NHTSA, Ford and CO Poisoning: Sickening

If your local police department has a fleet of Ford Explorer Interceptors, it’s probably trying to determine if the vehicle – an Explorer modified for law enforcement use – is sickening its officers during long periods of idling or hard acceleration. But if you are the civilian owner of one of these vehicles, keep a close eye on the noises Ford or the National Highway Traffic Safety Administration makes about a recall.     

In July 2016, NHTSA’s Office of Defects Investigation opened a probe into reports of occupants smelling exhaust odors in the occupant compartments of 2011-2015 Explorers. “Complainants expressed concerns about exposure to carbon monoxide.” At the time, the agency had tallied 154 complaints. What happened in the Preliminary Evaluation was – up until two weeks ago – anyone’s guess, because other than the Opening Resume and an Information Request letter to Ford demanding a response by August 24, 2016, nothing else was ever added to the public file.

In the space of a year, the complaints piled up. Ford reported fielding 2,051, while 791 drivers complained to NHTSA’s Vehicle Owner’s Questionnaire hotline. Some of those complaints were getting mad press because they came from police departments from Auburn, Mass. to Austin, Texas. Ford owns a large share of the law enforcement vehicle market. Introduced to the fleet in 2012, the Interceptor accounted for 60 percent of Ford police vehicle sales in 2013 – more than 14,000 police SUVs. By 2015, Ford was bragging in a press release that the Interceptor “quickly became America's best-selling police vehicle – which has helped Ford capture 61 percent market share through June 2015.”

Inconveniently for public safety, and Ford’s bottom line and brand ID as the go-to automaker for law enforcement, at least five officers lost consciousness, were hospitalized for CO exposure or crashed their SUVs after huffing the cabin air of their Interceptors.  For example, in September 2015, a Newport Beach, California officer “passed out while driving his Interceptor,” swerving “across two lanes of oncoming traffic, nearly hitting another car head on, and crashed into a tree at 55 mph,” according to CNN. After an Auburn, Massachusetts officer rear-ended another vehicle in late July, he and the vehicle tested positive for carbon monoxide.  

As stories of police departments parking their Interceptors have proliferated, Ford has been dispatching investigative teams to municipalities to assess the damage and assure its customers whose vehicles are paid for by the taxpayers that it will “cover the costs in every Police Interceptor with this issue, no matter what its age, mileage or post-purchase modifications,” according to news reports. 

If you paid for an Explorer directly from your own pocket, Ford seems a lot less interested in solving your problem – although there have been civilian Explorer buy-backs, and several apparently unsuccessful Technical Service Bulletins. Nonetheless, the company has been very careful to build what is known in Ford internal circles as the “defendable fence,” a way to limit the defect to a discreet population of vehicles, protecting the company from a much bigger recall that could include more than a million vehicles. This term surfaced in a 1995 memo on ignition switch fires in 28 million 1983 to 1995 light trucks and passenger cars with the same design. Ford has used this strategy to limit recalls of Ford F-150 cruise control deactivation switch fires, thick film ignition and stuck throttles.

The Explorer’s Chief Engineer Bill Gubing has been out there pushing the idea that the carbon monoxide is entering the occupant compartment via unsealed spaces and wiring holes drilled in the course of implementing after-market features specific to police work, such as emergency lights and radios. Other Ford Explorer owners need not be concerned Gubing reportedly said:

From a carbon monoxide perspective, the police duty cycle is very different than what a retail customer drives…It creates more combustion gas at the back of the vehicle because the engine’s working harder and faster. At the same time, there are modifications done to the back of the vehicle that certainly provide leak paths when those modifications are not done properly. We don’t see the retail customers driving like that. We don’t see retail customers with those modifications.

So that’s how carbon monoxide is getting into police Explorers. How is it getting into many, many, many more Explorers owned by regular folk? According to several Technical Service Bulletins Ford issued in 2012, 2014 and 2016, this problem surfaces when “the auxiliary climate control system is on,” and “may be worsened when the climate control system is in recirculate mode and the vehicle is heavily accelerated for an extended period.” The fixes concerned replacing vents, checking drain valves and reprogramming the heating ventilation air conditioning module to the latest calibration. 

In late July, ODI bumped up the investigation to an Engineering Analysis. By then the agency had collected 791 complaints and identified 41 injuries such as headaches, nausea and light-headedness in 25 incidents. Only 11 complaints involved police Interceptors. 

NHTSA’s first take on the Interceptor problem is cracks in the exhaust manifold, not deliberate, aftermarket perforations. Its tests at the Vehicle Research and Test Center (VRTC) in East Liberty, Ohio, along with field inspections, has led it to theorize that “CO levels may be elevated in certain driving scenarios, although the significance and effect of those levels remains under evaluation as part of the EA.” But it has also suggested that NHTSA may well respect Ford’s fence: “To date, no substantive data or actual evidence (such as a carboxyhemoglobin measurement) has been obtained supporting a claim that any of the alleged injury or crash allegations were the result of carbon monoxide poisoning, the alleged hazard.” 

The consumer-reported Vehicle Owner’s Questionnaires certainly support the notion that CO levels can become elevated during acceleration. Civilians, who also need to accelerate their vehicles – even if not engaging in a high-speed chase – have been reporting that the fumes engulf them when they hit the gas hard.

An owner from Strabane, Pennsylvania told NHTSA in June 2016:

Several times when driving two of my children ages 2 and 10 complained of a bad smell coming from the third row seating. They both became strangely ill, but only my 2 year old began vomiting. My 10 year old complained of being light headed during several long trips. I noticed on many occasions that during high acceleration anyone that sits in the third row complains of stomach aches after a lengthy time in the vehicle. I chalked it up to car sickness, but remembered this only became relevant when leasing this ford. Please help us. I have three kids and no other vehicle.

An Explorer owner in Canyon County, California told NHTSA in February 2017:

While driving the car on the freeway and under acceleration there is a horrible exhaust smell that makes my kids and myself nauseous. It also gives me constant headaches. I didn't realize what was happening until my husband got in the car for the first time and noticed the exhaust smell.

An owner from Brandon, Missouri reported in January 2017:

The smell is very harsh smells like burnt hair or sulfur. On long trips my wife has had severe headaches. This Explorer is the vehicle my wife and kids (ages 14, 5, & 2) use to get to work and school; I need to get this vehicle repaired or replaced. Please help!!!

From the owner of a 2015 Explorer in Juno Beach, Florida:

After heavy acceleration, the cabin has a strong foul sulfur odor that is unbearable. We have had it in to a Ford dealership to have both TSBs performed – the second took 5 days! And it still has not changed. Disgusting smell. This happens when we accelerate as on to the highway or to pass in challenging situations. I only have to press the gas pedal about half way down for 4-5 seconds and the smell is overwhelming. Activating the turbo chargers for any length of time brings this smell into the cabin. Then all of the windows have to go down to clear the smell. My mother can't take this anymore and my wife complains of headaches. This has been an ongoing for a year and a half!

Despite this defect’s high profile, the public information has only dribbled out of the National Highway Traffic Safety Administration’s Office of Defects Investigation. Neither Ford’s response to the Preliminary Evaluations or any work the agency has done has been shared with the public. As it opened the Engineering Analysis, ODI summarized parts of Ford’s response and testing it was doing out in East Liberty. The files themselves are not accessible, despite the agency’s regular transparency proclamations. 

For example, in 2012, the agency requested a $10,611,000 appropriation for Safety Defects Investigation activities, $782,000 above the FY 2010 funding level, to, among other things, “ensure that all public information related to investigations, recalls, and complaints is current.” In June 2015, NHTSA released a Workforce Assessment report in which one of its purported goals for ODI was: “Assure that information relating to investigations and recalls is readily available to the public.” On its website, NHTSA states that “NHTSA is committed to providing the most accurate and complete information available to its customers, the American traveling public, in a helpful and courteous fashion.”

Unfortunately, help and courtesy does not come cheap. In June, Safety Research & Strategies submitted a Freedom of Information Request for the non-confidential documents in the investigative file, and the agency told us that they’d be happy to oblige for about $780 dollars. 

First, these materials shouldn’t require a FOIA request – at least according to NHTSA. By law, all federal agencies are required to publish records that because of “the nature of their subject matter, the agency  determines have become or are likely to become the subject of subsequent requests for substantially the same records; or that have been requested 3 or more times.” In addition, agencies are required to publish a general index of those frequently-requested records. NHTSA’s Electronic Reading Room webpage listing those categories of records that “are available without the need for a FOIA request:” includes such “frequently requested records and information” such as downloads of defect investigation records. 

We’ve argued that these documents should be released at no charge because the information is squarely in the public interest, and because NHTSA by custom and by regulation is supposed to put non-confidential investigative material in the public files. We’ve requested that the fee be waived. Stay tuned.

Autonomous Vehicles – The Beta Test Coming to a Roadway Near You

The National Highway Traffic Safety Administration’s Automated Vehicles web page breathlessly forecasts: “Vehicle safety technologies signal the next revolution in roadway safety. We see great potential in these technologies to save lives—more than 30,000 people die on our roads every year and we can tie 94 percent of crashes to human choice—transform personal mobility and open doors to communities that today have limited mobility options.”

Sounds like an amazing marvel of tomorrow – and none too soon in the wake of recent news that traffic fatalities may have risen 6 percent over 2015. The National Safety Council estimated last month that 40,200 people died in motor vehicle crashes in 2016– the highest annual death toll since 2007. The increase comes on the heels of an 8 percent rise in traffic deaths in 2015. The two-year jump would be the largest in 53 years, according to the safety group.

But will autonomous vehicles – already driving among us with little to no oversight, regulation, or data collection – really deliver on its promise?

Already, two Tesla drivers have died in crashes that occurred while the vehicle was in Autopilot mode. In January 2016, a 23-year-old Chinese man died when his Tesla Model S crashed into a road-sweeper on a highway south of Beijing, according to a report on a Chinese government news channel. Five months later, Joshua Brown, a 40-year-old Tesla enthusiast died when his Tesla Model S crashed into a semi-trailer that had made a left-hand turn in front of it. NHTSA later said that the Tesla’s sensing system failed to distinguish the white tractor trailer against the sky and did not apply the brakes.  

By September, Tesla Motors Chief Executive Elon Musk announced that Tesla would impose limits on the vehicle’s semi-autonomous Autopilot function that would have potentially prevented Mr. Brown’s demise. According to news reports, the improvements were delayed by fears of the system over-reacting to information in the driving environment.

Musk said he had wanted to improve Autopilot’s capabilities last year but was told it was impossible to do so without incurring more “false positives.”  Two months after the Brown crash, Musk tweeted publicly that supplier Bosch had given him encouraging news about   improvements to its radar.

“I wish we could have done it earlier,” Musk said in an interview. “The perfect is the enemy of the good.”

Feds Bypass Regulation

The federal government, for the most part, has responded to the advent of automotive autonomy by vigorously shaking its pom-poms, consistently declaring its intention to “speed the deployment of lifesaving technology”

From The Federal Automated Vehicle Policy: “At each level, the safety potential grows as does the opportunity to improve mobility, reduce energy consumption and improve the livability of cities. To realize these tremendous benefits, NHTSA believes it should encourage the adoption of these technologies and support their safe introduction.”

From the preamble of NHTSA Enforcement Guidance Bulletin 2016–02: Safety-Related Defects and Emerging Automotive Technologies: “As the world moves toward autonomous vehicles and innovative mobility solutions, NHTSA is interested in facilitating the rapid advance of technologies that will promote safety.”

From NHTSA’s Automated Vehicles website: “The DOT Federal Automated Vehicles Policy sets the framework for the safe and rapid deployment of these advanced technologies.”

To hurry things along, NHTSA has issued two guidance bulletins, accompanied by requests for comments and held two public meetings, billed as an exploration of related topics, such as adapting the Federal Aviation Administration’s pre-market approval approach as a replacement for self-certification.

