Incident: Ford Mustang Mach-E EV 12-Volt Battery System Failure Incident

Published Date: 2021-04-08

Postmortem Analysis
Timeline 1. The software failure incident with the Ford Mustang Mach-E occurred before February 3rd, as mentioned in Article 113851. 2. Published on 2021-04-08, the incident likely happened in January 2021 or earlier.
System 1. 12-volt battery system in Ford Mustang Mach-E EV [113210, 113851]
Responsible Organization 1. Ford Motor Co. [113210, 113851]
Impacted Organization 1. Owners of Ford Mustang Mach-E EVs [Article 113210, Article 113851]
Software Causes 1. Software glitch causing the 12-volt battery to discharge while the larger high-voltage battery pack is charging [Article 113851] 2. Vehicle computer not allowing the 12-volt battery to charge from the high-voltage propulsion battery when the vehicle was on a charger, leading to draining of the 12-volt battery overnight [Article 113210]
Non-software Causes 1. The 12-volt battery system in the Ford Mustang Mach-E was unable to charge itself properly due to the vehicle computer not allowing it to siphon off energy from the high-voltage propulsion battery when the vehicle was on a charger [113210]. 2. The latch of the frunk in the Mach-E, which is electronically controlled, relied on power from the 12-volt battery, causing issues when the battery was drained [113210]. 3. A software glitch in the Mach-E caused the smaller 12-volt battery to discharge while the larger high-voltage battery pack was charging, leading to the vehicle being unable to start after charging [113851].
Impacts 1. Some early owners of Ford's Mustang Mach-E experienced a significant fault with the 12-volt battery system, leading to their vehicles being unable to start after charging [113210, 113851]. 2. The software glitch in the Mach-E caused the smaller 12-volt battery to discharge while the larger high-voltage battery pack was charging, resulting in the vehicle being in Deep Sleep Mode or becoming bricked [113210, 113851]. 3. Owners faced the inconvenience of not being able to start their vehicles after charging, requiring them to contact their local EV-certified Ford dealer for a resolution [113210, 113851]. 4. Ford had to issue a technical service bulletin to address the issue and dealers had to reprogram several electronic control modules on the affected vehicles to correct the software glitch [113851].
Preventions 1. Implement thorough testing procedures to identify and address potential software glitches before releasing the vehicle to customers [Article 113851]. 2. Conduct comprehensive quality assurance checks specifically focusing on the interaction between the 12-volt battery system and the vehicle's charging process [Article 113210]. 3. Enhance monitoring systems to detect early signs of battery discharge issues and implement proactive measures to prevent complete vehicle immobilization [Article 113851]. 4. Ensure robust communication channels with customers to promptly address any emerging software-related problems and provide timely solutions [Article 113210].
Fixes 1. Reprogramming several of the electronic control modules on the vehicle [113851] 2. Contacting the local EV-certified Ford dealer to have the matter resolved [113210]
References 1. The Verge [Article 113210, Article 113851] 2. National Highway Traffic Safety Administration [Article 113851]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the Ford Mustang Mach-E's 12-volt battery problem has happened again within the same organization. Ford Motor Co's newest electric vehicle, the Mustang Mach-E, experienced a battery problem that left some vehicles unable to start after charging due to a software glitch causing the 12-volt battery to discharge while the high-voltage battery pack is charging [113851]. Ford acknowledged the issue and mentioned that a small number of Mach-Es built before Feb. 3 were affected, and dealers could correct the problem by reprogramming electronic control modules on the vehicle [113851]. (b) The software failure incident related to the Ford Mustang Mach-E's 12-volt battery problem has not been reported to have happened at other organizations or with their products and services in the provided articles.
Phase (Design/Operation) design, operation (a) The software failure incident related to the design phase is evident in the articles. The issue with the 12-volt battery system in Ford's Mustang Mach-E EV was caused by a software glitch that led to the smaller 12-volt battery discharging while the larger high-voltage battery pack was charging [Article 113851]. This design flaw in the software architecture resulted in the vehicles being unable to start after charging, impacting the user experience and functionality of the EV. (b) The software failure incident related to the operation phase is also highlighted in the articles. Owners of the early Mach-E models found their vehicles in Deep Sleep Mode after leaving them on the charger overnight, rendering the EVs unusable [Article 113210]. This operational issue was caused by the vehicle computer not allowing the 12-volt battery to charge itself when the vehicle was on a charger, leading to the draining of the battery overnight in some instances.
Boundary (Internal/External) within_system, outside_system (a) within_system: The software failure incident with the Ford Mustang Mach-E EV was caused by a software glitch within the vehicle's system. The glitch caused the smaller 12-volt battery to discharge while the larger high-voltage battery pack was charging, leading to the vehicles being unable to start after charging [Article 113851]. (b) outside_system: The software failure incident was also influenced by factors outside the system, such as the charging process and the interaction between the 12-volt battery and the high-voltage propulsion battery. The issue arose when the vehicle computer prevented the 12-volt battery from charging itself while the vehicle was on a charger, leading to the draining of the 12-volt battery in some instances [Article 113210].
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident occurring due to non-human actions: - The software glitch causing the 12-volt battery discharge while the larger high-voltage battery pack is charging was identified as a contributing factor in the failure incident [Article 113851]. (b) The software failure incident occurring due to human actions: - The issue with the 12-volt battery system in the Mustang Mach-E was attributed to the vehicle computer not allowing the 12-volt battery to charge itself when the vehicle was on a charger, leading to draining of the battery overnight in some instances [Article 113210].
