Incident: Hyundai Kona EV Battery System Recall due to Fire Risks

Published Date: 2021-02-24

Postmortem Analysis
Timeline 1. The software failure incident involving the Hyundai Kona Electric occurred in late January 2021 [Article 111716]. 2. The incident can be estimated to have happened in January 2021 based on the information provided in Article 111716.
System 1. Battery management system in the Hyundai Kona Electric vehicles [Article 111716, Article 112829] 2. Battery cells produced at LG Energy's China factory [Article 111716]
Responsible Organization 1. LG Energy Solution, a division of LG Chem Ltd, was mentioned to have misapplied suggestions for fast-charging logic in the battery management system, deflecting criticism and stating that the battery cell should not be seen as the direct cause of the fire risks [111716]. 2. Hyundai Motor Co was responsible for causing the software failure incident as they were mentioned to have misapplied LG's suggestions for fast-charging logic in the battery management system, leading to fire risks in their electric vehicles [111716].
Impacted Organization 1. Hyundai Motor Co [Article 111716, Article 112829] 2. LG Energy Solution (a division of LG Chem Ltd) [Article 111716, Article 112829]
Software Causes 1. Misapplication of LG's suggestions for fast-charging logic in the battery management system by Hyundai [111716] 2. Defects found in some battery cells produced at LG Energy's China factory [111716]
Non-software Causes 1. Misapplication of fast-charging logic in the battery management system by Hyundai, according to LG Energy Solution [111716]. 2. Defects found in some battery cells produced at LG Energy's China factory, as reported by South Korea's transport ministry [111716].
Impacts 1. The software failure incident led to a costly $900 million recall for Hyundai, involving the replacement of battery systems in some 82,000 electric vehicles globally [Article 111716]. 2. The incident caused delays and poor communication in the recall process, leading to frustration among owners and potential loss of trust in Hyundai as a brand [Article 112829]. 3. Owners expressed concerns about privacy and potential backlash from Hyundai, impacting their willingness to continue using Hyundai vehicles in the future [Article 112829]. 4. The incident resulted in a class-action lawsuit filed by 173 Kona EV owners seeking compensation for the reduced value of their vehicles and other losses [Article 112829]. 5. The software failure incident affected the reputation of Hyundai and LG Energy Solution, with both companies facing criticism and potential reputational damage [Article 111716].
Preventions 1. Proper testing and validation of the software upgrade implemented in the first recall could have potentially prevented the software failure incident that led to the fires in the Hyundai Kona EVs [111716]. 2. Clear communication and collaboration between Hyundai and LG Energy Solution regarding the fast-charging logic in the battery management system could have helped prevent misapplications that led to fire risks [111716]. 3. Timely and effective communication with customers regarding the recall process and replacement plans could have mitigated delays and frustrations among Kona EV owners, potentially preventing negative impacts on customer loyalty and brand reputation [112829].
Fixes 1. Implementing a clear and effective communication plan with affected customers to provide timely updates and information on the recall process [112829]. 2. Ensuring transparent and detailed communication with customers regarding the battery replacement process and timeline [112829]. 3. Addressing potential issues with battery supplies and ensuring a steady flow of replacement batteries for affected vehicles [112829]. 4. Reviewing and improving the handling of customer complaints and concerns, including offering compensation where necessary [112829]. 5. Conducting a thorough investigation into the root cause of the software failure to prevent similar incidents in the future [111716].
References 1. Hyundai Motor Co 2. LG Energy Solution 3. Korea Institute for Industrial Economics & Trade 4. South Korea's transport ministry 5. Hyundai owners 6. Lee Hang-koo, executive adviser at the Korea Automotive Technology Institute