Enforcement Bulletin

First, NHTSA re-asserted its powers under The Safety Act to regulate autonomous vehicles. In April, the agency published in the Federal Register Enforcement Guidance Document 2016-02, a brief declaration of the agency’s “broad enforcement authority, under existing statutes and regulations, to address existing and emerging automotive technologies. technologies—including its view that when vulnerabilities of such technology or equipment pose an unreasonable risk to safety, those vulnerabilities constitute a safety-related defect—and suggests guiding principles and best practices for motor vehicle and equipment manufacturers in this context.”

The five-page Federal Register Notice walked readers through some of the seminal court cases of the 1970s that established enforcement standards: The 1975 “Wheels” decision, involving broken wheels in GM pickup trucks, which defined a safety defect; and the 1977 Pitman Arms Case, involving the failure of the steering mechanism in GM Cadillacs, which defined the concept of “unreasonable risk to safety.”

Then, the agency defined automated vehicle technologies, systems, and equipment – including software, even code that enables devices not located in or on the vehicle – as motor vehicle equipment, whether original equipment or after-market.

The agency warned would-be violators to iron out the kinks in their systems before bringing their products to market and to promptly follow the requirements of The Safety Act. At the same time, the agency was clear that it was not establishing a binding set of rules, or implementing a one-size-fits-all enforcement policy. In fact, it rallied its all-purpose, case-by-case approach to the cause:

 “NHTSA’s statutory enforcement authority is general and flexible, which allows it to keep pace with innovation.” (To the contrary, the agency’s history has repeatedly shown that it trails innovation badly, that it will ignore deaths and injuries caused by changes in automotive technology until Congress forces it to act, or regulates after a particular technology – warts and all – is already in widespread use, and codifies bad designs. For example, the agency has yet to correct the rollaway and carbon monoxide poisoning introduced by keyless ignitions via regulations.)

And, the agency signaled that its approach would be expansive:

“NHTSA considers the likelihood of the occurrence of a harm (i.e., fire, stalling, or malicious cybersecurity attack), the potential frequency of a harm, the severity of a harm, known engineering or root cause, and other relevant factors. Where a threatened harm is substantial, low potential frequency may not carry as much weight in NHTSA’s analysis.”

In the case of an unprotected network that hackers might access, the agency said that it would weigh several factors in determining the probability of a malicious cyber-attack: the amount of time that had elapsed since the vulnerability was discovered, how hard it would be to breach the system, the level of expertise and the equipment needed; whether the public had access to information about how the system works and the window of opportunity to exploit the system.

NHTSA offered the following example of a foreseeable vulnerability that might trigger agency action, even if no incidents have occurred:

“If a cybersecurity vulnerability in any of a motor vehicle’s entry points (e.g., Wi-Fi, infotainment systems, the OBD–II port)allows remote access to a motor vehicle’s critical safety systems (i.e., systems encompassing critical control functions such as braking, steering, or acceleration), NHTSA may consider such a vulnerability to be a safety related defect compelling a recall.”

The enforcement bulletin drew 37 commenters. (Safety Research & Strategies was among them, expressing concern that the framing language in the Guidance Bulletin was contradictory and its emphasis misplaced: “More importantly, we note that the agency, is in fact, doing very little to regulate automotive software and new technology, and absent rulemaking in this area, the rapid cycle automotive defect crises will continue and potentially accelerate.”)

The Telecommunications Industry Association re-stated a position it has long held – that the agency has no jurisdiction over their products: “We are concerned that NHTSA’s proposed guidance would potentially bring a broad range of  technologies under the agency’s enforcement authority beyond what is intended by the governing statute.”

Carmakers were more alarmed by the agency’s intentions of enforcing The Safety Act as it relates to cyber security. Tesla, the Alliance of Automobile Manufacturers and the Global Automakers all pushed back against the agency’s intention to treat a cyber-vulnerability as a defect:

“The Alliance submits, however, that a defect related to motor vehicle safety does not automatically exist merely because the engineering or root cause of a cybersecurity “vulnerability” is known. As discussed in more detail below, a theoretical “vulnerability”       to potential system failures through hacking or otherwise is not the same as an actual “risk” that is currently present in an item of motor vehicle equipment.”

NHTSA responded in the Final Notice of its enforcement bulletin, published that September by backing off, saying that it would take up cyber-security issues in a future interpretations and guidance.  

The Federal Automated Vehicles Policy

In tandem, the agency published the Federal Automated Vehicles Policy. The 116-page document, also released for comment in September 2016, was “intended as a starting point that provides needed initial guidance to industry, government, and consumers.” The document outlined what the agency deems best practices in safe design, development and testing prior to sale or deployment on public roads.

NHTSA declined to undertake actual rulemaking “to speed the delivery of an initial regula­tory framework and best practices to guide manufacturers.”

Instead, the Guidance is full of fine, vague language regarding system safety, cyber security, consumer privacy and education. Automakers should “follow a robust design and validation process based on a systems-engineering approach with the goal of designing HAV systems free of unreasonable safety risks.” They should “follow guidance, best practices, design principles, and standards developed by established standards organiza­tions.” Given how automakers have introduced innovations such as keyless ignitions and drive-by-wire systems without regulations, this gives us little comfort.

The agency also noted its interest in automakers’ definitions of the Operational Design Domain (ODD) of their HAVs – meaning the vehicle’s capabilities according to roadway types, the geographic area, the speed range and the environmental conditions in which it will operate – and its Object and Event Detection and Response (OEDR) – how it detects and responds to other vehicles, pedestrians, cyclists, animals, and objects in a variety of conditions.

The Model State Policy is another aspect of the guidance document. Neither NHTSA nor automakers want a patchwork of state regulations impeding the agency’s damn-the-torpedoes strategy. In fact, it advises states to “evaluate their current laws and regulations to address unnecessary impediments to the safe testing, deployment, and operation of HAVs.” So, it has been working with the administrators of state Department of Motor Vehicles to develop the first set of ground rules for states that allow manufacturers to test their HAVs on public roads (See what California is doing below.) NHTSA wants each state to create a special bureaucracy for automated vehicles including a “jurisdictional automated safety technology committee,” to establish rules and authority for regulating autonomous cars, including registrations, and applications for testing vehicles and licenses for test drivers.

In the absence of federal regulations, the agency intends to rely on some new regulatory tools. In the short-term, the agency wants to launch a new quasi-certification report called a Safety Assessment. Safety Assessments are used by the Nuclear Regulatory Commission and the Food and Drug Administration in various forms as a way of methodically evaluating risks to food safety and the handling of nuclear waste. NHTSA is proposing that manufacturers voluntarily provide reports about how closely they are hewing to the recommendations in the guidance document. Automakers and suppliers would submit these assessments to the Chief Counsel’s Office outlining their adherence to NHTSA’s broad outlines, their timelines for testing and deployment on public roads. They would cover data recording and sharing; privacy; system safety; vehicle cybersecurity; human machine interface; crashworthiness; consumer education and training; registration and certification; post-crash behavior; federal, state and local laws; ethical considerations; operational design domain; object and event detection and response; fall back (minimal risk condition).

Automakers probably have plenty of time to prepare. NHTSA won’t publish a Federal Register notice implementing this reporting it until it clears the Paperwork Reduction Act, a 1995 law requiring that any public information request to get Office of Management and Budget approval. Given the anti-regulatory bent of the GOP Congress and the near-daily turmoil that is the Trump White House, we don’t see any disclosures happening anytime soon.

In the long-term, NHTSA is looking at several options to ensure that HAVs enter the marketplace safely. One is the pre-market approval authority process, modeled after that used by the Federal Aviation Administration. Another is a hybrid certification and approval process, in which manufacturers could certify compliance with FMVSS and NHTSA or a third-party expert could conduct pre-market approval for those HAV features that are not covered by an FMVSS

NHTSA has already held two meetings on this policy, gathering panels of stakeholders, which did not seem to include too many domain experts, to engage in short discussions about topics such as  Safety Assurance,  Pre-Market Approval Authority,  Imminent Hazard Authority; Expanded Exemption Authority for HAVs.

But, as the guidance documents tells us, this is just a first step. NHTSA needs to conduct more research, scout out new standards to govern the initial testing and deployment of HAVs, and the agency’s approach will evolve as the level of automation in HAVs rises. Or so the document promises.

The First HAV Investigation

If the agency’s first six-month enforcement investigation into the alleged failure of an automated vehicle is any measure, manufacturers shouldn’t fear that NHTSA is going to stray too far from its well-established habits.

On May 7, 2016, Joshua Brown, died when his Tesla Model S, in Autopilot mode, crashed into an 18-wheel tractor-trailer truck that was turning left in front of it on US 27A, west of Williston, Florida. According to the Florida Highway Patrol, the vehicle underrode the truck, tearing off its top before it proceeded east on U.S. 27A. The vehicle left the roadway and struck several fences and a power pole, before coming to rest about 100 feet south of the highway. Brown, a 40-year-old Tesla enthusiast from Ohio, died at the scene.

June 21, 2016, NHTSA sent a Special Crash Investigations team to the crash site to evaluate the vehicle and study the crash environment. It concluded that Brown had increased the cruise control speed to 74 mph two minutes before the crash, and took no evasive action, nor did he apply the brake. The tractor trailer should have been visible to the Tesla driver for at least seven seconds prior to impact.” This report has not yet been made publicly accessible.

On June 28, 2016, the Office of Defects Investigation opened Preliminary Evaluation 16-007 into the crash that killed Brown. Officially, the investigation focused on “the Automatic Emergency Braking (AEB) or Autopilot systems that “may not function as designed, increasing the risk of a crash.”

The agency’s nine-page Information Request, issued on July 8, contained very specific questions. Question 7, for example had 12 sub-parts, seeking – among other things – information about Tesla’s object recognition and classification process for rear-end collision and crossing path collisions, how the Tesla S’s system detects compromised or degraded sensor/camera signals, the kinematic models the Tesla S used to judge collision risk, and all inhibit and override/suppression conditions.

Over the course of the seven-month investigation, Tesla filed four responses that were placed in the publicly accessible file.

On January 19, the agency closed the investigation with no defect finding, saying that the system performed as designed, and blamed the Brown for the crash:

“NHTSA’s examination did not identify any defects in the design or performance of the AEB or Autopilot systems of the subject vehicles nor any incidents in which the systems did not perform as designed. AEB systems used in the automotive industry through MY 2016 are rear-end collision avoidance technologies that are not designed to reliably perform in all crash modes, including crossing path collisions. The Autopilot system is an Advanced Driver Assistance System (ADAS) that requires the continual and full attention of the driver to monitor the traffic environment and be prepared to take action to avoid crashes. Tesla’s design included a hands-on the steering wheel system for monitoring driver engagement. That system has been updated to further reinforce the need for driver engagement through a “strike out” strategy. Drivers that do not respond to  visual cues in the driver monitoring system alerts may “strike out” and lose Autopilot function for the remainder of the drive cycle.”

Yet, this investigation was full of oddities. For one, the agency played hardball in wresting information out of Tesla, and its former supplier Mobileye. Under the regime of the recently-departed Administrator Mark Rosekind, the agency did not hesitate to bring its full authority to bear on the information-gathering portion of the probe. In an unusual move, the agency actually issued a subpoena for the diagnostic log data for another apparent Autopilot failure, involving a Tesla Model X.

The agency also issued three Special Orders.

One Special Order was issued to supplier Mobileye, a technology company that makes advanced- driver assistance systems using cameras and software to scout objects in a vehicle’s path. The Order sought communications between it and Tesla regarding hands-free operation in Autopilot mode. The Order also asked for an explanation of the “proper and substantial technological restrictions and limitations” Mobileye thought should have been in place before hands-free operation was permitted; and any other safety concerns, guidance or warnings that Mobileye might have communicated to Tesla about Autopilot’s limitations, intended use and potential misuse.