Dimension (Hardware/Software) hardware, software (a) The software failure incident related to hardware: - The incident with the Ford Mustang Mach-E EV was caused by a fault in the 12-volt battery system, specifically related to how the 12-volt battery keeps itself charged [113210]. - The issue was described as a software glitch that caused the smaller 12-volt battery to discharge while the larger high-voltage battery pack was charging, leading to the vehicle being unable to start after charging [113851]. (b) The software failure incident related to software: - The incident was primarily attributed to a software glitch that caused the 12-volt battery problem in the Ford Mustang Mach-E EV [113851]. - Ford mentioned that dealers could correct the issue by reprogramming several of the electronic control modules on the vehicle, indicating a software-related fix [113851].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident related to the Ford Mustang Mach-E EV was non-malicious. The incident was caused by a software glitch that led to the vehicle's smaller 12-volt battery discharging while the larger high-voltage battery pack was charging. This glitch resulted in owners being unable to start their vehicles after charging [Article 113851]. Ford acknowledged the issue and stated that only a small number of Mach-Es built before a certain date were affected. The problem could be corrected by reprogramming several electronic control modules on the vehicle [Article 113851]. Additionally, Ford issued a technical service bulletin to assist its technicians in addressing the issue, indicating a proactive approach to resolving the software glitch [Article 113210].
Intent (Poor/Accidental Decisions) accidental_decisions [a] The software failure incident related to the Ford Mustang Mach-E EV was primarily due to accidental_decisions. The incident was caused by a software glitch that led to the vehicle's smaller 12-volt battery discharging while the larger high-voltage battery pack was charging [Article 113851]. This unintended consequence resulted in owners being unable to start their vehicles after charging, requiring dealers to reprogram several electronic control modules to correct the issue.
Capability (Incompetence/Accidental) development_incompetence (a) The software failure incident related to the Ford Mustang Mach-E EV was primarily due to development incompetence. The incident was caused by a software glitch that led to the vehicle's 12-volt battery discharging while the larger high-voltage battery pack was charging [Article 113851]. This issue was identified as affecting a small number of Mach-Es built before a certain date, indicating a fault in the development process that allowed this glitch to occur. Additionally, the article mentions that Ford issued a technical service bulletin to assist its technicians in resolving the issue, indicating that the company had to actively work on fixing the problem caused by the software glitch [Article 113210]. This proactive response suggests that the software failure was a result of a lack of professional competence in ensuring the proper functioning of the vehicle's battery system. (b) The incident does not seem to be related to an accidental software failure. The articles do not mention any accidental factors contributing to the software glitch that caused the battery problem in the Ford Mustang Mach-E EV.
Duration temporary The software failure incident related to the Ford Mustang Mach-E involved a temporary failure. The issue was caused by a software glitch that discharged the vehicle's 12-volt battery while the larger high-voltage battery pack was charging. Ford mentioned that only "a small number" of Mach-Es built before Feb. 3 were affected by this issue, and dealers were able to correct the problem by reprogramming several electronic control modules on the vehicle [Article 113851]. Additionally, Ford proactively worked with early owners experiencing this issue to identify the root cause and a fix. In rare instances where the problem still occurred, customers could contact their local EV-certified Ford dealer to have the matter resolved. Ford issued a technical service bulletin to assist its technicians in sorting out the issue, indicating that the problem was not permanent but could be addressed through reprogramming and fixes [Article 113210].
Behaviour crash, omission, value, other (a) crash: The software failure incident in the articles can be categorized as a crash. Owners of the Ford Mustang Mach-E experienced a situation where the vehicle's 12-volt battery system failed, leading the vehicle to enter Deep Sleep Mode, rendering it unusable or "bricked" [113210]. This crash occurred due to the system losing its state and not performing its intended functions as the vehicle could not be started after charging, indicating a significant failure in the software system. (b) omission: The software failure incident can also be categorized as an omission. The issue arose from a software glitch that caused the smaller 12-volt battery to discharge while the larger high-voltage battery pack was charging, leading to the omission of the intended function of maintaining the 12-volt battery's charge [113851]. (c) timing: The timing of the software failure incident is not explicitly mentioned in the articles. (d) value: The software failure incident can be categorized as a value failure. The system performed its intended functions incorrectly by not allowing the 12-volt battery to charge itself when the vehicle was on a charger, leading to the draining of the battery overnight and rendering the vehicle unusable [113210]. (e) byzantine: The software failure incident is not described as a byzantine failure in the articles. (f) other: The other behavior exhibited by the software failure incident is the system behaving in a way that caused the latch of the frunk to be electronically latched, with the power coming from the 12-volt battery. This behavior added to the complexity of the issue and the challenges faced by the owners in accessing the battery for a jump start [113210].

