Incident: Ford F-150 Lightning Recall: Tire Pressure Monitoring Software Issue

Published Date: 2022-06-27

Postmortem Analysis
Timeline 1. The software failure incident with the Ford F-150 Lightning trucks happened on June 27, 2022, as reported in [Article 128996] and [Article 129266].
System 1. Tire pressure monitoring system software in Ford F-150 Lightning trucks [Article 128996, Article 129266]
Responsible Organization 1. Ford Motor Co - Ford Motor Co was responsible for causing the software failure incident in the F-150 Lightning trucks due to a software issue in the tire pressure monitoring system [128996, 129266].
Impacted Organization 1. Ford Motor Co [128996, 129266]
Software Causes 1. The software issue in the tire pressure monitoring system of the Ford F-150 Lightning trucks was caused by the recommended tire cold inflation pressure value being incorrectly set to 35 psi instead of the correct inflation pressure of 42 psi [128996, 129266].
Non-software Causes 1. Incorrectly set recommended tire cold inflation pressure value of 35 psi instead of the correct 42 psi [128996, 129266] 2. Misapplied label for the tire pressure monitoring system [129266]
Impacts 1. The software failure incident in the Ford F-150 Lightning trucks led to a failure to provide adequate warning of low tire pressure, potentially resulting in poor vehicle handling and a possible loss of vehicle control, increasing the risk of a crash [128996, 129266]. 2. The incorrect setting of the recommended tire cold inflation pressure value to 35 psi instead of the correct 42 psi caused the tire pressure monitoring system light to not illuminate when intended, further exacerbating the risk of driving on improperly inflated tires [128996, 129266]. 3. The impacts of the software failure incident necessitated a recall of approximately 2,900 Ford F-150 Lightning trucks in the U.S. and Canada to address the issue and prevent potential accidents or injuries [128996, 129266].
Preventions 1. Proper validation and testing procedures during the software development phase to ensure accurate configuration of values in the tire pressure monitoring system could have prevented the software failure incident [128996, 129266]. 2. Implementing robust quality assurance processes to catch any discrepancies in recommended tire inflation pressure values before the vehicles are released to the market could have helped prevent the issue [128996, 129266]. 3. Conducting thorough risk assessments and scenario testing to identify potential safety risks associated with software bugs in critical systems like the tire pressure monitoring system could have preemptively addressed the issue [128996, 129266].
Fixes 1. Dealers will update the Body Control Module software for undelivered vehicles, and customers who want the remedy immediately can have a fix that takes approximately 20 minutes [128996]. 2. Ford will send an over-the-air update to fix the issue in 30 days for all current customers [129266].
References 1. Ford Motor Co press release [Article 128996] 2. Reporting by David Shepardson [Article 128996] 3. Ford [Article 129266]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the tire pressure monitoring system issue in Ford F-150 Lightning trucks is specific to Ford Motor Co. This incident is the first recall for the Ford electric pickup truck due to a software issue with the tire pressure monitoring system [128996, 129266]. (b) There is no information in the provided articles about a similar software failure incident happening at other organizations or with their products and services.
Phase (Design/Operation) design (a) The software failure incident in the Ford F-150 Lightning trucks was due to a design issue. The tire pressure monitoring system's control module was incorrectly configured during the development phase, setting the recommended cold-tire inflation pressure value to 35 psi instead of the correct 42 psi. This design flaw led to the TPMS light not illuminating when the tires were below the true recommended inflation, potentially causing poor vehicle handling and increasing the risk of a crash [128996, 129266]. (b) The articles do not provide information indicating that the software failure incident was due to factors introduced by the operation or misuse of the system.
Boundary (Internal/External) within_system (a) within_system: The software failure incident in the Ford F-150 Lightning trucks was due to a software issue within the system. Specifically, the tire pressure monitoring system's control module was incorrectly configured with a value of 35 psi for the recommended cold-tire inflation pressure instead of the correct 42 psi, leading to the TPMS light not illuminating when the tires were below the true recommended inflation [Article 128996, Article 129266]. (b) outside_system: There is no information in the articles suggesting that the software failure incident was caused by contributing factors originating from outside the system.
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident in this case was due to non-human actions. The issue stemmed from a software bug in the tire pressure monitoring system of the Ford F-150 Lightning trucks. The control module was incorrectly configured with a value of 35 psi for the recommended cold-tire inflation pressure instead of the correct 42 psi, leading to the TPMS light not illuminating when the tires were below the true recommended inflation level. This non-human error introduced a software issue that could potentially impact vehicle handling and increase the risk of a crash [Article 128996], [Article 129266]. (b) Human actions were involved in addressing the software failure incident. Ford announced a recall to address the software issue in the affected vehicles. Dealers will update the Body Control Module software for undelivered vehicles, and customers who want an immediate remedy can have the fix applied, which takes approximately 20 minutes. Additionally, Ford will provide an over-the-air update for all current customers within 30 days to address the software bug. Owners also have the option to visit dealerships for the software upgrade free of charge [Article 128996], [Article 129266].