The agency’s first Special Order to Tesla sought information about incidents (or alleged incidents) of Autopilot failures that Tesla was receiving – especially if Tesla wanted to make a public statement about it before reporting it to NHTSA – for the duration of the investigation. An Amended Special Order, issued in October, required Tesla to continue weekly reporting of incidents – by COB every Friday – until further notice.

These Special Orders appear to be responses, in part, to public statements by Tesla and Mobileye. It is not unheard of for a manufacturer or supplier to defend its reputation during an ongoing investigations – especially if it involves high profile deaths. However, Tesla and Mobileye were particularly determined to get out in front of the probe, and direct public attention to their own analyses.

Two days after receiving NHTSA’s Information Request, Tesla issued a public statement about the crash, attributing the Autopilot’s indifference to a large object directly in its path to a white-out conditions:

“Neither Autopilot nor the driver noticed the white side of the tractor trailer against a brightly lit sky, so the brake was not applied. The high ride height of the trailer combined with its positioning across the road and the extremely rare circumstances of the impact caused the Model S to pass under the trailer, with the bottom of the trailer impacting the windshield of the Model S. Had the Model S impacted the front or rear of the trailer, even at high speed, its advanced crash safety system would likely have prevented serious injury as it has in numerous other similar incidents.”

In September, Mobileye issued a press release, pushing back against any suggestion that it bore responsibility for the crash. The release asserted that it had warned Tesla that the Autopilot should not have been allowed to operate hands-free “without proper and substantial technological restrictions and limitations,” but that Tesla disregarded those admonitions, releasing it “hands-free” in late 2015, after assuring Mobileye that it would not do so.

“Mobileye has made substantial efforts since then to take more control on how this project can be steered to a proper functional safety system. Tesla’s response to the May 7 crash, wherein the company shifted blame to the camera, and later corrected and shifted blame to the radar, indicated to Mobileye that Mobileye’s relationship with Tesla could not continue. Failing agreement on necessary changes in the relationship, Mobileye terminated its association with Tesla. As for Tesla’s claim that Mobileye was threatened by Tesla’s internal computer vision efforts, the company has little knowledge of these efforts other than an awareness that Tesla had put together a small team.”

Finally, this investigation was notable for the amount of black on Tesla’s four responses submitted to the public file. In its August 8 and September 2 submissions to the questions in the IR, every answer is redacted, as are separate submissions to answer Question 7 and Question 10, about the automaker’s assessment of the alleged defect. A fifth response has a few bits of information available for public consumption, but most of the test is blacked-out.

In reviewing literally hundreds of investigations, The Safety Record can honestly say that we have never seen investigation responses in the public file so redacted – especially with no request for confidentiality on file. In fact, the IR specifically instructs Tesla to submit all confidential business information directly to the Office of Chief Counsel. In addition, the IR notes, “do not submit any business confidential information in the body of the letter submitted to this office [ODI].” Instead, Tesla addressed its responses to ODI, which presumably painted them black and put them in the public file. There are no requests from Tesla for confidentiality in the public file.

Also missing from the public file were any responses Mobileye filed in response to its Special Order.

In the end, we know very little about Tesla’s responses to the crash, except – Tesla’s first response was to blame it on a white-on-white interpretation error. Only later did Tesla argue that its Automatic Emergency Braking system was never designed to recognize a front-to-side crash. According to one answer that escaped the censor’s Sharpie:

“Like other manufacturers’ AEB systems, Tesla’s AEB is designed to mitigate front-to-rear collisions,” Tesla said.

If that was the case, why didn’t Tesla say that from the beginning?

State Legislation

In the absence of federal regulations, several states have passed legislation related to autonomous vehicles, and more – six in 2012 to 20 in 2016 – consider such legislation each year. Currently California, Florida, Louisiana, Michigan, Nevada, North Dakota, Tennessee, Utah and Virginia—and Washington D.C. have laws on the books, while Arizona and Massachusetts governors have issued executive orders, according to the National Council on State Legislatures related to autonomous vehicles.

California was one of the most active regulatory schemas. In 2014, the state passed regulations for the registration of autonomous vehicles with the Department of Motor Vehicles. Currently, 22 companies have registered, including Google, Bosch, Delphi, Honda, Mercedes-Benz, Tesla, Ford, Volvo, Nissan, Subaru and GM. (Transportation problem child Uber has been  testing its autonomous vehicles without seeking a permit, throwing the litigation-magnet into more conflict.)

The state is now in the process of writing regulations to cover the deployment of autonomous vehicles.

California is also the only state collecting autonomous car crash data. Manufacturers are required to report all crashes involving autonomous vehicles within 10 business days. Once a year, they must also report instances when a human test driver seizes control of the vehicle from its autonomous system for safety’s sake.

To date, the California has collected reports in 24 crashes since October 2014. The majority involve Google vehicles – not surprising, as the tech giant has the largest fleet of self-driving  vehicles – including Toyota Prius, Lexus RX450 and other prototype vehicles on the road in Mountain View since 2009 and expanded to Kirkland, WA, Austin, TX and Phoenix, AZ. This year, Google, which has spun off its autonomous car project to a company called “Waymo,” intends to add 100 new 2017 Chrysler Pacifica Hybrid minivans to the fleet.

All were minor, non-injury crashes. Oddly, more than 60 percent of the crashes involved a conventional vehicle rear-ending a Google HAV in a scenario in which the driver in the striking car, clearly thought that the vehicle in front of it ought to have been moving. For example, here’s a narrative from an October 26, 2016 incident:

“A Google prototype autonomous vehicle (“Google A V”) traveling southbound in autonomous mode on Shoreline Boulevard in Mountain View was involved in an accident. The Google AV entered a slip lane in order to tum right onto El Camino Real and came to a stop to yield to westbound traffic on El Camino Real. As the Google A V began to move forward onto El Camino Real, another vehicle immediately behind the Google AV collided with the rear of the Google AV. At the time of the collision, the        Google AV was traveling at approximately 3 mph, and the other vehicle was traveling at approximately 6 mph. The Google A V sustained minor damage to its rear hatch. The        other vehicle sustained minor damage to its front bumper. There were no injuries reported by either party at the scene.”

NHTSA has estimated that rear-end crashes make-up about 23-30 percent of all crashes, so the reason for the high number of rear-enders bears more analysis.

There are many more disengagements – incidents, as defined by the California DMV, in which “a failure of the autonomous technology is detected,” or “when the safe operation of the vehicle requires that the autonomous vehicle test driver disengage the autonomous mode and take immediate manual control of the vehicle.” In 2016, nine companies who tested autonomous vehicles reported 2,887 disengagements, for reasons including poor lane markings, weather and road surface conditions, construction, emergencies, and collisions

Ensuring the Safety of Autonomous Vehicles?

Are vehicles driven by LIDAR, cameras and algorithms safer than those driven by that passe technology, people? The federal government, Tesla and other autonomous vehicle enthusiasts are insulted that you have even posed the question.

This groups loves the numerator of crashes and the denominator of vehicle miles travelled to show that so far, the self-driving fleet should feel very proud of its record. For example, NHTSA used this simple division to acquit Tesla’s autopilot function, as it closed PE16-007, a probe into the crash that killed Brown, in January with no defect finding.

“ODI analyzed mileage and airbag deployment data supplied by Tesla for all MY 2014 through 2016 Model S and 2016 Model X vehicles equipped with the Autopilot Technology Package, either installed in the vehicle when sold or through an OTA update, to calculate crash rates by miles travelled prior to and after Autopilot installation. Figure 11 shows the rates calculated by ODI for airbag deployment crashes in the subject Tesla vehicles before and after Autosteer installation. The data show that the Tesla vehicles crash rate dropped by almost 40 percent after Autosteer installation.”

(NHTSA mis-characterizes these figures as crash data, when it is actually instances of airbag deployments. There are two problems with this: there are many more crashes than airbag deployments; and it is unlikely that Tesla knows about all airbag deployments. Both of these factors affect how we interpret the comparison.)

Tesla relies on this basic calculation, as does Waymo, which, in an uplifting video, talks about the million vehicle miles travelled without incident.

Nidhi Kalra and Susan M. Paddock, researchers from the RAND Corporation, have recently challenged these assessments, and concluded that the paucity of data make it impossible to determine whether autonomous vehicles will have a measureable effect on death and injury rates. The duo’s statistical analysis shows that “Autonomous vehicles would have to be driven hundreds of millions of miles and sometimes hundreds of billions of miles to demonstrate their reliability in terms of fatalities and injuries.” Further, “Under even aggressive testing assumptions, existing fleets would take tens and sometimes hundreds of years to drive these miles—an impossible proposition if the aim is to demonstrate their performance prior to releasing them on the roads for consumer use.”

Therefore, Kalra and Paddock note, in terms of fatalities and injuries, the entire raison d’etre for pushing vehicle autonomy ahead of their oversight and regulation, test-driving alone “cannot provide sufficient evidence for demonstrating autonomous vehicle safety.” They call for the development of new and innovative ways to demonstrate safety and reliability and most importantly for the development of “adaptive regulations that are designed from the outset to evolve with the technology so that society can better harness the benefits and manage the risks of these rapidly evolving and potentially transformative technologies.”

Big Promise, Mixed Messages

What, ultimately, do we expect from autonomous cars? That we will be passengers in our own vehicles. The informational video fronting Waymo’s website shows a couple snuggling, a grandmother and a child absorbed in an I-pad screen, and teens chatting as the landscape flies by, like back-seat passengers in a cab, wholly unconcerned about how they will get to their destination. As Waymo originally envisioned it, fully autonomous cars would have no steering wheels or foot pedals. That future raises a lot of questions: do we license vehicles instead of drivers? What do public roads look like when then large numbers of driverless vehicles mingle with equally large numbers of conventional vehicles? What are the fail safes?

The present reality is the semi-autonomous vehicle, equipped with software such as Tesla’s Autopilot, which is not reliable enough to offer a hands-free experience, let alone an attention-free experience. Some Tesla drivers have found that out the hard way. A video posted earlier this month shows a Tesla operated in the Autopilot mode clip the side of a highway barrier after the lanes suddenly shift to the right due to construction.

The official, explicit message is that that Autopilot “is an assist feature that requires you to keep your hands on the steering wheel at all times,” and that “you need to maintain control and responsibility for your vehicle” while using it. And the system is designed to warn drivers who test its limits with visual and audible alerts, gradually slowing the vehicle down until the steering wheel detects the presence of the driver’s hands.

But there is another message out there – one that promises that you can ride shot-gun while the car does all of the work. At an April conference in Norway, Musk told the Norway Transport and Communications Minister Ketil Solvik-Olsen:

“The probability of having an accident is 50 percent lower if you have Autopilot on, even with our first version. So we can see basically what’s the average number of kilometers to an accident — accident defined by airbag deployment. Even with this early version, it’s almost twice as good as a person.”

In an October 19 blog post, the company published: “We are excited to announce that, as of today, all Tesla vehicles produced in our factory – including Model 3 – will have the hardware needed for full self-driving capability at a safety level substantially greater than that of a human driver.”

YouTube is full of videos showing Tesla owners demonstrating Autopilot, including Musk’s two-time wife and ex-wife (the pair married in 2010, divorced in 2012, re-married in 2014 and divorced again in 2016.)  Talulah Riley turned to a camera, giggling with fluttering jazz hands as her car zips down a crowded highway.

And that gives the public a very different impression – one which NHTSA recognized in its automated vehicle guidance document carries some dangers:

“New complexity is introduced as HAVs take on driving functions, in part because the vehicle must be capable of accurately conveying information to the human driver regarding intentions and vehicle performance. This is particularly true of SAE Level 3 systems in which human drivers are expected to return to the task of mon­itoring and be available to take over driving responsibilities, but drivers’ ability to do so is limited by humans’ capacity for staying alert when disengaged from the driving task. Manufacturers and other entities should consider whether it is reasonable and appropri­ate to incorporate driver engagement monitoring to Level 3 HAV systems.”  

