Incident: Recall of Ram 3500, 4500, and 5500 Models Due to Engine Software Issue

Published Date: 2020-09-09

Postmortem Analysis
Timeline 1. The software failure incident involving the 6.7-liter Cummins diesel engine in Ram trucks happened when FCA announced the recall due to the issue with the computer-controlled warmup procedure [104873]. Therefore, the software failure incident happened in September 2020.
System The software failure incident in Article 104873 involved the computer-controlled warmup procedure in the 6.7-liter Cummins diesel engine found in the 2019 and 2020 Ram 3500, 4500, and 5500 models. Therefore, the systems/components that failed are: 1. Computer-controlled warmup procedure in the 6.7-liter Cummins diesel engine [104873].
Responsible Organization 1. FCA (Fiat Chrysler Automobiles) - FCA announced the recall due to the issue involving the computer-controlled warmup procedure of the 6.7-liter Cummins diesel engine in certain Ram models [Article 104873].
Impacted Organization 1. Owners of 2019 and 2020 Ram 3500, 4500, and 5500 models [104873]
Software Causes 1. Insufficient oil flow governed by the engine computer during vehicle startup leading to rod bearing starvation and serious damage [104873].
Non-software Causes 1. Insufficient oil flow governed by the engine computer during vehicle startup leading to rod bearing starvation and serious damage [104873].
Impacts 1. The software failure incident in the 6.7-liter Cummins diesel engine in certain Ram models led to insufficient oil flow during vehicle startup, potentially causing damage to rod bearings [104873].
Preventions 1. Proper testing and validation of the software controlling the warmup procedure in the Cummins diesel engine could have potentially prevented the software failure incident [104873].
Fixes 1. Bringing the affected vehicles to a dealer for a reflash of the vehicle's computer with new software [104873].
References 1. FCA representative [104873] 2. National Highway Traffic Safety Administration [104873]

Software Taxonomy of Faults

Category Option Rationale
Recurring unknown (a) The software failure incident related to the Cummins diesel engine warmup procedure issue in Ram trucks has not been reported to have happened again at the same organization (FCA) or with its products and services. The article does not mention any previous occurrences of this specific issue within FCA or with their vehicles [104873]. (b) The software failure incident related to the Cummins diesel engine warmup procedure issue in Ram trucks has not been reported to have happened again at other organizations or with their products and services. The article does not provide information about similar incidents occurring in vehicles from other manufacturers or organizations [104873].
Phase (Design/Operation) design (a) The software failure incident in this case is related to the design phase. The issue with the Cummins diesel engine's computer-controlled warmup procedure, causing insufficient oil flow during vehicle startup, was attributed to a problem with the engine computer's programming. This design flaw led to potential serious damage by starving rod bearings [104873].
Boundary (Internal/External) within_system (a) The software failure incident described in the article is within_system. The issue with the Cummins diesel engine's computer-controlled warmup procedure causing insufficient oil flow and potential damage to rod bearings is a result of a software issue originating from within the system itself, leading to the recall and the need for a software reflash at the dealer [104873].
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident in this case was not due to non-human actions. It was caused by an issue involving the computer-controlled warmup procedure of the engine, specifically related to insufficient oil flow governed by the engine computer during vehicle startup, which could lead to serious damage [104873]. (b) The software failure incident was a result of human actions, as it was identified as a software issue that required reprogramming the vehicle's computer with new software to address the problem. The recall was initiated by FCA due to this software-related issue, and owners of affected vehicles were advised to bring their trucks to a dealer for the reflash process [104873].
Dimension (Hardware/Software) hardware, software (a) The software failure incident in Article 104873 occurred due to a hardware-related issue. The issue was related to the computer-controlled warmup procedure of the 6.7-liter Cummins diesel engine found in certain Ram models. The insufficient oil flow governed by the engine computer during vehicle startup led to potential damage to rod bearings, which is a hardware-related consequence of the software issue. The solution involved reprogramming the vehicle's computer with new software to address the hardware-related problem [104873].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident described in Article 104873 is non-malicious. The issue with the 6.7-liter Cummins diesel engine in certain Ram models was related to the computer-controlled warmup procedure causing insufficient oil flow during vehicle startup, leading to potential damage to rod bearings. The fix for this problem involved reprogramming the vehicle's computer with new software, and it was classified as a recall by FCA, with the service being provided free of charge to affected vehicle owners. Additionally, there have been no reported injuries resulting from this software issue, indicating that the failure was not caused by malicious intent [104873].
Intent (Poor/Accidental Decisions) (a) The software failure incident in Article 104873 was not due to poor decisions but rather a technical issue related to insufficient oil flow governed by the engine computer during vehicle startup, leading to potential damage to rod bearings. The recall and fix for the issue involve reprogramming the vehicle's computer with new software, indicating a technical flaw rather than poor decisions [104873].
Capability (Incompetence/Accidental) accidental (a) The software failure incident in Article 104873 was not attributed to development incompetence. The issue with the Cummins diesel engine's warmup procedure was identified as a result of insufficient oil flow governed by the engine computer during vehicle startup, leading to potential damage to rod bearings. The solution involved reprogramming the vehicle's computer with new software, which was described as an easy fix. The article did not mention any incompetence in the development process. (b) The software failure incident in Article 104873 was categorized more as an accidental issue rather than intentional. The insufficient oil flow issue during vehicle startup, which could lead to serious damage, was not portrayed as a deliberate act but rather as an unintended consequence of the computer-controlled warmup procedure. The article highlighted that there were no reported injuries resulting from this issue, indicating that the incident was accidental rather than intentional.
Duration temporary The software failure incident described in the article is temporary. The issue with the 6.7-liter Cummins diesel engine's computer-controlled warmup procedure led to insufficient oil flow during vehicle startup, causing potential damage to rod bearings. However, the fix for this problem involves reprogramming the vehicle's computer with new software, indicating that the failure is not permanent but can be rectified through a software update [104873].
Behaviour value (a) crash: The software failure incident in the article does not involve a crash where the system loses state and does not perform any of its intended functions. The issue with the Cummins diesel engine's computer-controlled warmup procedure does not lead to a complete system failure [Article 104873]. (b) omission: The software failure incident does not involve the system omitting to perform its intended functions at an instance(s). The issue with insufficient oil flow during vehicle startup is not described as a case of omission by the system [Article 104873]. (c) timing: The software failure incident is not related to the system performing its intended functions correctly but too late or too early. The issue with the engine computer's warmup procedure causing insufficient oil flow is not about timing problems [Article 104873]. (d) value: The software failure incident is related to the system performing its intended functions incorrectly. Specifically, the issue with the engine computer during startup leads to insufficient oil flow, which can cause serious damage to the vehicle [Article 104873]. (e) byzantine: The software failure incident is not characterized by the system behaving erroneously with inconsistent responses and interactions. The issue with the Cummins diesel engine's warmup procedure causing insufficient oil flow is a specific and consistent problem identified by FCA [Article 104873]. (f) other: The software failure incident in the article is primarily related to the system performing its intended functions incorrectly, leading to potential damage. The behavior of the software failure incident does not fall into the categories of crash, omission, timing, or byzantine behavior [Article 104873].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence no_consequence The consequence of the software failure incident related to the article is as follows: (g) no_consequence: The article mentions that there have been no reported injuries resulting from the software failure incident. [104873]
Domain transportation (a) The failed system in this incident was related to the transportation industry, specifically affecting Ram's 6.7-liter Cummins diesel engine found in certain models of Ram trucks [104873].

Sources

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