Dimension (Hardware/Software) hardware, software (a) The software failure incident in the Ford F-150 Lightning trucks was due to a hardware-related issue. The tire pressure monitoring system light may not illuminate when intended and may not provide adequate warning of low tire inflation pressure because the recommended tire cold inflation pressure value was incorrectly set to 35 psi rather than the correct inflation pressure of 42 psi. This incorrect configuration of the control module in the hardware led to the software issue [128996, 129266]. (b) The software failure incident in the Ford F-150 Lightning trucks was due to a software-related issue. The software issue was specifically related to the incorrect configuration of the control module, which resulted in the tire pressure monitoring system not functioning as intended. The fix for this issue involved updating the Body Control Module software for undelivered vehicles and providing an over-the-air software update for all current customers [128996, 129266].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident related to the Ford F-150 Lightning trucks was non-malicious. The failure was due to a software bug in the tire pressure monitoring system, specifically the incorrect configuration of the control module with a value of 35 psi for the recommended cold-tire inflation pressure instead of the correct 42 psi. This led to the TPMS light on the dashboard not illuminating when the tires were below the true recommended inflation, potentially impacting vehicle handling and increasing the risk of a crash. Ford issued a recall to address this issue, with a fix that involved updating the Body Control Module software for undelivered vehicles and providing an over-the-air update for current customers [128996, 129266].
Intent (Poor/Accidental Decisions) poor_decisions (a) The software failure incident related to the Ford F-150 Lightning trucks was due to poor_decisions. The issue stemmed from the control module being incorrectly configured with a recommended cold-tire inflation pressure value of 35 psi instead of the correct 42 psi. This incorrect setting led to the tire pressure monitoring system not illuminating the warning light when the tires were below the true recommended inflation, potentially resulting in poor vehicle handling and an increased risk of a crash [128996, 129266].
Capability (Incompetence/Accidental) development_incompetence (a) The software failure incident related to development incompetence is evident in the articles. The incident occurred due to a software issue in the tire pressure monitoring system of Ford F-150 Lightning trucks. The problem arose because the recommended tire cold inflation pressure value was incorrectly set to 35 psi instead of the correct inflation pressure of 42 psi. This misconfiguration was a result of human error or lack of professional competence during the development or configuration of the control module software [128996, 129266]. (b) The software failure incident does not appear to be accidental. The articles do not mention the failure being accidental; instead, they highlight the specific issue with the tire pressure monitoring system software and the incorrect configuration of the recommended tire inflation pressure value [128996, 129266].
Duration temporary The software failure incident related to the tire pressure monitoring system in the Ford F-150 Lightning trucks can be categorized as a temporary failure. The issue was caused by the incorrect configuration of the control module, setting the recommended cold-tire inflation pressure value to 35 psi instead of the correct 42 psi. This led to the TPMS light on the dashboard not illuminating when the tires were below the true recommended inflation, potentially impacting vehicle handling and increasing the risk of a crash. However, Ford was able to provide a fix for the issue through a software update. The fix was implemented by updating the Body Control Module software for undelivered vehicles and offering an over-the-air update for all current customers within 30 days [128996, 129266].
Behaviour omission, value, other (a) crash: The software failure incident in this case is not related to a crash where the system loses state and does not perform any of its intended functions. The issue with the tire pressure monitoring system in the Ford F-150 Lightning trucks did not lead to a complete system failure but rather a specific issue with the tire pressure monitoring functionality [128996, 129266]. (b) omission: The software failure incident can be categorized under omission as the system omitted to perform its intended function of providing adequate warning of low tire pressure. The incorrect setting of the recommended tire cold inflation pressure value led to the TPMS light not illuminating when the tires were below the correct inflation pressure, thus omitting to alert the driver of the low tire pressure [128996, 129266]. (c) timing: The software failure incident is not related to timing issues where the system performs its intended functions but at the wrong time. The issue with the tire pressure monitoring system was more about incorrect settings rather than timing-related problems [128996, 129266]. (d) value: The software failure incident falls under the category of value as the system performed its intended functions incorrectly. The incorrect setting of the recommended tire cold inflation pressure value to 35 psi instead of the correct 42 psi led to the failure to provide adequate warning of low tire inflation pressure [128996, 129266]. (e) byzantine: The software failure incident is not characterized by a byzantine behavior where the system behaves erroneously with inconsistent responses and interactions. The issue with the tire pressure monitoring system was more straightforward, involving an incorrect setting that affected the system's functionality in a specific way [128996, 129266]. (f) other: The software failure incident can be categorized as a specific software bug related to the tire pressure monitoring system in the Ford F-150 Lightning trucks. The issue was identified as a software bug that led to the incorrect setting of the recommended tire cold inflation pressure value, impacting the system's ability to provide accurate warnings of low tire pressure [128996, 129266].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property, non-human, theoretical_consequence The consequence of the software failure incident related to the Ford F-150 Lightning trucks was primarily related to potential harm and property impact. The software issue in the tire pressure monitoring system could lead to poor vehicle handling and a possible loss of vehicle control, increasing the risk of a crash. However, there were no reported accidents or injuries connected to the recall, indicating that the potential harm was a theoretical consequence that did not materialize [128996, 129266]. The property impact was in terms of the incorrect tire pressure setting causing a potential risk to the vehicles and the need for a software update to rectify the issue [128996, 129266].
Domain transportation, manufacturing (a) The software failure incident reported in the articles is related to the manufacturing industry, specifically affecting Ford Motor Co's 2021 F-150 Lightning trucks. The failure was due to a software issue in the tire pressure monitoring system, which could lead to inadequate warning of low tire pressure, potentially impacting vehicle handling and safety [Article 128996, Article 129266].

Sources

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