And really, what is the point of Autopilot if you have to pay constant attention – and be prepared to grab the wheel in a split second? That seems more stressful than actually driving.

After the Brown crash, Musk got roundly criticized for these contradictory messages, and updated the software to lock-out drivers from the feature who fail to heed the system’s warning to keep their hands on the wheel.  

He also back-pedaled a bit, saying that Autopilot “is by far the most advanced driver assistance system on the road, but it does not turn a Tesla into an autonomous vehicle and does not allow the driver to abdicate responsibility.”

And what about NHTSA? What is its responsibility? Musk has always been very clear that Autopilot was introduced to the marketplace as a beta test. Just to be perfectly clear, a beta test is “a trial of machinery, software, or other products, in the final stages of its development, carried out by a party unconnected with its development.” Not only is the Tesla driver participating in this beta test on public roads, but so is every vehicle, pedestrian, and cyclist that share those roads.

How is Tesla permitted to dragoon the public into testing its automotive software?

Well, there’s no law against it.

And Now, the Rest of the Story on Keyless Ignition

For more than two years, The Safety Record had sought to report the results of a 2014 National Highway Traffic Safety Administration keyless ignition compliance investigation that involved seven major automakers, and to have our Freedom of Information Act request to the agency be awarded media status.

It has taken dogged persistence – and a lawsuit – but as 2016 drew to a shuddering close, we got our answers. And now (for those of you old enough to remember Paul Harvey’s famous radio show) the rest of the story: the agency closed the keyless ignition investigation after five months, with no findings of non-compliance. And, in the eyes of U.S. District Judge Ketanji Brown Jackson of the D.C. Circuit, The Safety Record is most definitely a legitimate news entity that pursued a legitimate journalistic objective in trying to report to our readers the conclusion of an agency action. (Judge Jackson spared the agency no quarter in her 35-page decision. The Safety Record found it delightful reading.)

Of course, there is much more to the plot, which we will recount in greater detail below.

But, we pause here to reflect on the real story: the failure of the agency to anticipate the consequences of a technological shift and to deal with them post-design and production, the utter failure of FOIA to serve as a tool to help citizens and journalists understand the innerworkings of their government, and the failure of NHTSA to put aside its petty antagonisms to answer some simple questions on a safety issue of genuine public interest.     

Compliance Probe Closes with a Whimper

In August 2013, with a 2011 proposal to upgrade Federal Motor Vehicle Safety Standard 114 to address the rollaway and carbon monoxide poisoning hazards caused by keyless ignitions on the table, NHTSA began testing 34 recent model-year vehicles to determine if these new push-button systems allowed the vehicle to be turned off in a gear other than park, or the key fob to be removed from a running vehicle with no warning to the driver, or allowed vehicles to be restarted without the key fob present.

This probe grew out of a compliance investigation involving rollaways in Ford vehicles. On February 25, 2013, a 2013 Ford Focus EV failed the agency’s FMVSS 114 compliance test, because “When the vehicle is started, shifted out of “park”, turned off, and the Driver’s door is opened no audible alert is given.” This violated a provision in the regulation requiring the vehicle to issue an audible alert when the driver exits and leaves the key in the ignition. (Manufacturers self-certify that their vehicles are compliant with all federal motor vehicle safety standards. Each year, the agency submits a small sampling of the fleet to test their compliance with various FMVSSs.)

In late June 2013, the agency contacted Ford to convey the following observations:

“When the vehicle is turned off using the push-button while not in “park” and the key fob is out of range of the vehicle:

1. It does not appear that the electronic key code remains present in the vehicle because it cannot be restarted. Section S5.2 of the Regulation states that if the key is able to be removed from the vehicle while the transmission is not locked in “park”, the vehicle’s transmission should become locked in “park” as a direct result of key removal. Like the Focus, the C-MAX was able to roll in this circumstance showing that the transmission had not locked itself in ‘park’.

2. If, like in the Focus, Ford states that the electronic key is still in the vehicle though not authorized to start the vehicle, the issue becomes that there is no door chime when the driver’s door is opened. Section 55.1.3 of the Regulation states that if the key is present in the vehicle and the driver’s door is opened, an audible warning to the vehicle operator must be activated.”

 

The agency asked Ford in an email to provide information regarding the 2013 Ford C-MAX’s certification to FMVSS 114, including test reports or video documentation of the door chime upon opening the driver’s door with the invisible electronic key still present in the vehicle.

This led the agency to expand the scope of its inquiry to look at other keyless ignition vehicles’ compliance with FMVSS 114, running a series of unofficial field tests on models manufactured by Toyota, Ford, General Motors, Nissan, Mazda, Hyundai and Kia in late summer of 2013. (The Safety Record obtained documents associated with the opening of this compliance investigation via a FOIA request and reported this story in March 2014.)

NHTSA’s field survey showed that many of the vehicles could be turned off, with the fob outside of the vehicle without automatically locking the transmission into Park, and could be rolled out of position. It also showed that there was no consistency among manufacturers, or even among models produced by the same manufacturer in terms of the types of visual warnings to drivers, the decibel level of audible warnings, or the scenarios under which a driver was warned that the key was not present or that the transmission was not in the Park position.

By September 30, Ford decided to recall 23,000 2012-2013 Ford Focus and 2013 Ford C-Max keyless vehicles to add an audible warning when the driver exited the vehicle.

The agency officially launched the larger compliance probe in January 2014. The agency’s Information Requests sought a host of details related to manufacturers’ keyless ignition systems, ranging from the electronic architecture of the system, when the electronic code that now constitutes NHTSA’s two-part key schema is purged from the system and the audio and visual telltales used to alert the driver when he or she has exited the vehicle. NHTSA also asked for complaint data and the safety information manufacturers provide to their customers about keyless systems.

The agency actually sent two IR letters. The first, sent on January 15, 2014 contained this sentence: “During testing it was determined that there may have been a non-conformance based on 49 CFR § 571.114 Section 5.1, and possibly Section 5.2, detailed below:”

A second version of the IR letter went out on January 28. The sentence alleging a non-compliance was removed.

In early June, the Office of Vehicle Compliance closed the probes with no findings of noncompliance. For example, in its closing report regarding potential non-compliances in Kia vehicles, Amina Fisher, the safety compliance engineer who conducted the investigation, notes:

“Each vehicle was started with the push button control and the transmission selection control was placed in Drive. The starting system was deactivated with the push button control and the key fob was removed from the vehicle. We verified that the vehicle was not in Park by pushing it.”

After conversations with Kia, NHTSA’s Office of Vehicle Compliance learns:

“The information and test data provided by Kia indicates the vehicles listed above meet all requirements of FMVSS No. 114. Regarding SS .2.1, if the vehicles’ starting system is deactivated when the transmission is not in Park, the starting system will be in the accessory position, the key (electronic code) has not been removed, and the transmission control is not required to be in Park. In addition, drivers are provided audible and, for some vehicles, visual warnings about the key and transmission position.”

 

And just like that – it’s over.

 

Where’s the @#&)+! Key?

Let’s unpack this.

One of the great downsides to electronic key systems is the transition of the key from a physical object to an invisible electronic code. We have complained to anyone who will listen that the average consumer doesn’t really understand this, and conflates the fob with the key, because you need the former to start the vehicle, and because manufacturers brand the fob with names like Smart Key, or the visual alerts in the vehicle say “Key not Detected” in reference to the fob. However, as we have noted many times, unlike a traditional key, the fob plays no role in turning off the vehicle.

The consumer doesn’t always realize where the “key” is, and it turns out neither did NHTSA or experienced compliance testers. In email exchanges, NHTSA officials discuss their inability to determine exactly where the “key” is, and Ford’s inability to demonstrate its location. In fact, Ford had to create a special tool to show when the key was actually still in the vehicle.

From a March 27 email from NHTSA to Ford:

“Patrick Culkeen from Ford called. He said that since our last conversation with them Ford has been working with their engineers in Germany to create a tool to determine if the key code is present within the vehicle. Ford is currently validating the tool to make sure it is functioning correctly. Per his understanding this tool plugs into the diagnostic port of the vehicle and gives readouts (to a computer with the software installed) saying whether or not the key code is present in the vehicle.”

 

From a May 23 email from NHTSA to Ford:

“A question came up regarding the electronic key code. Where in the vehicle’s system is this code housed after pressing the start button with the key fob inside the vehicle? Is there anything else you can tell me about how long the key code remains in the vehicle and/or under what circumstances?”

 

And maybe most importantly, some at NHTSA didn’t believe that these systems satisfied the intent of FMVSS 114. From an April 25 email:

“Eric [Britton of Ford] sent me their 114 reports. For SS.2.1 [in the Test Report 2] it specifies that in when the vehicle is turned off (and door opened) in all positions other than Park the status remained “Key Approved” as required. As I mentioned before, when they brought the device that determines the status of the key code to GTL, it also said the key was still in the vehicle when turned off (and door opened) in all positions other than Park. The instrument cluster always read “No key detected” during those tests. Christie lanetta [sic] [then senior trial attorney for Litigation and Enforcement at NHTSA, now at  King & Spaulding representing manufacturers] said that she wanted to discuss our Compliance Test results with Lloyd [Guerci, an attorney in NHTSA office of Chief Counsel], because though this vehicle may meet each individual requirement, it does not meet the intent of the standard (to prevent accidental rollaway).”
 

The Question of Question 9

One of the things we were most eager to learn in asking for the documents related to the investigation, was: How often are consumers reporting rollaways, carbon monoxide near-misses or injuries, or simply complaining that they forgot to turn off the vehicle, but the engine kept running, even though they had the fob?

Vehicle owners have been lodging such complaints (Vehicle Owners Questionnaires – VOQs) with NHTSA, which we know is a tiny sub-set of the customer contacts that manufacturers are getting directly.

Still capable of wide-eyed innocence as The Safety Record is, we thought that NHTSA would want to know, too. Question 9 in NHTSA’s January Information Request to the seven manufacturers asked for each vehicle model the number of consumer complaints about the starting system, including those from fleet operators; field reports, property damage and warranty claims, injuries, fatalities crashes and third-party claims.

This information would have been particularly helpful to the agency’s rulemaking efforts. Six years ago, the agency published a Notice of Proposed Rulemaking that would standardize engine termination procedures during panic stops (a legacy of the Toyota Unintended Acceleration crisis), and mandate loud auditory alerts to mitigate the rollaways and the carbon monoxide hazard. The Final Rule has been pushed off at least three times, and is still pending.

Among the many complaints the Alliance of Automobile Manufacturers had about the proposal was its basis. Manufacturers complained that it was illegal for the agency to use Vehicle Owner Questionnaires (VOQs) to promulgate a rule. Its objections ranged from the lack of information about each consumer complaint, the small numbers of VOQs, the difficulty in locating the VOQs mentioned in the Federal Register Notice, to the use of VOQs as a violation of the DOT’s data quality guidelines. A sample of the disdain dripping from AAM’s multiple submissions to the NPRM docket:

“In the case of keyless ignitions and the risks of carbon monoxide poisoning and rollaway from leaving the engine running when the vehicle is exited, the Alliance contends that the anecdotal reports referenced in the NPRM do not show that any new hazard is emerging, and thus cannot provide the safety justification for an FMVSS that is legally required under the statute.”

 

By February, NHTSA was revising Question 9, as it was deemed to be too broadly written. But by April 1, the agency lost all interest in the answer. Each manufacturer got an email like this: “This email is to inform you that we are no longer requesting a response to Question 9 of the FMVSS 114 IR letter dated January 28, 2014.”

In conclusion:

  • Neither consumers nor the agency can tell where the key is.
  • Ford has to invent a special tool to show where it is.
  • The invisible key may still be in the ignition unbeknownst to the driver, leaving the vehicle vulnerable to a rollaway.
  • At least one lawyer at NHTSA noticed that this violates the intent of FMVSS 114.
  • But, it’s all technically within the regulations, so never mind.
  • Consumers, it sucks to be you.

