) crash: The software failure incident in the articles can be categorized as a crash since the brake booster failure leads to the deactivation of the Vehicle Stability Control system and the brake assist not functioning as intended, resulting in the system losing its state and not performing its intended functions [88231].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence harm, property, theoretical_consequence The consequence of the software failure incident related to the Toyota recall mentioned in Article 88231 is primarily related to the potential harm caused by the brake booster fault. The article states that if the brake booster fails in the recalled cars, it deactivates the Vehicle Stability Control system, and brake assist will not function as intended, which could lead to safety risks for the drivers. Additionally, the fault causes the cars not to meet federal requirements for stability control systems, indicating a potential safety hazard [88231].
Domain transportation (a) The software failure incident reported in the article is related to the transportation industry. The recall affects vehicles such as the 2019 Toyota Prius, RAV4 Hybrid, Corolla Hybrid, and various Lexus hybrid models [Article 88231].

Sources

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