Incident: Regenerative Braking Issue in Toyota Prius, Impacting Safety Systems

Published Date: 2010-02-03

Postmortem Analysis
Timeline 1. The software failure incident involving faulty brakes on the Toyota Prius occurred in July 2009 [675].
System unknown
Responsible Organization 1. Toyota - The software failure incident in this case was related to faulty brakes on the Prius, a gas-electric hybrid car manufactured by Toyota [675].
Impacted Organization 1. Toyota - The software failure incident involving faulty brakes on the Prius impacted Toyota, leading to concerns over the safety of the vehicle and potential damage to Toyota's reputation [675].
Software Causes 1. Unknown
Non-software Causes 1.
Impacts 1. The software failure incident involving faulty brakes on the Toyota Prius led to a drop in Toyota's stock price by almost 5 percent in early trading [675]. 2. Concerns over the safety of the Prius due to brake malfunctions threatened to undermine Toyota's reputation, especially in its home market [675]. 3. The software failure incident with the Prius brakes could deal a second blow to Toyota's reputation for quality, following previous recalls related to sticky gas pedals and unintended acceleration [675]. 4. The software failure incident raised doubts about the effectiveness of the regenerative brake system in the Prius, impacting not only Toyota but also the entire industry and environmental advocates who saw the technology as a way to improve fuel economy and reduce emissions [675].
Preventions 1. Implementing more rigorous testing procedures during the development phase to catch any potential brake system software bugs or faults before the product release [675]. 2. Conducting thorough risk assessments and simulations to identify and address any possible scenarios where the regenerative brake system might fail or malfunction [675]. 3. Enhancing communication channels between the software development team and quality assurance team to ensure prompt identification and resolution of any software-related issues [675]. 4. Implementing a more robust monitoring and feedback system to gather real-world data on the performance of the regenerative brake system post-launch, allowing for quick response to any emerging problems [675].
Fixes 1. Conduct a thorough investigation into the reported brake malfunctions on the Prius to identify the root cause of the issue and determine if it is related to the software controlling the regenerative braking system [675]. 2. Implement software updates or patches to address any identified software-related defects or anomalies in the regenerative braking system of the Prius [675]. 3. Collaborate with experts in environmental engine technologies and urban systems engineering to ensure that the software controlling the regenerative braking system functions effectively and efficiently to improve fuel economy and reduce environmental impact [675].
References 1. Japanese authorities 2. Toyota executives 3. National Highway Traffic Safety Administration 4. Transport Ministry 5. Shinichi Sasaki, an executive at Toyota 6. John German, auto engineer and expert on environmental engine technologies 7. Danilo J. Santini, urban systems engineer at Argonne National Laboratory 8. Program director at the International Council on Clean Transportation 9. Japanese regulators 10. Transport Minister, Seiji Maehara [675]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization, multiple_organization (a) In the provided article [675], it is mentioned that Toyota had faced a quality crisis due to various issues with their vehicles, including the Prius. The Prius had been experiencing problems with faulty brakes, which led to concerns about safety and quality. This incident with the Prius was not the only issue Toyota was dealing with; they had also faced recalls of other models due to sticky gas pedals and unintended acceleration. The article highlights that Toyota executives were facing complaints about cars accelerating against the driver's will and failing to stop promptly when the brakes were applied. This indicates that the software failure incident related to faulty brakes in the Prius had happened again within the same organization, Toyota. (b) The article [675] also mentions that the National Highway Traffic Safety Administration in the United States had received complaints about the brakes on the 2010 Prius, with incidents of the vehicle surging forward or temporarily losing braking after driving over uneven surfaces. Some of these incidents resulted in crashes and injuries. This suggests that similar incidents related to faulty brakes may have occurred with other organizations or their products, indicating a broader issue in the industry beyond just Toyota.
Phase (Design/Operation) design, operation (a) The software failure incident related to the design phase can be inferred from the article. The article mentions concerns over the Prius's safety due to brake malfunctions, which could be attributed to a design flaw in the braking system of the hybrid Prius [675]. The article discusses how the Prius model was fitted with an overhauled regenerative brake system different from previous models, which had not caused any complaints. This indicates that the design change in the regenerative braking system for the newest Prius model may have introduced a potential flaw leading to brake malfunctions [675]. (b) The software failure incident related to the operation phase can also be identified from the article. The article reports complaints from drivers about the brakes on the 2010 Prius momentarily stopping working at low speeds, especially on slippery surfaces, and some incidents where the vehicle surged forward or temporarily lost braking after driving over uneven surfaces. These issues point towards operational challenges or misuse of the braking system in certain conditions, leading to failures during the operation of the vehicle [675].
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the Prius brakes can be categorized as within_system. The article mentions that concerns arose over the Prius's safety due to issues with the brakes on the hybrid model, specifically mentioning reports of momentary brake failure since the car went on sale in May [675]. The article also discusses how the Prius model was fitted with an overhauled regenerative brake system different from previous models, which had not caused any complaints, indicating an internal system change that could have contributed to the failure [675]. (b) outside_system: The software failure incident related to the Prius brakes does not seem to be primarily attributed to factors originating from outside the system. The focus of the article is on the internal issues with the Prius brakes, such as momentary brake failure and concerns over the regenerative brake system within the car itself [675]. There is no explicit mention of external factors causing the software failure incident in the provided article.