 

The Safety Record’s FOIA Journey

It took The Safety Record 831 days – two years, three months, and eight days – to get a response to our inquiry about the conclusion to the compliance probe. Running in the background was a dispute with the agency over whether The Safety Record would be considered a member of the news media for the purpose of assessing fees. Under the FOIA laws, commercial requesters can be charged for the number of hours a government agency spends gathering and reviewing the documents and for reproducing documents. Media requesters are only responsible for paying copying fees. NHTSA wanted to charge The Safety Record $2,070 to get the materials that served as the basis for this story.

The Safety Record actually started to examine what NHTSA had learned about the rollaway or carbon monoxide poisoning problems introduced by keyless ignition systems on October 30, 2013, when we submitted a FOIA request for any investigations the agency might have conducted into this issue. (Safety Research & Strategies had been studying the safety hazards associated with keyless ignitions since 2009 and had met with the agency in August 2010 to raise its concerns). So, it’s taken us basically about three years to report a simple story about a five-month investigation.

Our organization, Safety Research & Strategies, files many, many FOIA requests with a number of government agencies.

While we get adequate responses to some of our queries within a reasonable time frame, our FOIA requests to NHTSA are rarely promptly, simply or straightforwardly satisfied. Much of the delays are the result of the lack of FOIA staff at NHTSA. It’s a small handful of people trying to satisfy nearly 300 FOIA requests in a year. In its latest FOIA report to Congress, NHTSA reported starting the fiscal year with 77 pending requests, and received another 262 during that fiscal year. It finished with 249 responses and 90 pending.

Nonetheless, we usually find the first production wanting. After combing the documents, we find lots missing, such as documents referenced in emails or other documents, but not produced, or a suspicious dearth of communications with a manufacturer. We regularly file appeals. When we aren’t satisfied with the response, we take litigate, and that has proven to be a great motivator.

Since 2010, we have launched seven FOIA lawsuits – six against the Department of Transportation and one against the State of Florida seeking public records on a variety of safety issues – child safety seats, guardrails, unintended acceleration and keyless ignitions. All of these cases have been settled to our satisfaction. The four against NHTSA have ended with the agency agreeing to turn over more records and paying our fees, before a court judgement was rendered. (You can read about some of them HERE.)

The Safety Record, seeking information for stories to post on our blog, makes far fewer requests. Our newsletter and blog have been recognized as a news entity for FOIA purposes by other government agencies, such as the U.S. Consumer Product Safety Commission, and we have been credentialed as media by other entities such as the Society of Automotive Engineers. And while we have unsuccessfully sought media status from NHTSA in the past, this time, we took the DOT to court over it.

The suit was filed in July 2015, after the agency denied our administrative appeal to be considered a news entity. Two months later, the lawsuit was on hold. The agency said it would re-consider its decision, in light of another lawsuit, Cause of Action v. FTC, which made it pretty clear that The Safety Record would be considered a news entity for FOIA purposes. But, the agency denied our request a second time, and everybody got busy on their briefs.

We argued in U.S. District Court that The Safety Record satisfied FOIA’s five-part standard to be considered news media, and that we intended to use the information as the basis of a news story. The Department of Transportation argued that SRS and The Safety Record are virtually indistinguishable, and that the blog only served as a marketing tool for the business, so any FOIA request The Safety Record might make would necessarily be considered commercial use. 

Over 35 well-reasoned and somewhat pointed pages, Judge Jackson told the government that they had nothing. There were only two questions at issue: Did The Safety Record qualify under the terms set by FOIA as a news entity, and did The Safety Record intend to use the information for a journalistic purpose? The government, she noted, wisely tried to avoid the first question, since Cause of Action v. FTC made it pretty clear it was an argument they couldn’t win. And she called the government’s efforts to persuade her otherwise “utterly misguided.”

For example, here’s Judge Jackson’s take on the issue of whether The Safety Record uses “its editorial skills to turn raw materials into a distinct work”—The Safety Record again easily passes muster. “The Safety Record blog and newsletter are replete with opinionated articles that report on and editorialize about information relating to regulatory developments at NHTSA and other agencies.” (Opinionated – that’s definitely us.)

She rapped government lawyers for characterizing everything in The Safety Record published as “commercial speech,” and dismissed their evidence – an article talking about a FOIA request SRS submitted and another announcing a new staff member – as outliers.

“This Court also rejects DOT’s contention that Liberman’s publication of FOIA information in The Safety Record is necessarily a “commercial use” because the content of The Safety Record expressly promotes SRS’s services. (See Def.’s Mem. at 19–20.) This line of attack is substantively indistinguishable from DOT’s argument that The Safety Record is an advertising vehicle for SRS rather than a news media entity (see id. at 23–26; Def.’s Reply at 13–16), and thus, once again, DOT has veered away from the evaluation of “use” that is the proper focus of the “commercial use” analysis and wandered back into the thicket of its misguided concerns about the status of this records requester.” (Thicket of misguided concerns – we love that.)

Finally Judge Jackson chastised the government for failing to offer any evidence that The Safety Record sought this information for commercial use. In fact, she noted that the DOT said in oral arguments: “I have no reason to think it is not in good faith what they say they plan to do with it,”

“Third, and finally, to the extent that DOT’s requester-burden argument is actually a veiled attack on Liberman’s veracity (Tr. of Oral Arg. at 22 (counsel stating that Plaintiff “purport[s] they’re going to” publish the requested information on The Safety Record blog)), DOT has done little to demonstrate that such doubt is warranted. The Safety Record has a long history of requesting documents under the FOIA and then disseminating them to the public through its articles, and this Court sees no basis in the record for drawing an inference that Liberman did not, in fact, intend to do the same when she made the request at issue here.”

Bang!

Our longtime FOIA attorney, David Sobel, noted the painstaking nature of Judge Jackson’s opinion:

“Judge Jackson’s careful and thorough decision makes clear that the agency had no basis for its refusal to recognize The Safety Record as an established news entity,” he said.

This memorandum opinion – filed on the last day of 2016 — does not end the matter. The government has 60 days – but, really, no basis – to appeal the judge’s decision.

 

To read more of our coverage on keyless ignition:

Keyed up With Anticipation: Smart Key Hazards Still Unresolved

The Keyless Ignition Litigation Solution

Another CO Smart Key Death… and what Happens when Smart Keys Collide?

A Funny Thing Happened on the Way to My Car…

Stupid Tricks with Smart Keys

 

 

 

GM Stiffs Takata Recall, Petitions for Delay

Safety Research & Strategies response to this request: Deny! It’s rare for an automaker to request such a change – it’s even rarer for the agency to ask for comments. But, our focus on this issue tells us that the petition is a stunning display of chutzpah, considering that the automaker is already flouting the Consent Order it signed. GM has been selling unremedied recalled vehicles while telling its customers it isn’t replacing the airbags because there’s no problem. Everything we’ve learned about the history of this defect assures us – there ain’t no such guarantees.

Read the SRS comments below.

NHTSA Progress Slow as Safety Crises Keep Coming

On Friday, the Office of the Inspector General threw another report on the stack of official criticisms of the way the National Highway Traffic Safety Administration’s Office of Defects Investigation operates.

As its title suggests, Additional Efforts are Needed to Ensure NHTSA’s Full Implementation of OIG’s 2011 Recommendations was a look at the progress the agency didn’t make in the last five years on 10 recommendations to implement process improvements that would track consumer complaints, thoroughly document Defect Assessment Panels decisions on which risks to investigate, achieve its timeliness goals for completing investigations, create a systematic process for determining when to involve a third-party or Vehicle Research and Test Center for assistance,  train its staff, and keep identifying information out of public files, among others.

Five years later, the OIG found that NHTSA had satisfactorily completed three of the action items: it conducted a workforce assessment, it boosted its communication and coordination with foreign countries on safety defects and it reviewed and tracked consumer complaints associated with specific investigations. But it also noted that the agency was lagging in some of most important process improvements. Sure, NHTSA created a bunch of systems to address these deficiencies, but it did little to ensure that those systems were used with consistency:

Although NHTSA took actions to address all 10 of our 2011 recommendations, our review determined that ODI lacks sufficient quality control mechanisms to ensure compliance with the new policies and procedures, and lacks an adequate training program to ensure that its staff have the skills and expertise to investigate vehicle safety defects. Earlier this year, NHTSA stated that it will “aggressively implement” the 17 recommendations from our June 2015 report. The results of this review of NHTSA’s implementation of OIG’s 2011 recommendations can provide lessons learned as NHTSA makes important decisions regarding future process improvements.

In the aftermath of the first big safety crisis of the modern era – Firestone Tire tread separation failures the caused the tippy Ford Explorer to rollover – the General Accounting Office, in response to Congressional inquiries, and mostly the DOT Office of the Inspector General, began to pump out reports. But, with the successive waves of high-profile safety problems –Toyota unintended acceleration; the General Motors ignition switch failures and exploding Takata airbag inflators – the pace has accelerated. 

There have been seven censorious assessments since 2002 – with critiques on NHTSA’s data collection and analysis, its recall management practices, its lack of investigative and decision-making processes, and its enforcement and transparency. (We have been covering these reports, as well as documenting these problems: 

Inspector Agrees with SRS: NHTSA Ain’t Right

Elective Warning Reports: When Manufacturers Don’t Report Claims 

Elective Warning Reports Redux

How NHTSA and NASA Gamed the Toyota Data

What NHTSA Doesn’t Want You to Know about Auto Safety

The Pedal Error Error  )

The most recent take-down, Inadequate Data and Analysis Undermine NHTSA’s Efforts to Identify and Investigate Vehicle Safety Concerns, was released by the OIG a mere seven months ago. This report rapped the agency for ODI’s lack of process, for prioritizing probes by chances of recall success rather than threat to safety; lack of transparency; failure to audit manufacturer’s EWR reports; and the lack of enforcement. 

To determine NHTSA’ s progress on the ten action items it cited in 2011, OIG investigators pored through agency records, looking for evidence that agency staff was documenting its reasons for not meeting its deadlines to complete investigations, or its decisions to move forward with defect investigations, and found pretty spotty performance.

For example, NHTSA had agreed to start putting its defect screening meeting minutes and other pre-investigation information, such as data from insurance companies, in its Advanced Retrieval Tire, Equipment, Motor Vehicle Information System (ARTEMIS), the system originally implemented in July 2004 to analyze and identify trends in the early warning reporting data. But the OIG found that NHTSA managers hadn’t developed any processes to ensure that staff was actually putting the stuff in. Out of a sample of 42 issue evaluations opened in 2013, 42 percent had no documentation of any pre-investigative work. 

The documentation for failing to meet a timeliness goal was worse: more than 70 percent of delayed investigations the OIG reviewed did not include justifications for why ODI’s goals for timely completion of investigations were not met. 

Under policies ODI established in 2013, managers developed a checklist to ensure that all evidence associated with an investigation “such as consumer complaints and information exchanged with manufacturers was documented.” The OIG reviewed documentation for 36 preliminary evaluations and six engineering analyses opened between March 2013 and December 2013 and found that ODI used the checklist for 4 preliminary evaluations and zero engineering analyses. (This may explain why FOIAs to the agency regarding its investigatory activities often turn up next to nothing.) The OIG concluded: “As a result, ODI may not be capturing all evidence associated with an investigation, potentially hampering its ability to assess or support the adequacy of its investigations.”

Less egregious but still inconsistent was how well NHTSA’s contractor redacted files for public consumption (the OIG found nine out of 62 investigation documents were not fully redacted, containing birth dates, driver’s license numbers and e-mail addresses.) and filing meeting minute notes of defect screening meetings (out of 21 panel meetings held in 2013 and 2014, 17 percent were not appropriately documented).  