IoT System Layer

Layer Option Rationale
Perception processing_unit, embedded_software (a) sensor: The articles do not mention any sensor-related issues contributing to the software failure incident [113210, 113851]. (b) actuator: The articles do not mention any actuator-related issues contributing to the software failure incident [113210, 113851]. (c) processing_unit: The software failure incident in the articles is related to a processing error. The issue was caused by a software glitch that led to the smaller 12-volt battery discharging while the larger high-voltage battery pack was charging [113851]. (d) network_communication: The articles do not mention any network communication-related issues contributing to the software failure incident [113210, 113851]. (e) embedded_software: The software failure incident in the articles is related to embedded software error. The issue was caused by a software glitch in the Mustang Mach-E EV that left some vehicles unable to start after charging [113851].
Communication unknown The software failure incident related to the Ford Mustang Mach-E EV was not directly related to the communication layer of the cyber-physical system that failed. Instead, the incident was attributed to a software glitch causing the vehicle's smaller 12-volt battery to discharge while the larger high-voltage battery pack is charging [Article 113851]. This issue led to owners being unable to start their vehicles after charging, and Ford addressed the problem by reprogramming several electronic control modules on the vehicle. The failure was more related to the interaction between the vehicle's battery systems and software rather than a failure at the communication layer of the cyber-physical system.
Application FALSE The software failure incident related to the Ford Mustang Mach-E EV was not specifically mentioned to be related to the application layer of the cyber physical system. The articles primarily highlighted a battery problem caused by a software glitch that affected the 12-volt battery system of the vehicle, leading to issues with starting the vehicle after charging. Therefore, based on the information provided in the articles, it is unknown whether the failure was related to the application layer of the cyber physical system [Article 113210, Article 113851].

Other Details

Category Option Rationale
Consequence property (a) death: People lost their lives due to the software failure (b) harm: People were physically harmed due to the software failure (c) basic: People's access to food or shelter was impacted because of the software failure (d) property: People's material goods, money, or data was impacted due to the software failure (e) delay: People had to postpone an activity due to the software failure (f) non-human: Non-human entities were impacted due to the software failure (g) no_consequence: There were no real observed consequences of the software failure (h) theoretical_consequence: There were potential consequences discussed of the software failure that did not occur (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 consequence of the software failure incident described in the articles is related to option (d) property. The software glitch in Ford's Mustang Mach-E caused a problem with the 12-volt battery system, leading to the vehicles being unable to start after charging, impacting the owners' property as their vehicles became unusable [113210, 113851].
Domain transportation (a) The software failure incident related to the Ford Mustang Mach-E EV affected the transportation industry as it impacted the functionality of the electric vehicle, rendering it unusable for owners [Article 113210, Article 113851].

Sources

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