Incident: Battery Pack Manufacturing Defect in Fisker Karma Software.

Published Date: 2012-03-26

Postmortem Analysis
Timeline 1. The software failure incident involving a fault in the battery packs fitted to the Fisker Karma sedan happened when the article was published on 2012-03-26 [10762].
System 1. Prismatic cells produced by A123 Systems at its Livonia, Michigan facility [10762]
Responsible Organization 1. A123 Systems [10762]
Impacted Organization 1. Fisker [10762] 2. A123 Systems [10762]
Software Causes 1. The software causes of the failure incident were not explicitly mentioned in the provided article [10762].
Non-software Causes 1. Manufacturing defect in some of the prismatic cells produced by A123 Systems at its Livonia, Michigan facility [10762]
Impacts 1. Decreased durability and battery underperformance were reported as impacts of the software failure incident in the high-voltage battery packs fitted to the Fisker Karma sedan [10762].
Preventions 1. Implementing thorough quality control measures during the manufacturing process of the prismatic cells by A123 Systems at its Livonia, Michigan facility could have prevented the software failure incident [10762]. 2. Conducting comprehensive testing and validation of the battery packs before installation in the Karma sedan could have helped identify the manufacturing defect earlier and prevent the issue from affecting the vehicles [10762]. 3. Regular software updates and maintenance checks on the vehicle's software systems could have potentially detected any anomalies or issues related to the battery performance, thus preventing the software failure incident [10762].
Fixes 1. Replacement of faulty battery packs with fault-free packs produced by A123 Systems [10762] 2. Vehicle software update to improve all aspects of the Karma, including powertrain and infotainment [10762]
References 1. Fisker 2. A123 Systems 3. Roger Ormisher, Fisker's director of global communications 4. Consumer Reports 5. Wired [Cited from Article 10762]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the high-voltage battery fault in the Fisker Karma sedan has happened again within the same organization. The article mentions that the issue involving a manufacturing defect in the battery packs was similar to the one that affected the Consumer Reports Karma previously [10762].
Phase (Design/Operation) unknown (a) The software failure incident related to the design phase is not explicitly mentioned in the provided article [10762]. (b) The software failure incident related to the operation phase is not explicitly mentioned in the provided article [10762].
Boundary (Internal/External) within_system (a) within_system: The software failure incident related to the Fisker Karma sedan involved a fault in the high-voltage battery packs supplied by A123 Systems. The issue was identified as a manufacturing defect in some of the prismatic cells produced by A123 Systems at its Livonia, Michigan facility. Fisker's director of global communications mentioned that a software update would be released to improve all aspects of the Karma, indicating that the failure was within the system [10762].
Nature (Human/Non-human) non-human_actions (a) The software failure incident in this case is related to a manufacturing defect in some of the prismatic cells produced by A123 Systems at its Livonia, Michigan facility, which could result in "battery underperformance and decreased durability" [10762]. This indicates a non-human_actions related failure. (b) The article does not provide information about the software failure incident being related to human actions.
Dimension (Hardware/Software) hardware (a) The software failure incident in this case is related to hardware. The article mentions a fault in the battery packs fitted to the Karma sedan, specifically a manufacturing defect in some of the prismatic cells produced by A123 Systems at its Livonia, Michigan facility. This hardware issue could result in "battery underperformance and decreased durability" [10762].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident mentioned in the article is non-malicious. The issue identified in the battery packs of the Fisker Karma sedan was due to a manufacturing defect in some of the prismatic cells produced by A123 Systems at its facility in Michigan. This defect could lead to "battery underperformance and decreased durability" [10762]. The article does not indicate any malicious intent behind the software failure incident.
Intent (Poor/Accidental Decisions) unknown The software failure incident mentioned in the article does not directly relate to poor decisions or accidental decisions. Instead, it focuses on a manufacturing defect in the battery packs produced by A123 Systems, leading to battery underperformance and decreased durability in Fisker's Karma sedan [10762].
Capability (Incompetence/Accidental) accidental (a) The software failure incident related to development incompetence is not mentioned in the provided article [10762]. (b) The software failure incident was due to an accidental manufacturing defect in some of the prismatic cells produced by A123 Systems at its Livonia, Michigan facility, leading to "battery underperformance and decreased durability" in the Karma sedan [10762].
Duration temporary The software failure incident mentioned in the article is temporary. Fisker plans a vehicle software update to improve all aspects of the Karma, indicating that the software issue is not permanent but can be addressed through an update [10762].
Behaviour crash, other (a) crash: The article mentions that Fisker plans a vehicle software update to improve all aspects of the Karma, indicating that there might have been a crash or system failure leading to the need for a software update [10762]. (b) omission: There is no specific mention of the system omitting to perform its intended functions in the provided article. (c) timing: There is no specific mention of the system performing its intended functions too late or too early in the provided article. (d) value: The article does not mention the system performing its intended functions incorrectly. (e) byzantine: The article does not describe the system behaving erroneously with inconsistent responses and interactions. (f) other: The behavior of the software failure incident in this case is related to a manufacturing defect in the high-voltage battery packs fitted to the Karma sedan, leading to battery underperformance and decreased durability. This defect is not directly related to the software itself but rather to the hardware component [10762].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property The consequence of the software failure incident described in the article is related to property. The software failure incident involving a fault in the battery packs fitted to the Fisker Karma sedan resulted in "battery underperformance and decreased durability" [10762]. This issue impacted the material goods (battery packs) of the affected vehicles, leading to decreased performance and durability.
Domain transportation, manufacturing (a) The failed system in the article was related to the transportation industry as it involved the replacement of faulty battery packs in Fisker Karma sedans [10762].

Sources

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