One of the most troubling observations was the lack of training for ODI staff. Back in 2011, NHTSA argued that a formal training program wasn’t necessary, but agreed to offer basic training in automotive technology, ODI policies and processes, computer skills for data analysis, and ARTEMIS. But, when ODI investigators paid a visit, they found this: 

During our audit, ODI’s pre-investigative staff told us that they received little or no training in their areas of concentration, some of which can be quite complex. For example, ODI staff charged with interpreting statistical test results for early warning reporting data told us they have no training or background in statistics. 

Since data are at the root of all NHTSA activities, allowing the people to make the first cut with no training and no understanding of statistics seems counterproductive, to say the least. (Although given NHTSA’s many numerically dubious claims, The Safety Record cannot say that it is surprised.)

In the last year, we have seen a lot of positive changes at NHTSA, and we know that jack-hammering a better agency out of decades of calcified practice will take time. But, if this 5-year progress report is any indication, it’s going to be a long time before we see the OIG’s 17 recommendations from June come to fruition. 

Preventable Ford Airbag Death Touches off Latest Recalls

Another day, another episode of the long-running soap opera, All My Airbags. Last week, on the heels of the tenth death and the eve of an historic blizzard, the National Highway Traffic Safety Administration announced that another five million vehicles with defective Takata airbag inflators will be recalled. This recall will include driver’s side SDI-type airbag inflators in Ford vehicles.

We are now moving into the eighth year of recalls for a defect that first asserted itself to the Japanese supplier and its OEM customers in 2003. If you have become lost in the maze of inflator acronyms, Congressional hearings, rolling recalls and a Chinese menu of 13 root cause explanations, The Safety Record will draw you a map.

Takata combined a chemically volatile propellant with crappy manufacturing processes and little quality control to build a slow-release IED. Takata made many versions of its inflators, single stage, dual-stage, and side inflators, each with its own acronym and recall variations.  But they all have enough commonalities to be dangerous.

NHTSA, Safety-Crisis-Enabler-In-Chief, first investigated the problem in 2009, with a Recall Query probing Honda’s decision to radically expand its first, limited recall. But, the agency took Takata’s first explanation, and probed no further, despite Honda’s decision to launch second, third, and fourth Takata airbag recalls. It only took five more years before NHTSA officially declared itself unsatisfied with Takata’s root cause analyses. In 2014, the agency opened a Preliminary Evaluation and eventually began conducting its own tests. Meanwhile, the cancer has spread to 14 manufacturers and affected about 24 million vehicles, a number that is about to rise. In 2015, NHTSA decided this fiasco was too big to let the OEMs handle individually, and took over the whole show.

And that brings us to today. Despite the mind-numbing volume of replacement campaigns and an unprecedented regulatory intervention, the death of Joel Knight, a 52-year-old South Carolina man, demonstrated that all of the defective airbag inflators have not been added to the recall roster (let alone actually replaced) – yet. Knight died on December 22, at the wheel of a 2006 Ford Ranger, when he struck a cow in the roadway. The minor crash deployed the airbag, which ruptured with such force that a large metal shard severed his spinal cord. Knight should have walked away from that crash with nothing more than a story to tell at Christmas dinner.

The driver’s side airbag in Knight’s 2006 Ford Ranger was an SDI – a single-stage Smokeless Driver Inflator. This iteration had already ruptured with deadly force on July 27, 2014, killing a pregnant woman in Malaysia in her 2003 Honda City vehicle. That event caused Honda, and then Toyota, to recall in November 2014 more than 200,000 vehicles with SDI inflators in at least 61 countries.  Ford was the only OEM in the U.S. that had SDI inflators in a limited number of vehicles that included the 2004-2006 MY Rangers. But Ford did not join Honda and Toyota in recalling all of its SDI-inflator equipped vehicles, and the record shows an OEM with a distinct lack of urgency.

June 2014 – Ford launched a voluntary parts collection at NHTSA’s behest for inflator inspections and testing in four high humidity areas. Only four models – the 2004 Ranger (passenger-only); 2005-2007 Mustang (driver only); and 2005-2006 GT (passenger and driver) – originally sold in four locations – Florida, Hawaii, Puerto Rico, and the U.S. Virgin Islands — were included.

November 2014 – Again at NHTSA’s request, Ford added the SDI driver’s side inflators in 2004-2005 Rangers made in certain date ranges and originally sold in Florida, Hawaii, Puerto Rico, and the U.S. Virgin Islands.

December 2014 – Ford expanded its campaign for passenger inflators to include vehicles in Guam, Saipan, American Samoa, and parts of Alabama, Mississippi, Louisiana, Texas, and Georgia. They also launched a national recall for the PSDI-4 driver’s side inflators for the GT and Mustang vehicles which share some components with the SDI.

May 2015 – Ford expanded the Mustang driver recall to 2005-2014 model years, because Takata said all PSDI-4 inflators with batwing shaped propellant wafers could be dangerous.

June 2015 – Ford expanded its regional recall of 2004-2006 Ranger passenger inflators into a nationwide recall.

The sharp-eyed reader will notice: Ford never recalled the 2004-2005 MY Ranger with the SDI inflator – the same inflator type that ruptured in July 2014 with fatal consequences in Malaysia – beyond Florida, Hawaii, Puerto Rico and the U.S. Virgin Islands. The 2006 Ford Ranger with the same SDI inflator was never recalled at all.

And if that wasn’t bad enough, consider this: Honda and Toyota told NHTSA in November 2014 that the root cause of SDI inflator ruptures was Takata’s failure to control the propellant’s exposure to moisture during the manufacturing process. In fact in 2013, five manufacturers – including Toyota and Honda – named moisture exposure during manufacture as a root cause in  passenger inflator recalls. Meanwhile NHTSA, and Ford in numerous recall submissions and amendments, linked the problem to high absolute humidity in certain regions, and a scenario in which the defect presents itself after years of exposure to humidity that degrades the propellant, making it more vulnerable to over-pressurization when ignited.  

On the one hand, you’re saying: Why didn’t Ford recall all of its vehicles with these inflators? It wasn’t that many. On the other hand, Ford’s saying: Why bother? It’s not that many vehicles. What are the odds? Unfortunately, Joel Knight found out.

Many want to claim that the Takata crises was precipitated by a rogue supplier that hid information and altered data on its product problem. But this scenario, which now has become the largest recall in history, could not have unfolded for more than a decade without the OEMs enabling it and without a federal agency failing to question and investigate the many red flags set by years of rolling recalls and shifting explanations.   

 

NHTSA Proposes to Affirm Canadian Underride Standard

Q: When’s the best time to pass a rule? A: When nearly everyone already complies! While it puts you at the trailing edge of safety, it diminishes the intensity of the opposition – so it’s all good. Such is the state of a National Highway Traffic Safety Administration proposal to upgrade the Federal Motor Vehicle Safety Standards 223 and 224, for rear impact guard and rear impact protection, respectively.

The agency is proposing to align the two U.S. standards with the eight-year-old Canadian standard for rear impact guards. The proposal represents the first major upgrade to the rear impact protection standards for trucks in 21 years. It has been so long since NHTSA has addressed the current standards’ weaknesses, that an estimated “93 percent of new trailers sold in the U.S. subject to FMVSS Nos. 223 and 224 are already designed to comply with CMVSS No. 223.”

The proposed upgrade would mandate that rear impact guards meet new strength requirements at several test locations. Specifically, the current quasi-static point load test at the area around the guard’s vertical support location would be replaced by a uniform distributed load test of 350,000 Newtons (N). The performance requirements would mandate the rear impact guard to resist the 350,000 N load without deflecting more than 125 mm, and absorb at least 20,000 Joules of energy within 125 mm of guard deflection. The proposal would also require that any portion of the guard and the guard attachments not completely separate from its mounting structure after completing the test.

What NHTSA did not do: lower the guard height from the current 22 inches, nor extend the standard’s applicability to currently excluded classes of truck configurations, such as wheels back trailers, pole trailers, logging trailers, low chassis trailers and specialty equipment trucks.

Russ Rader, of the Insurance Institute for Highway Safety, which has been pushing for better rear impact guards for nearly 40 years, and formally petitioned the agency in 2011 for an upgrade, said the proposal is “a good first step, because the Canadian standard is an improvement.”

“But our tests show that they could have gone a lot further,” he added. “The Canadian standard misses protection in some offset crashes, and we know that truck manufacturers can address that in a straightforward, inexpensive way and it’s not addressed in this proposal.”

A Brief Regulatory History

Rear guard protection has been a federal requirement since 1952, when the Bureau of Motor Carriers of the Interstate Commerce Commission (ICC) established regulation 393.86 which required heavy trucks, trailers, and semitrailers to be equipped with a rear-end protection device designed to help prevent underride. The regulation contained no specifics as to the device’s efficacy, but merely required the guard to be “substantially constructed and firmly attached.”

In 1967, the Federal Highway Administration, the precursor to NHTSA, attempted to begin a rulemaking to require a rear underride guard for trucks, buses and trailers, but industry fought off any substantive upgrade to the regulations for 44 years. In 1981, the agency published an NPRM amending the equipment requirement to a moderate strength guard that would permanently deform when subjected to a load of 45,000 pounds. The agency also proposed to extend the standard to most trucks and trailers with GVWR of more than 10,000 pounds, which would include heavy single-unit trucks. In the proposed rule, the rear impact guard could not have a ground clearance greater than 21.65 inches (55 cm). The trucking industry also heavily criticized this proposal, submitting more than 100 comments. In 1992, the agency responded by proposing to split the standard in two: one for the rear guard itself, and a separate standard for the vehicle.

In 1996, NHTSA published a final rule establishing two Federal Motor Vehicle Safety Standards (FMVSS) – 223, Rear Impact Guards, and 224, Rear Impact Protection. FMVSS 223, the equipment standard, specified strength requirements and compliance procedures for rear impact guards on semitrailers. FMVSS 224, the vehicle standard, specified mounting instructions and location specifications for those guards. The final rule retained the prosed 22" guard height.  Single unit trucks were excluded from the requirements, because, the agency said, single unit trucks are far less likely to be involved in fatal accidents than combination trucks.

In 1998, the agency responded to some petitions for reconsideration and amended the Final Rule  

In the meantime, research by John E. Tomassoni, a former NHTSA safety standards engineer demonstrated the inadequacy of the U.S. rules in a series of crash tests involving rear underride guards built to reflect the then-new rear impact protection standard. The work showed that underride guards that minimally complied with the new rule were effective at impact speeds of 30 mph. But in some of the tests, the underride magnitude was such that passenger compartment intrusion occurred – in some instances, the dummy head contacted the deformed occupant compartment. And, in 2002, Transport Canada conducted a series of tests using a 1998 Ford Windstar, a 1998 Chevrolet Cavalier, and a 1998 Honda Civic,  to verify the performance of rear impact guards built under FMVSS 223/224.  It found that “none of the minimally compliant guards were effective for all three vehicle types tested.” Transport Canada effectively upgraded its standard in 2007.

The IIHS petitioned the agency in 2011. In May 2014, Marianne Karth and the Truck Safety Coalition also petitioned NHTSA to require underride guards on single unit trucks and other vehicles excluded from the current standard and to improve the standards’ requirements for all guards. NHTSA granted both petitions in July 2014, saying that it would pursue rulemaking through an ANPRM pertaining to rear impact guards for single-unit trucks and “other safety strategies not currently required for those vehicles” and a separate NPRM to upgrade FMVSS Nos. 223 and 224.

In July 2015, the agency published the advanced notice of proposed rulemaking regarding underride protection for single unit trucks.

IIHS and Karth Petitions

The IIHS has been researching various aspects of the issue, from determining the scope of the problem to developing a new underride guard. In 1977, it launched a program to develop a lightweight and effective guard that might serve as a prototype. Researchers designed and tested two guards and concluded that it was feasible to achieve substantial improvements in underride protection without significant increases in the weight of underride protection devices.

