Incident: Chevrolet Bolt Recall Due to LG Battery Manufacturing Defects

Published Date: 2021-08-25

Postmortem Analysis
Timeline 1. The software failure incident involving the faulty batteries in Chevrolet Bolt cars occurred in November [117433]. 2. The article was published on 2021-08-25. 3. Estimation: The incident occurred in November 2020.
System unknown
Responsible Organization unknown
Impacted Organization unknown
Software Causes unknown
Non-software Causes 1. Manufacturing defect in the cars' LG-made batteries [117433] 2. Torn anode tab and folded separator in the batteries [117433] 3. Issues in battery manufacturing at LG Chem factories [117433]
Impacts 1. The software failure incident led to the recall of every Chevrolet Bolt made to date, including new electric utility vehicle models, due to concerns about a manufacturing defect in the cars' LG-made batteries that could cause a fire [117433]. 2. The recall affected a total of nearly 142,000 cars, with over 100,000 having been sold in the US, leading to significant financial implications for GM. The initial recalls were estimated to cost $800 million, with an additional $1 billion expected for the latest recall [117433]. 3. As a result of the software failure incident, GM recommended that Bolt owners park their vehicles outside and limit their battery's state of charge to 90 percent or lower until replacement batteries are ready and service appointments can be scheduled [117433]. 4. The incident highlighted the challenges faced by battery manufacturers in balancing cost, stability, and performance when developing new chemistries for lithium-ion batteries used in electric vehicles, emphasizing the complexities and risks associated with battery technology [117433].
Preventions 1. Implementing rigorous quality control measures during the manufacturing process to detect and prevent defects in the batteries [117433]. 2. Conducting thorough testing and inspections on the batteries before they are installed in the vehicles to ensure they meet safety standards [117433]. 3. Enhancing collaboration and communication between the automaker (GM) and the battery supplier (LG Chem) to promptly address any identified issues and prevent widespread recalls [117433]. 4. Investing in research and development to explore alternative battery chemistries that offer improved stability and safety features to reduce the risk of fires [117433].
Fixes 1. Replacing the faulty batteries in the Chevrolet Bolt vehicles could fix the software failure incident [117433].
References 1. AP report [117433] 2. CNBC [117433]

Software Taxonomy of Faults

Category Option Rationale
Recurring unknown The articles do not mention any software failure incidents happening again at either the same organization (GM) or at multiple organizations. The focus of the articles is on the manufacturing defect in the Chevrolet Bolt's batteries, leading to fire risks and subsequent recalls. Therefore, the information related to software failure incidents happening again at specific organizations or across multiple organizations is unknown based on the provided articles.
Phase (Design/Operation) design Unknown
Boundary (Internal/External) within_system The software failure incident reported in the articles is related to a manufacturing defect in the LG-made batteries of Chevrolet Bolt electric vehicles, leading to concerns about potential fires. This incident falls under the category of within_system failure as the root cause of the issue originates from the manufacturing defects in the batteries themselves, which are integral components of the vehicles [117433].
Nature (Human/Non-human) non-human_actions, human_actions The software failure incident related to the Chevrolet Bolt battery recall is primarily attributed to non-human_actions, specifically a manufacturing defect in the LG-made batteries. The defects in the batteries, such as a torn anode tab and a folded separator, were identified as the root cause of the problem, leading to conditions that could cause a short in affected cells [117433]. However, human_actions also played a role in addressing the issue, as GM announced recalls and initiated efforts to replace the faulty batteries, seeking reimbursement from LG for the costs incurred. The collaboration between GM and LG Chem to rectify the problem and ramp up production of replacement cells demonstrates human intervention in response to the non-human-induced software failure incident [117433].
Dimension (Hardware/Software) hardware (a) The software failure incident in the GM Chevrolet Bolt recall was primarily due to hardware issues related to a manufacturing defect in the LG-made batteries. The defects in the batteries, specifically a torn anode tab and a folded separator, created conditions that could lead to a short in affected cells, ultimately causing fires in the vehicles [117433]. (b) The software failure incident did not have contributing factors originating in software.
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 to determine the nature of the software failure incident is unknown.
Intent (Poor/Accidental Decisions) unknown unknown
Capability (Incompetence/Accidental) accidental Development incompetence: The software failure incident related to the Chevrolet Bolt recalls was not directly attributed to development incompetence but rather to manufacturing defects in the LG-made batteries [117433]. Accidental: The software failure incident related to the Chevrolet Bolt recalls was accidental in nature, as it was caused by two manufacturing defects - a torn anode tab and a folded separator - that could occur simultaneously, leading to a short in affected cells [117433].
Duration unknown Unknown
Behaviour other (a) crash: The software failure incident in this case does not involve a crash of the system losing state and not performing any of its intended functions. The failure is related to a manufacturing defect in the cars' batteries that could cause a fire, leading to a recall of Chevrolet Bolt vehicles [117433]. (b) omission: The software failure incident is not related to the system omitting to perform its intended functions at an instance(s). Instead, the issue lies in the manufacturing defects in the batteries that could lead to fires, prompting the recall of the vehicles [117433]. (c) timing: The software failure incident is not due to the system performing its intended functions too late or too early. The issue is related to a manufacturing defect in the batteries that could potentially cause fires in Chevrolet Bolt vehicles [117433]. (d) value: The software failure incident is not due to the system performing its intended functions incorrectly. The issue stems from a manufacturing defect in the batteries that could result in fires, leading to the recall of the vehicles [117433]. (e) byzantine: The software failure incident does not involve the system behaving erroneously with inconsistent responses and interactions. The issue is specifically related to a manufacturing defect in the batteries of Chevrolet Bolt vehicles that could lead to fires, prompting a recall [117433]. (f) other: The behavior of the software failure incident in this case is related to a manufacturing defect in the batteries of Chevrolet Bolt vehicles that could potentially cause fires. This defect was traced to two manufacturing defects - a torn anode tab and a folded separator - that could lead to a short in affected cells, resulting in fires. The recall of the vehicles is aimed at addressing this safety concern [117433].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property, non-human (property) The consequence of the software failure incident related to the Chevrolet Bolt's battery manufacturing defect was primarily property damage. The defect in the LG-made batteries could cause a fire, leading to 10 fires involving faulty batteries identified by GM. As a result, GM announced a recall of nearly 142,000 cars, with estimated costs of $800 million for the initial recalls and an additional $1 billion for the latest recall. Owners were advised to park their vehicles outside, limit the battery's state of charge, and not let the estimated range dip below 70 miles until replacement batteries are ready [117433].
Domain manufacturing The software failure incident reported in the articles is related to the manufacturing industry. The incident involves a manufacturing defect in the LG-made batteries used in Chevrolet Bolt electric vehicles, leading to concerns about fires and subsequent recalls by GM [117433]. The defect was traced to two manufacturing defects in the batteries, specifically a torn anode tab and a folded separator, which could cause a short in affected cells [117433]. GM estimates significant costs for the recalls and replacement of batteries, indicating the impact on the manufacturing process [117433]. Additionally, the partnership between GM and LG Chem in a joint venture to manufacture Ultium batteries for electric vehicles further emphasizes the connection to the manufacturing industry [117433].

Sources

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