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident having happened again at one_organization: The software failure incident related to the Hyundai Kona Electric vehicles occurred again within the same organization. The Kona EV was first recalled late last year for a software upgrade after a spate of fires. However, one of the recalled Kona EVs caught fire in January, leading to concerns about the adequacy of the first recall [Article 111716]. (b) The software failure incident having happened again at multiple_organization: There is no specific information in the provided articles about the software failure incident happening again at other organizations or with their products and services.
Phase (Design/Operation) design, operation (a) The software failure incident in the Hyundai Kona Electric vehicles was primarily related to the design phase. The incident was attributed to a software upgrade conducted late last year after a spate of fires, which was followed by another fire in January. LG Energy Solution, the manufacturer of the batteries, mentioned that Hyundai misapplied their suggestions for fast-charging logic in the battery management system, indicating a design flaw in the software implementation [111716]. (b) Additionally, there were issues related to the operation phase. Some Kona EV owners complained about delays and poor communication from Hyundai regarding the battery replacement process, leading to frustration and concerns about safety. Owners mentioned difficulties in getting clear information on when their vehicles would be fixed, indicating operational challenges in managing the recall process effectively [112829].
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the Hyundai Kona Electric vehicles was primarily within the system. The initial recall was for a software upgrade after a spate of fires involving the Kona EVs [111716]. The software upgrade was offered to address the issue of fires, but it was later determined that the software upgrade was not sufficient, leading to the decision to replace the battery systems in the affected vehicles [112829]. The failure originated from within the system in terms of the software management of the battery systems in the vehicles.
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident occurring due to non-human actions: - The software failure incident related to the Hyundai Kona Electric vehicles was primarily due to battery system issues, specifically fire risks associated with the battery packs [Article 111716]. - LG Energy Solution, the manufacturer of the batteries, mentioned that the battery cell should not be seen as the direct cause of the fire risks, indicating that the issue was not solely due to the battery cells themselves [Article 111716]. (b) The software failure incident occurring due to human actions: - LG Energy Solution stated that Hyundai misapplied LG's suggestions for fast-charging logic in the battery management system, implying that human actions in the application of these suggestions may have contributed to the fire risks [Article 111716]. - There were complaints from Kona EV owners about delays and poor communication from Hyundai regarding the battery replacement process, which could be attributed to human actions in managing the recall process [Article 112829].
Dimension (Hardware/Software) hardware, software (a) The software failure incident occurring due to hardware: - The software failure incident related to the Hyundai Kona Electric vehicles was primarily due to battery system issues, specifically fire risks originating from the battery systems [Article 111716]. - LG Energy Solution, the manufacturer of the batteries, mentioned that Hyundai misapplied LG's suggestions for fast-charging logic in the battery management system, indicating a hardware-related issue in the battery management system [Article 111716]. (b) The software failure incident occurring due to software: - The initial recall of the Kona EV was for a software upgrade after a spate of fires, suggesting a software-related issue that needed to be addressed [Article 111716]. - Hyundai offered a software upgrade in October to address the issue of fires in the Kona EVs, indicating a software-related issue that required a fix [Article 112829].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident related to the Hyundai Kona Electric vehicles was non-malicious. The incident involved a recall of 82,000 electric vehicles globally due to fire risks associated with the battery systems. The recall was initiated after a spate of fires involving the Kona EV, leading to concerns about safety and the need for battery replacements [Article 111716, Article 112829]. (b) The software failure incident was not malicious but rather a result of issues with the battery management system and defects in some battery cells produced at LG Energy's China factory. The incident was attributed to misapplication of fast-charging logic in the battery management system, and there were disagreements between Hyundai and LG Energy Solution regarding the cause of the fires. The focus was on addressing the safety concerns and potential fire hazards associated with the battery systems in the electric vehicles [Article 111716].
Intent (Poor/Accidental Decisions) poor_decisions (a) The software failure incident related to the battery fires in Hyundai's Kona EVs was primarily due to poor decisions. Hyundai had initially conducted a software upgrade after a spate of fires, but one of the recalled Kona EVs caught fire again, leading to a probe by South Korean authorities to determine if the first recall was adequate [111716]. LG Energy Solution, the manufacturer of the batteries, mentioned that Hyundai misapplied their suggestions for fast-charging logic in the battery management system, indicating a misalignment in decision-making between the two companies [111716]. Additionally, there were delays and poor communication in the recall process, with owners expressing frustration over the lack of clarity and communication from Hyundai, potentially exacerbating the situation [112829].
