Incident: Tesla Model S and Model X Front Suspension Safety Issue

Published Date: 2020-11-27

Postmortem Analysis
Timeline 1. The software failure incident involving Tesla vehicles' front suspension safety issue happened in 2017 as per the article [107823].
System 1. Front suspension fore links in 2015-2017 Tesla Model S and 2016-2017 Tesla Model X vehicles [Article 107823]
Responsible Organization 1. Tesla - The software failure incident in the form of front suspension safety issues in Tesla vehicles was attributed to a manufacturing condition described in a service bulletin issued by Tesla [107823].
Impacted Organization 1. Tesla vehicles - The software failure incident impacted around 115,000 Tesla vehicles, specifically the 2015-2017 Model S and 2016-2017 Model X vehicles due to front suspension safety issues [107823].
Software Causes 1. Unknown
Non-software Causes 1. Manufacturing condition leading to front suspension fore link failures in Tesla vehicles [107823] 2. Defects in front and rear suspension control arm assembly components in Model S and X vehicles [107823] 3. Environmental factors in China requiring stronger suspension due to local roads and driving conditions [107823]
Impacts 1. The software failure incident in Tesla vehicles led to front suspension fore link failures, potentially causing the tire to contact the wheel arch liner, impacting vehicle control [107823]. 2. Complaints indicated failures during low-speed parking maneuvers and while driving, with some incidents occurring at highway speeds, posing safety risks [107823]. 3. The failure trend prompted a class-action lawsuit against Tesla over suspension issues in Model S and X vehicles, alleging premature failures of suspension control arm assembly components [107823]. 4. Tesla faced a recall of around 30,000 Model S and Model X vehicles in China for front suspension link issues, highlighting the global impact of the software failure incident [107823].
Preventions 1. Implementing rigorous quality control measures during the manufacturing process to ensure that front suspension components meet strength specifications [107823]. 2. Conducting thorough testing and inspection of front suspension components before vehicles are released to the market to detect any potential defects [107823]. 3. Proactively addressing reported complaints and issues related to front suspension failures to prevent them from escalating and causing safety concerns [107823].
Fixes 1. Conducting a thorough investigation into the front suspension safety issue in Tesla Model S and Model X vehicles to identify the root cause of the problem and implement necessary fixes [107823]. 2. Implementing a recall for affected vehicles to address the front suspension link issues and prevent potential failures [107823]. 3. Reviewing and potentially revising the manufacturing processes to ensure that front suspension fore links meet Tesla strength specifications to prevent future failures [107823]. 4. Enhancing quality control measures during production to prevent similar issues from occurring in new vehicles [107823].
References 1. U.S. National Highway Traffic Safety Administration (NHTSA) [Article 107823] 2. Tesla [Article 107823]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to Tesla vehicles' front suspension safety issue has happened again within the same organization. The U.S. National Highway Traffic Safety Administration (NHTSA) opened a formal investigation into around 115,000 Tesla vehicles over front suspension safety concerns, specifically regarding the failure of the left or right front suspension fore links in Model S and Model X vehicles [Article 107823]. (b) The software failure incident related to touchscreen failures in Tesla vehicles has also occurred at the same organization. NHTSA expanded a probe into nearly 159,000 Tesla Model S and Model X vehicles due to touchscreen failures that can result in various issues, including loss of rear-camera image display, reduced rear visibility, impact on defogging ability, and issues with audible chimes related to Autopilot and turn signals [Article 107823].
Phase (Design/Operation) design (a) The article mentions a software-related issue with Tesla vehicles' front suspension, specifically the front suspension fore links. The National Highway Traffic Safety Administration (NHTSA) opened an investigation into around 115,000 Tesla vehicles due to complaints alleging failure of the left or right front suspension fore links [107823]. This issue was linked to a manufacturing condition described in a 2017 service bulletin by Tesla, indicating that some vehicles had front fore links that did not meet Tesla strength specifications, potentially leading to link failures [107823]. (b) The article also discusses a separate software-related issue involving touchscreen failures in Tesla Model S and Model X vehicles. NHTSA opened a preliminary evaluation in June over touchscreen failures that could result in the loss of rear-camera image display, reduced rear visibility, impact defogging ability, and affect audible chimes related to Autopilot and turn signals [107823]. This issue is related to the operation of the vehicles and how the touchscreen functions during driving.
Boundary (Internal/External) within_system (a) The software failure incident related to the Tesla vehicles' front suspension safety issue seems to be within the system. The failure was attributed to a manufacturing condition that may result in front suspension fore link failures, as mentioned in a service bulletin issued by Tesla in February 2017 [107823]. The complaints and incidents reported to NHTSA also point towards issues with the front suspension components of the vehicles, indicating an internal system failure.
