Incident: Defective Battery Production at A123 Systems' Michigan Plant

Published Date: 2012-03-26

Postmortem Analysis
Timeline 1. The software failure incident involving defective batteries made at A123 Systems' Livonia, Mich., plant happened in March 2012 as per Article 10641.
System unknown
Responsible Organization 1. A123 Systems' automated welding machine at its Michigan plant was responsible for causing the software failure incident [10641].
Impacted Organization 1. Fisker Automotive, specifically its Fisker Karma plug-in hybrid luxury car, was impacted by the software failure incident [10641].
Software Causes Unknown
Non-software Causes 1. Incorrect calibration of a welding machine caused a misalignment of certain components in a battery cell, leading to a break in electrical insulation and potential short circuit [10641].
Impacts 1. A123 Systems incurred a cost of $55 million to replace defective batteries made at its Livonia, Mich., plant, impacting the company financially [10641]. 2. The defect in the prismatic lithium ion cells caused issues for five auto companies, including delays and potential performance problems for the Fisker Karma plug-in hybrid luxury car [10641]. 3. The software failure incident led to concerns over demand for A123 Systems' batteries, particularly in transportation, causing the company's stock to languish [10641]. 4. Fisker Automotive reported a net loss of $85 million in the fourth quarter on revenue of $40.4 million, indicating financial impacts due to the delays and issues related to the defective batteries supplied by A123 Systems [10641].
Preventions 1. Implementing thorough quality control measures during the initial ramp-up phase at the Michigan plant could have potentially prevented the defect in the prismatic lithium ion cells. This could involve more rigorous testing procedures to catch misalignments and calibration errors in the welding machines [10641]. 2. Conducting regular maintenance and calibration checks on the automated welding machines to ensure they are functioning correctly and accurately aligning components in the battery cells could have helped prevent the misalignment issue that led to the defect [10641]. 3. Investing in comprehensive training programs for employees operating the welding machines to ensure they understand the importance of proper calibration and alignment of components in the battery cells, thereby reducing the likelihood of errors that could lead to defects [10641].
Fixes 1. Correcting the calibration of the welding machine that caused the misalignment of components in the battery cell could fix the software failure incident [10641].
References 1. CEO David Vieau during a conference call [10641]

Software Taxonomy of Faults

Category Option Rationale
Recurring unknown The articles do not mention any software failure incident related to either one_organization or multiple_organization. Therefore, the information about the software failure incident happening again at a specific organization or multiple organizations is unknown based on the provided articles.
Phase (Design/Operation) design Unknown
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the defective batteries at A123 Systems' Livonia, Mich., plant was caused by an incorrect calibration of one welding machine, leading to a misalignment of certain components in a battery cell. This misalignment resulted in a break in the electrical insulation and potential short circuit within the battery cells, ultimately causing the batteries to short out and prematurely fail [10641]. The CEO of A123 Systems, David Vieau, mentioned that the defect was isolated to a single automated welding machine at the Michigan plant, indicating an internal system issue within the manufacturing process. (b) outside_system: The software failure incident was not attributed to factors originating from outside the system. The defect in the prismatic lithium-ion cells was identified as an internal issue within A123 Systems' manufacturing process at their Michigan plant, specifically linked to a misalignment caused by incorrect calibration of a welding machine [10641].
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident in this case was not related to non-human actions but rather to a defect in the manufacturing process of the batteries. The issue was traced back to an incorrect calibration of an automated welding machine at A123 Systems' Michigan plant, which caused a misalignment of components in the battery cells leading to a potential short circuit [10641]. (b) The software failure incident was a result of human actions, specifically the incorrect calibration of the welding machine at the manufacturing plant. The misalignment caused by this human error led to the defect in the battery cells, ultimately resulting in the premature failure of the batteries [10641].
Dimension (Hardware/Software) hardware (a) The software failure incident in this case is related to hardware. The article mentions that the defect in A123 Systems' prismatic lithium ion cells, causing batteries to short out and prematurely fail, was due to an incorrect calibration of one welding machine at the Michigan plant. This misalignment of components in a battery cell led to a break in electrical insulation and potential short circuit, ultimately originating from a hardware issue [10641].
Objective (Malicious/Non-malicious) unknown unknown
Intent (Poor/Accidental Decisions) accidental_decisions The software failure incident described in the article does not directly relate to poor or accidental decisions. Instead, it is attributed to a defect in the manufacturing process of lithium-ion batteries at A123 Systems' plant in Michigan. The issue was traced back to an incorrect calibration of a welding machine, leading to misalignment of components in the battery cells, causing a potential short circuit [10641].
Capability (Incompetence/Accidental) unknown Unknown
Duration temporary The software failure incident described in the article is not related to a temporary or permanent failure caused by software issues. Instead, it pertains to a defect in A123 Systems' prismatic lithium ion cells, specifically due to an incorrect calibration of a welding machine at the Michigan plant. This defect led to a misalignment of components in the battery cell, causing a break in electrical insulation and potential short circuits in the batteries [10641].
Behaviour other (a) crash: The software failure incident in the article is not related to a crash where the system loses state and does not perform any of its intended functions. The failure is more related to a defect in the batteries causing them to short out and prematurely fail, leading to issues like the car not starting after being parked [Article 10641]. (b) omission: The software failure incident is not due to the system omitting to perform its intended functions at an instance(s). Instead, the issue is with a defect in the manufacturing process of the batteries that can cause them to fail prematurely [Article 10641]. (c) timing: The software failure incident is not due to the system performing its intended functions correctly but too late or too early. The issue is more related to a defect in the batteries that can lead to failures like the car not starting after being parked [Article 10641]. (d) value: The software failure incident is not due to the system performing its intended functions incorrectly. The issue is more related to a defect in the batteries causing them to short out and fail prematurely, affecting the starting of cars like the Fisker Karma [Article 10641]. (e) byzantine: The software failure incident is not related to the system behaving erroneously with inconsistent responses and interactions. The root cause of the issue was identified as a misalignment of components in the battery cells due to incorrect calibration of a welding machine, leading to potential shorts and failures [Article 10641]. (f) other: The behavior of the software failure incident in the article is more related to a manufacturing defect in the batteries that can cause them to short out and fail prematurely. The issue was traced back to a misalignment of components in the battery cells due to an incorrect calibration of a welding machine, rather than a specific software-related behavior [Article 10641].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property Property: The software failure incident resulted in a financial impact on A123 Systems, costing the company $55 million to replace defective batteries made at its plant in Michigan [10641].
Domain transportation, manufacturing, finance (a) The failed system was related to the transportation industry as it affected the Fisker Karma, a plug-in hybrid luxury car [10641]. (f) The manufacturing industry was impacted by the software failure incident as A123 Systems had to replace defective batteries made at its plant, affecting the production of battery packs for various auto companies [10641]. (h) The finance industry was indirectly affected as A123 Systems reported a net loss of $85 million in the fourth quarter due to delays in releasing the plug-in hybrid and scaled back sales projections of the Fisker Karma, for which it supplied batteries [10641]. (m) The failed system was not directly related to any other industry mentioned in the options provided.

Sources

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