Nature (Human/Non-human) human_actions (a) The software failure incident related to non-human actions: - The article does not mention any software failure incident specifically caused by non-human actions. It primarily focuses on the issues with the Prius brakes and the potential problems related to regenerative braking technology [675]. (b) The software failure incident related to human actions: - The article discusses the concerns and complaints raised by drivers regarding the brakes on the 2010 Prius, indicating potential issues introduced by human actions or decisions during the design or manufacturing process [675].
Dimension (Hardware/Software) software (a) The software failure incident occurring due to hardware: - The article does not mention any software failure incident occurring due to contributing factors originating in hardware. (b) The software failure incident occurring due to software: - The article discusses a software failure incident related to the Prius model's brakes. Drivers reported issues with the brakes on the newest Prius model, with complaints of momentary brake failure at low speeds, especially on slippery surfaces [675]. - The article also mentions that the Prius model was fitted with an overhauled regenerative brake system different from the ones used in previous models, which had not caused any complaints. Toyota executives were investigating complaints related to the regenerative brakes in the Prius [675].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident related to the Prius brake issues does not appear to be malicious, but rather a non-malicious failure. The articles do not indicate any intentional actions by individuals to harm the system. The issues with the Prius brakes were attributed to potential defects in the regenerative brake system and conventional brakes, leading to concerns about safety and performance [675]. The focus was on investigating and addressing the technical problems rather than any malicious intent behind the software failure.
Intent (Poor/Accidental Decisions) unknown The software failure incident related to the Prius brake issues does not directly involve software failures but rather focuses on potential mechanical and electronic issues with the braking system. Therefore, the options of poor_decisions and accidental_decisions are not applicable in this context [675].
Capability (Incompetence/Accidental) accidental (a) The software failure incident related to development incompetence is not explicitly mentioned in the provided article [675]. (b) The software failure incident related to accidental factors is discussed in the context of the Prius brake issues. The article mentions concerns over the Prius's safety due to brake malfunctions, with reports of
Duration temporary The software failure incident related to the Prius brake issues described in Article 675 can be categorized as a temporary failure. The article mentions that drivers complained about the brakes on the newest Prius momentarily stopping working at low speeds, especially on slippery surfaces, and that the brakes momentarily lost braking after driving over a pothole or uneven surface [675]. These issues indicate that the failure was not permanent but rather occurred under specific circumstances, such as low speeds or uneven surfaces, suggesting a temporary nature of the software failure incident.
Behaviour crash, omission, value, other (a) crash: The software failure incident related to the Prius involved a crash where the brakes momentarily stopped working at low speeds, especially on slippery surfaces, leading to a collision in July 2009 [675]. (b) omission: The software failure incident involved the system omitting to perform its intended functions at instances where drivers complained that the brakes on the newest Prius momentarily stopped working, particularly after driving over potholes or uneven surfaces [675]. (c) timing: The software failure incident did not specifically mention a timing-related failure where the system performed its intended functions but too late or too early. (d) value: The software failure incident related to the Prius involved a value-related failure where the brakes on the newest Prius model were reported to have issues, such as the vehicle surging forward or temporarily losing braking functionality after certain driving conditions [675]. (e) byzantine: The software failure incident did not exhibit a byzantine behavior where the system behaved erroneously with inconsistent responses and interactions. (f) other: The software failure incident could be categorized under the "value" behavior as it involved the system performing its intended functions incorrectly, leading to safety concerns and accidents [675].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence harm (a) There were incidents mentioned in the article where the faulty brakes on the 2010 Prius led to crashes, resulting in injuries to individuals. For example, in one incident in July 2009, a Prius crashed head-on into another vehicle at an intersection, hurting two people in that car [675]. (b) The article mentions that there were cases where individuals were physically harmed due to the software failure. For instance, the National Highway Traffic Safety Administration in the United States logged at least 136 complaints about the brakes on the 2010 Prius, with four cases involving a crash, and two of those resulted in injuries [675].
Domain transportation <Article 675> The software failure incident related to the Prius involved issues with the braking system of the gas-electric hybrid vehicle. The incident affected the transportation industry, specifically the automotive sector, as the faulty brakes on the Prius led to concerns about safety and potential collisions [675]. The article highlights how the Prius, a symbol of cutting-edge technology and environmental awareness, faced a quality crisis due to reported brake malfunctions, which could undermine Toyota's reputation in the automotive market [675]. The software failure incident in this case directly impacted the transportation industry by raising concerns about the safety and reliability of hybrid vehicles.

Sources

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