IIHS also performed a series of crash tests to determine which underride guards perform better than others and under various crash speeds and configurations (head-on and off-set) and to determine what types of failures occurred.  Testing was done using the Chevy Malibu into trailers that were certified to Canadian and U.S. requirements.  In general the testing found that the Canadian guards performed significantly better, and that there are fundamental weaknesses in the guard attachments which don’t have to be tested as a whole system. 

In 2011, the IIHS petitioned the agency to upgrade the rear impact protection standards because “the current standards allow underride guard designs that fail catastrophically when struck by passenger vehicles at speeds that frequently produce minimal intrusion and injury risk in regulatory and consumer information frontal crash test programs.”

In support, the Institute used the Large Truck Crash Causation Study, a federal database of roughly 1,000 real-world crashes in 2001-03.  The organization examined crash patterns leading to rear underride of heavy trucks and semi-trailers with and without guards and found that underride was a common outcome of the 115 crashes involving a passenger vehicle striking the back of a heavy truck or semi-trailer. Only 22 percent of the crashes didn’t involve underride or had only negligible underride, which they indicated was consistent with prior studies. The study noted that “In 23 of the 28 cases in which someone in the passenger vehicle died, there was severe or catastrophic underride damage, meaning the entire front end or more of the vehicle slid beneath the truck.”

IIHS also pointed to the regulatory gaps that allow some heavy trucks to forgo guards altogether and if they are on trucks exempt from the regulations, the guards don’t have to meet 1996 rules for strength or energy absorption.

In its petition, the IIHS asked NHTSA to consider: substantially increasing the quasi-static force requirements, move the one of the test locations farther outboard to address offset crash protection; require that attachment hardware remains intact throughout the tests; require guards be certified while attached to the trailers for which they are designed; investigate whether the maximum guard ground clearance can be reduced; and reduce the number of exempt truck and trailer types.

Marianne Karth became an activist for truck underride safety after a horrific underride crash that killed two of her nine children. In May 2013, Karth was on a Georgia highway approaching slowed traffic, when a semi trying to switch lanes hit the Karth vehicle in the rear, sending it underneath another tractor trailer.  Karth’s 17-year-old and 13-year-old daughters died in the crash.  One year later, Karth and the Truck Safety Coalition presented NHTSA with its petition and 11,000 signatories acquired online. Their petition asked for the Secretary of Transportation to raise the minimum level of insurance for truck drivers, for a final rule on electronic logging devices to reduce truck driver fatigue; and to improve the rear underride guard rules.

In July 2014, NHTSA granted the Karth petition without mentioning the IIHS at all. In July 2015, the agency published the separate ANPRM to consider conspicuity and rear impact guard standards for single unit trucks.

The Proposed Rule

According the NPRM, NHTSA’s interest in improving this rulemaking goes back to 2009 when the agency evaluated a study showing that fatalities were still occurring in frontal crashes “despite high rates of seat belt use and the presence of air bags and other advanced safety features.”  NHTSA’s review of cases in model year 2000 or newer vehicles in the Crashworthiness Data System of the National Automotive Sampling System found 14 percent were underrides into single unit trucks and trailers.  In 2010, NHTSA published another study analyzing the effectiveness of trailer rear impact guards, which showed what Tomassoni demonstrated more than a decade earlier: FMVSS 223 and 224 rear impact guard had had no impact on fatality rates.  

Now that the agency’s interest has been translated into action, it is only inclined to increase the force and energy absorption requirements without lowering the guard height or bringing other types of trucks into the standard. In the former case, NHTSA said that the issue was discussed extensively in 1996. Public comments, vehicle geometry, heavy vehicle operations, and crash test data led the agency to conclude that it would present an undue burden to industry. Apparently, it now is not the burden it was, because NHTSA now declines to decrease the guard height because “fleet data suggest that where possible, trailer manufacturers are voluntarily installing rear impact guards with ground clearances under 560 mm (22 inches).”

On the issue of extending the standard to other types of trucks, the agency said that its analysis showed that there are relatively few fatal rear-impact crashes involving the current excluded categories, such as wheels back trucks, and of those that do occur, many are at speeds that are not survivable – with or without an underride guard

Rader says that the Institute will continue its work on better rear impact guards, despite the gaps in the NPRM.

 “From our standpoint, we know that the trailer manufacturers will need to deal with offset crashes,” he said. “We plan to continue testing – we want to work with trailer manufacturers to go beyond the Canadian standards. We’ve gotten tremendous cooperation, and we are working with Marianne Karth to set up an underride round table to discuss further steps.”  

Not Very FAST Act Tackles Recall, Tire Issues, Closes Rental Loophole

After years of short-term fixes as durable as a pothole cold patch, Congress has cobbled together a $300 billion, five-year comprehensive transportation bill, the Fixing America’s Surface Transportation (FAST) Act.

(We know that Congress loves it some acronyms. But, it’s been a decade since House and Senate passed the last long-term transportation bill, the mouthful known as the Safe, Accountable, Flexible, Efficient Transportation Equity Act –a Legacy for Users [SAFETEA-LU] so perhaps they deserve some points for brevity. And irony. Or chutzpah.)

And on Friday, President Obama signed it into law. For the National Highway Traffic Safety Administration, the bill resolves one lingering safety issue, gives the agency the authority to exact larger fines, bumping the cap for civil penalties from $35 million to $105 million. It calls for some rulemakings, some improvements in the tire and vehicle recall systems, and requires the agency to collect information that – presumably – will help it improve processes and broaden its footprint.

But many advocates, like Henry Jasny of Advocates for Highway and Auto Safety, say that the bill, for all of its mass, could have done a lot more for safety.

“This was a missed opportunity to promote new safety policies over the next five years – things based on technologies, like rear seat belt reminders and child minders,” he says. “It should be packed full of initiatives for safety, but a lot of things were left on the cutting room floor.”

The Other Missed Opportunity: Tires

The current tire-recall system was established 38 years ago, when recalls and government defect investigations of tires were rare. The FAST Act has attended but lightly to its two key components: the Tire Identification Number (TIN) and the tire registration system.

Once again, it has taken an act of Congress to get NHTSA to do something to make recalls more effective. In 2012, the Moving Ahead for Progress in the 21st Century Act, (MAP-21, for short) required NHTSA to make recalls Internet-based and searchable by Vehicle Identification Number (VIN), by requiring manufacturers to submit the VIN ranges of recalled vehicles directly to the agency to augment its current consumer search interface, which allows users to look up recalls by vehicle make and model, or by the recall campaign number. In response to the Notice of Proposed Rulemaking, Safety Research & Strategies suggested that while the agency was designing a web interface, it might add a TIN look-up.

The agency declined:

“We considered the comments from SRS and ARA suggesting expanding the scope of this portion of our rulemaking to include certain aspects relevant to equipment recalls. At this time, we decline to expand the scope of the rule; the directive of MAP-21 is plainly limited to recalled vehicles.”

But that’s just how NHTSA rolls. The agency didn’t even require tiremakers to submit TIN ranges with their recall documents until 2009. Since most tire recalls relate to defects that occur during a discrete time range, tire recall information without TIN ranges was pretty much useless.

So, finally, the FAST Act requires NHTSA to create a web-accessible tire recall database that allows users to search by TIN, and any other information the agency deems useful.

Adding a TIN searchable system will certainly improve the current dataset, but again, this doesn’t work well in a service environment nor does it address the inherent problems with the use of the TIN.

The tire recall system has long been riddled with inefficiencies, and it has the recall return rates to show for it – an average of 30 percent, compared to the 72 percent and above rates vehicles, equipment or child restraints.

But a TIN look-up without the ability to automate tire identification still leaves the problem of discerning a tire’s status in a service shop environment, where it is not practical to expect techs to manually retrieve a 13 alpha-numeric code off each tire and accurately enter those numbers into a website. Technologies such as Radio Frequency Identification have the potential to transform the current cumbersome, inefficient system into one that fulfills its purpose – to remove defective and unsafe tires from the nation’s fleet, Instead of requiring NHTSA to take action and mandate a method to automate the TIN look-up (i.e., scanning), the bill only asks the agency to study the possibility of requiring “electronic identification on every tire that reflects all of the information currently required in the tire identification number.” The agency is to report its findings to the Senate and House Commerce committees, but there is no deadline for this study, so no urgency. The 21st century is still young. Plenty of time to catch up.

In the meantime, the FAST Act turns back the clock on tire registration. More than 30 years ago, tire dealers persuaded Congress to remove them from the tire recall system. Since 1983, dealers have only had to hand their customers a registration card to be filled out and returned to the manufacturer. The passage of the FAST passed that responsibility back to independent tire dealers, much to the chagrin of The Tire Industry Association. The required rulemaking will compel independent dealers to maintain customer tire purchase information and electronically transmit those records to tire manufacturers. The TIA lobbied hard against it, but apparently was no match for the Rubber Manufacturers Association, which had promoted the provision.

The FAST Act advances the tire recall system only marginally, and avoids product identification automation technology – used in so many other sectors – that would make a significant impact. And the tire makers again get to foist the defect issue to dealers and customers with no changes to their system.

Other tire provisions:

Tire manufacturers are now required to extend the remedy period for tires from 60 to 180 days. The cap was originally established to address fears that drivers might drive on a recalled tire until it was worn out and then seek free replacement, instead of removing it right away. Most manufacturers already take back tires beyond the 60-day period. 

The FAST Act also initiates several tire safety rulemakings:

Within a year of enactment, NHTSA must publish a rulemaking proposal to improve the Tire Pressure Monitoring Systems, so that such systems cannot be over-ridden, re-set or re-calibrated so that the system cannot detect significant under-inflation. 

NHTSA is required to promulgate a rule to establish minimum performance standards for passenger tire fuel efficiency and wet traction.  

Closing the Rental Car Recall Loophole

Two years after the Raechel and Jacqueline Houck Safe Rental Car Act was introduced, the measure made it into the highway bill. It requires rental car companies and dealers with fleets of at least 35 vehicles to remedy recalled vehicles before renting, leasing or selling them, or, the case of a rental, at least mitigating the hazard if a remedy is not immediately available.

The bill is named for the Houck sisters, Raechel, 24, and Jacqueline, 20, who died on October 7, 2004, in a rented 2004 PT Cruiser. The Chrysler vehicle was under a recall for power steering hoses which could fail and cause an underhood fire. Enterprise received the recall notice in early September 2004, but rented the unfixed vehicle anyway — to other three customers before the Houcks. The young women died in a fiery crash while traveling northbound on Highway 101 in Monterey County outside of King City, caused by the defect.

The Raechel and Jacqueline Houck Safe Rental Car Act was first introduced in 2013, and supported by the car rental companies. The original bill set the fleet size for rental companies and auto dealers to at least five vehicles. The auto dealers fought hard against the measure, and demanded a carve-out for loaners. Many of them got that wish, with the provision that increased the applicable fleet size to 35 vehicles. Nonetheless, Rosemary Shahan of Consumers for Auto Reliability (CARS) says it’s the greatest expansion of NHTSA’s recall authority in years.

“It’s a big deal,” she says. “One reason that we wanted the rental car companies in the bill is that they are the biggest purchasers of new cars in North America. The fact they are required to fix them before they can go back on market as used cars – that’s huge.”

Vehicle Recalls Improvements

The FAST Act includes a variety of measures to further streamline vehicle recalls.

It extends the vehicle life-span for which a manufacturer is required to make recall repairs from 10 to 15 years. And it mandates NHTSA to write a regulation requiring automakers to retain safety records for their vehicle for at least 10 years.

Under another provision, NHTSA has two years to “implement current information technology, web design trends, and best practices that will help ensure that motor vehicle safety recall information available to the public on the Federal website is readily accessible and easy to use.” specifically, Congress is requiring NHTSA to improve the organization, availability, readability, and functionality of the website. The Comptroller General is charged with studying these improvements and reporting out NHTSA’s progress

NHTSA has to study the feasibility of creating a public Web portal that allows the searching multiple vehicle identification numbers at a time to retrieve motor vehicle safety recall information

By next September, NHTSA must prescribe a final rule requiring manufacturers to make electronic notification of recalls to consumer, in addition to first class mail – that could mean emails, social media and targeted online campaigns.