Capability (Incompetence/Accidental) development_incompetence (a) The software failure incident occurring due to development incompetence: - The software failure incident involving the Hyundai Kona Electric was initially addressed with a software upgrade after a series of fires [Article 111716]. - Hyundai faced criticism for misapplying LG's suggestions for fast-charging logic in the battery management system, potentially contributing to the fire risks [Article 111716]. - There were concerns about the adequacy of the first recall and whether it had been effective in addressing the fire risks, leading to a probe by South Korean authorities [Article 111716]. (b) The software failure incident occurring accidentally: - The software failure incident involving the Hyundai Kona Electric was initially addressed with a software upgrade after a series of fires [Article 111716]. - Hyundai faced criticism for misapplying LG's suggestions for fast-charging logic in the battery management system, potentially contributing to the fire risks [Article 111716]. - LG Energy Solution, the manufacturer of the batteries, stated that the battery cell should not be seen as the direct cause of the fire risks, implying that the issue may have been accidental rather than intentional [Article 111716].
Duration temporary The software failure incident related to the Hyundai Kona Electric vehicles was temporary. The initial recall late last year for a software upgrade was conducted after a spate of fires, indicating that the software issue was introduced by certain circumstances [111716]. Additionally, the article mentions that following a consumer outcry and at least one fire in a vehicle that had been recalled for the upgrade, Hyundai agreed to replace the batteries, indicating that the software upgrade did not fully address the issue [112829].
Behaviour crash, value, other (a) crash: The software failure incident in the Hyundai Kona Electric vehicles can be categorized as a crash. The article mentions that the vehicles were first recalled for a software upgrade after a spate of fires, indicating that the software was not functioning correctly, leading to potential safety hazards [111716]. (b) omission: There is no specific mention of the software failure incident being related to omission in the articles. (c) timing: The software failure incident is not related to timing issues where the system performs its intended functions but at the wrong time. (d) value: The software failure incident in the Hyundai Kona Electric vehicles can be categorized as a value failure. LG Energy Solution, the manufacturer of the batteries, mentioned that Hyundai misapplied LG's suggestions for fast-charging logic in the battery management system, indicating that the system was not performing its intended functions correctly, leading to fire risks [111716]. (e) byzantine: There is no indication in the articles that the software failure incident exhibited byzantine behavior with inconsistent responses and interactions. (f) other: The software failure incident could also be categorized as a flaw in the system design or implementation, leading to potential safety risks and the need for a costly recall of battery systems in the electric vehicles [111716].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property, delay, non-human, other (a) death: People lost their lives due to the software failure - There were no reported deaths due to the software failure incident related to the Hyundai Kona EV battery fires [Article 111716, Article 112829]. (b) harm: People were physically harmed due to the software failure - The articles do not mention any physical harm caused to individuals due to the software failure incident [Article 111716, Article 112829]. (c) basic: People's access to food or shelter was impacted because of the software failure - The articles do not mention any impact on people's access to food or shelter due to the software failure incident [Article 111716, Article 112829]. (d) property: People's material goods, money, or data were impacted due to the software failure - Owners of the Hyundai Kona EVs were impacted as they faced delays and poor communication regarding the battery replacement, potentially leading to a reduced value of their vehicles and other losses [Article 112829]. (e) delay: People had to postpone an activity due to the software failure - Owners of the Hyundai Kona EVs had to delay the replacement of their battery systems due to poor communication and delays in the recall process [Article 112829]. (f) non-human: Non-human entities were impacted due to the software failure - The software failure incident primarily affected the battery systems in Hyundai Kona EVs, leading to fire risks and subsequent recalls for battery replacements [Article 111716, Article 112829]. (g) no_consequence: There were no real observed consequences of the software failure - The software failure incident resulted in significant consequences such as fire risks, recalls, delays, and potential loss of value for the affected vehicles [Article 111716, Article 112829]. (h) theoretical_consequence: There were potential consequences discussed of the software failure that did not occur - The articles do not mention any potential consequences discussed that did not occur due to the software failure incident [Article 111716, Article 112829]. (i) other: Was there consequence(s) of the software failure not described in the (a to h) options? What is the other consequence(s)? - The software failure incident led to frustration among owners, concerns about privacy, potential backlash from Hyundai, and the initiation of a class-action lawsuit seeking compensation for reduced vehicle value and other losses [Article 112829].
Domain transportation, finance (a) The failed system was related to the transportation industry as it involved the recall of battery systems in Hyundai's electric vehicles, particularly the Kona EV model, due to fire risks [Article 111716, Article 112829]. (h) The incident also has implications for the finance industry as the recall of 82,000 electric vehicles globally is estimated to cost Hyundai $900 million, highlighting the financial impact of such software failures [Article 111716, Article 112829]. (m) The software failure incident is not directly related to any other industry mentioned in the options provided.

Sources

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