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident related to non-human actions: - The article mentions a front suspension safety issue in around 115,000 Tesla vehicles, specifically 2015-2017 Model S and 2016-2017 Model X vehicles, due to a manufacturing condition that may result in front suspension fore link failures [Article 107823]. - The failure of the front suspension fore links was attributed to a manufacturing condition that did not meet Tesla strength specifications, leading to potential failures during low-speed parking maneuvers or while driving [Article 107823]. (b) The software failure incident related to human actions: - Tesla issued a service bulletin in February 2017 describing the manufacturing condition that could lead to front suspension fore link failures, indicating a potential human error in the manufacturing process [Article 107823]. - A class-action lawsuit was filed against Tesla in the U.S. District Court in California over suspension issues in Model S and X vehicles, alleging defects that can result in premature failures of suspension control arm assembly components, suggesting potential human oversight or error in design or production [Article 107823].
Dimension (Hardware/Software) unknown (a) The articles do not mention any software failure incident related to hardware issues. (b) The articles do not mention any software failure incident related to software issues. Therefore, based on the provided articles, there is no information available regarding software failure incidents related to either hardware or software issues.
Objective (Malicious/Non-malicious) non-malicious (a) The articles do not mention any malicious software failure incidents related to the Tesla vehicles investigated by the U.S. National Highway Traffic Safety Administration (NHTSA) [107823]. (b) The software failure incidents related to Tesla vehicles investigated by NHTSA were non-malicious in nature. The failures were attributed to a front suspension safety issue, specifically concerning the front suspension fore links in certain Model S and Model X vehicles. The failures were linked to a manufacturing condition that may result in front suspension fore link failures, leading to potential contact between the tire and the wheel arch liner. Tesla issued a service bulletin in 2017 addressing this issue. Additionally, there were complaints of failures occurring during low-speed parking maneuvers and while driving, indicating a safety concern. Tesla stated that it did not believe there was a suspension defect and considered the issue "exceedingly rare" [107823].
Intent (Poor/Accidental Decisions) unknown The articles do not mention any software failure incident related to poor decisions or accidental decisions. Therefore, the intent of the software failure incident in this case is unknown.
Capability (Incompetence/Accidental) accidental (a) The articles do not mention any software failure incident related to development incompetence. (b) The articles mention a software failure incident related to accidental factors. The U.S. National Highway Traffic Safety Administration (NHTSA) opened a formal investigation into around 115,000 Tesla vehicles over a front suspension safety issue. The investigation was initiated after receiving 43 complaints alleging failure of the left or right front suspension fore links. Tesla had issued a service bulletin in February 2017 describing a manufacturing condition that may result in front suspension fore link failures. The agency noted that some vehicles had front fore links that did not meet Tesla strength specifications, leading to potential failures during low-speed parking maneuvers or while driving. The incidents reported an increasing trend, with some occurring at highway speeds within the last three months [107823].
Duration unknown The articles do not mention any software failure incident being permanent or temporary.
Behaviour other (a) crash: The articles do not mention any software failure incident related to a crash where the system loses state and does not perform any of its intended functions. (b) omission: The articles do not mention any software failure incident related to omission where the system omits to perform its intended functions at an instance(s). (c) timing: The articles do not mention any software failure incident related to timing where the system performs its intended functions correctly, but too late or too early. (d) value: The articles do not mention any software failure incident related to value where the system performs its intended functions incorrectly. (e) byzantine: The articles do not mention any software failure incident related to a byzantine behavior where the system behaves erroneously with inconsistent responses and interactions. (f) other: The articles describe a software failure incident related to a front suspension safety issue in Tesla vehicles. The failure involves the front suspension fore links not meeting Tesla strength specifications, potentially leading to link failures. This issue could be categorized as a "defect" where the system is not meeting the required specifications, leading to potential failures [107823].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence harm, property, theoretical_consequence The consequence of the software failure incident related to the Tesla vehicles' front suspension safety issue was primarily categorized under the following options: (d) property: The software failure incident resulted in defects in the front suspension fore links of Tesla Model S and Model X vehicles, potentially impacting the material goods (vehicles) of the owners [107823]. (h) theoretical_consequence: While Tesla stated that it did not believe there was any suspension defect and no U.S. recall was needed, there were concerns raised by complaints and a class-action lawsuit regarding defects that could lead to premature failure of suspension components, potentially causing harm or property damage [107823].
Domain transportation (a) The failed system in the incident reported in Article 107823 is related to the transportation industry. The U.S. National Highway Traffic Safety Administration (NHTSA) opened a formal investigation into around 115,000 Tesla vehicles over a front suspension safety issue, specifically the 2015-2017 Model S and 2016-2017 Model X vehicles [Article 107823]. This issue with the front suspension fore links could impact the safety and performance of the vehicles, which are part of the transportation industry.

Sources

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