For the next four years, NHTSA is required to analyze recall completion rates by manufacturer, model year, component, and vehicle type to determine what actions it must take to improve them.

Although Sen. Richard Blumenthal (D-Conn.) and Sen. Edward Markey (D.-Mass.), did not succeed in inserting legislation to require states to withhold registration renewals for vehicles with open recalls, the FAST Act does require NHTSA to implement a two-year pilot program to examine the feasibility and effectiveness of having state DMVS at least inform vehicle owners of open recalls on their vehicles. 

Event Data Recorders and Driver Privacy

The legislation clarifies that Event Data Recorder data is owned by the owner or lessee unless a legal authority, such as a court, or the owner/lessee authorizes a download. It also requires NHTSA to submit a report, within a year of enactment, the results of a study conducted to determine the amount of time event data recorder “should capture and record for retrieval vehicle-related data in conjunction with an event in order to provide sufficient information to investigate the cause of motor vehicle crashes.” Within two years after submitting this report, NHTSA must promulgate a rule establishing that amount of time.

Reports, Reports, Reports

The FAST Act provides NHTSA with plenty of other opportunities for self-reflection, improvement and report-writing.

Three months from now, NHTSA is require to submit the first of periodic progress reports on implementing the recommendations of the Department of Transportation’s Inspector General  last scathing audit. Released in June, “Inadequate Data and Analysis Undermine NHTSA’s Efforts to Identify and Investigate Vehicle Safety Concerns,” rapped the agency for its opacity, and for a host of process failures, such as the absence of EWR audit procedures to verify that manufacturers submit complete and accurate early warning reporting data and the failure to follow “standard statistical practices when analyzing early warning reporting data.” Next November, NHTSA has to produce a final report on its implementation plans.

A year from now, NHTSA is required to give the public detailed guidance for consumers submitting safety complaints, including a detailed explanation of what information a consumer should include in a complaint; and of the possible actions NHTSA can take to address a complaint and respond to the consumer.

Also on the Act’s one-year anniversary, the agency must submit to Senate and House commerce committees, a catalogue of the accomplishments of the Council for Vehicle Electronics, Vehicle Software, and Emerging Technologies, which was established under the Moving Ahead for Progress in the 21st Century Act (MAP-21).

SAFETEA-LU expired in 2009, and in the last six years, our entire transportation system suffered while a Congress that is in session for a little over 130 days a year, couldn’t find common ground beneath its collective feet on any issue. The Safety Record Blog supposes that we should be grateful that they only took six years to strike a deal. But seeing as it will be a long time before another opportunity arises to move the ball on safety legislation, the FAST Act isn’t too swift.

Decoding NTSB’s Tire Safety Report

Tuesday, the National Transportation Safety Board issued findings and recommendations following a 10-month long investigation into tire safety. The effort was launched after two February 2014 two deadly tire-related crashes in Louisiana and Florida. (The latter crash involved an uncaptured recalled BF Goodrich tire and the former an 11-year old Michelin Cross Terrain.) In December 2014, the NTSB followed up with a tire safety symposium to gather testimony from industry, the National Highway Traffic Safety Administration, advocates such as Sean Kane of Safety Research & Strategies, and researchers.

The final report, which will be released in the coming weeks, is focused on two key issues – the tire recall system and tire age degradation (service life). Tuesday’s hearing provided a pretty sturdy outline of the NTSB’s major conclusions. It amounted to a long-ignored to-do list for the regulated and the regulators (nine recommendations for NHTSA and two for industry) like implementing a web-based TIN look-up database and having the complete TIN on both the inboard and outboard sidewalls of a tire.

Board Vice Chair Dr. T. Bella Dinh-Zarr crystalized the tire safety problem with a simple question to the NTSB staff: Why tire techs can’t determine if a tire was recalled? 

And the answer is because no one has built the systems to do this, is best summarized in two of the NTSB’s most important and intertwined conclusions:

  • A computerized system for capturing, storing, and uploading tire registration information would expedite the tire registration process, reduce transcription errors, and encourage more dealers to register tires at the point of sale.
  • The guidance provided by the tire and automotive industries regarding tire service life and the risks associated with tire aging can be inconsistent and confusing, which may lead consumers to make inappropriate tire replacement decisions.

In other words, the tire identification and recall system, which have relied on manual review of hard to find information, must be automated in order to alert techs – and consumers – to tire service life recommendations and recalls. With automated tire tracking, these critical elements of tire safety come together, and service techs can tell a consumer with the swipe of a scanner if a particular tire is recalled and if it’s at the end of its service life – in addition to the typical visual inspection for tread and condition. No complex internet searching and document review, crawling under a tire to capture the full TIN, or pawing through desk drawers for ten-year-old tire technical bulletins – just useful safety information, in real time, quick and easy.

The industry stakeholders preferred to focus elsewhere.

According to Tire Business, the Rubber Manufacturers Association was as happy as clam: “Daniel Zielinski, RMA senior vice president-public affairs, said his association found it encouraging that the NTSB agreed with a number of the RMA’s recommendations, especially tire registration by dealers, recall search engines based on TIN lookups, and consumer education.”

(Although, having the TIN on both sides is the kind of suggestion that makes the RMA very cranky, having successfully fought off NHTSA’s attempts to require it since 1970.  But the RMA is totally in favor of recommendations that require others to assume their responsibilities like a TIN lookup and tire registration.)

And Roy Littlefield, vice president of the Tire Industry Association fretted about an NTSB recommendation to require all tire dealers to register tires at the point of sale. According to Tire Business: “I can’t believe this industry thinks that the best solution to this problem is to hand it over to a government agency,” he said. “This is 2015, not 1982. We have technology that works. To go back to that archaic system would be a disaster.”

Safety Research & Strategies, which has been studying the gaps in the tire recall system and the hazards of aged tires has long advocated for machine readability of tires as a practical way for tire techs and consumers to quickly determine a tire’s recall status and age. Regardless of the changes made to the tire registration system and the plethora of tire service life recommendations, without the ability to scan a tire, there is no efficient way for  service professionals or consumers to determine if a specific tire is recalled or is old enough to be replaced. No doubt, the recommendations for a TIN lookup website and full TINs on both sides of the tire would make it easier (also advocated by SRS), but tire techs and consumers still need to translate the 11 Alpha-numeric characters from each tire accurately into a computer. This is a task fraught with error and isn’t practical in a shop environment. Given the cost-effective and available technology – from RFID to laser-etched QR codes – and the magnitude of the safety issues at stake when recalled and aged tires stay in service, tire scan-ability is where the industry already headed. Most tire makers have added that feature to some lines of tires.  In June 2013, Kumho Tire Co. Inc. announced it would put RFID tags in all of its tires.

The NTSB also appeared to discount NHTSA’s contention that tires that met the new FMVSS 138 and 139 were so robust, that no rulemaking on tire aging was required. In March 2014, NHTSA released Tire Aging: A Summary of NHTSA’s Work, in which the agency announced that it had no plans to turn its tire aging research into a regulation. NHTSA cited 2007 through 2010 stats that purported to show a 35 percent reduction in tire crashes; a 50 percent reduction in fatalities; and a 42 percent reduction in injuries (11,005 to 6,361) when compared with annual averages from 1995 through 2006. A January 2015 study, sponsored by non-profit The Safety Institute, disputed that claim. It found that the number of tire-related crashes and resulting deaths has remained relatively constant since 1995. At the December 2014 tire symposium study co-author Randy Whitfield told the NTSB that the agency’s conclusions were based on a survey with a small sample size of crashes involving light passenger vehicles towed for tire-related damage, rather than evaluating all tire-related crashes.

NTSB concluded: “Further research is needed to confirm that the implementation of Federal Motor Vehicle Safety Standard Nos. 138 and 139 has substantially reduced the risk of tire-aging, related crashes, injuries, and fatalities.”

Improvements to tire safety have long been stalled by the intransigence of the RMA, which puts all of its efforts into keeping the status quo firmly in place and NHTSA, which has not mustered the energy to overcome it. The NTSB has no authority to implement policy – but its pronouncements are influential. And here’s hoping that this round of safety recommendations gets the process moving.

NTSB to Release Long-Awaited Tire Safety Recommendations

In February 2014, there were two tragic, fatal, and high-profile tire crashes on U.S. highways that might very well constitute a tipping point for tire safety.

One involved an 11-year-old Michelin Cross Terrain tread separation on a 2004 Kia Sorrento that led to a crash into a school bus carrying 34 members of a Louisiana high school baseball team in Centerville, La. Four of the Kia occupants died, and the fifth was severely injured. Thirty of the bus passengers suffered injuries.

The other involved the failure of a recalled BF Goodrich tire that was on the left rear tire on a 2002 Ford 350 XLT 15-passenger on an interstate in Lake City, Fla. The driver lost control, and the van swerved onto an embankment and rolled over. Two adults died, and all of the other occupants, including several children, suffered injuries. The tire had been recalled for tread loss or rapid air loss from a tread-belt separation shortly after Sam’s Club put it on the vehicle in 2012. In November 2013, Sam’s Club mechanics inspected the tire, but failed to identify and remove it.

Deaths and injuries in crashes caused by aged and recalled tires are entirely preventable, but neither the tire industry nor the National Highway Traffic Safety Administration has been inclined to do anything to prevent them. On Tuesday, the public might finally see some leadership on this issue from the National Transportation Safety Board. The board is meeting to discuss its new report on tire-related passenger vehicle crashes, “and “the safety issues uncovered during these investigations and the December 2014 NTSB tire symposium.”

Within 10 months of those horrific crashes, the NTSB resolved to take up the issue of tire safety and convened, in lieu of formal hearings, a two-day tire symposium in which stakeholders presented information on tire age, the recall system, tire construction, technology and tire-related crash data. 

The symposium was notable, in part, for NHTSA’s decision to cite inaccurate tire data purporting to show that tire-related deaths and injuries have decreased by half since Federal Motor Vehicle Safety Standard 139 was established, and the Board’s skepticism at the Rubber Manufacturers Association contention that it could do nothing to change the way it did business. Tracey Norberg’s (RMA’s Senior Vice President of Regulatory Affairs and General Counsel) flat-earth argument that it would be too difficult to make tires that could be scanned for tire age and recall information, fell flat.

“That’s interesting because I think an awful lot of people in this audience have an iPhone,” said symposium chair Earl Weener, an aviation safety expert, and NTSB member since 2010. “That iPhone can read QR codes, can read barcodes, can read UBS codes. But somehow that is too much technology for the tire manufacturers and for the tire distribution process. You know, you go to the airport and about every third person checks in with their iPhone, with a barcode on them. So it seems to me that maybe some imagination is required.” (See Safety Research & Strategies 2007 whitepaper on tire RFID)

Safety Research & Strategies president Sean Kane presented an overview on the tire age issue, noting that rubber manufacturers have been publishing papers on thermo-oxidative aging as far back as the 1920s. In the last quarter-century, the debate over, the research on, and the official recognition of this safety hazard has garnered much more attention from automakers, tiremakers and the government. Automakers preceded U.S. tiremakers in issuing tire age warnings by at least a decade. Throughout the 1990s, the majority of vehicle manufacturers worldwide added warnings to their owner’s manuals about aged tires.  These warnings all focused on a six-year threshold.  In October 2005, that Bridgestone/Firestone broke ranks with other tire makers and issued a “Technical Bulletin” to its dealers advising them that tires should be inspected after 5 years and replaced after 10. Other major tiremakers, such as Cooper, Michelin and Continental-General followed.  Many tiremakers defer to auto manufacturers’ recommendations, a defacto service life of six years. NHTSA, which has studied the problem extensively since early the 2000s, has clearly stated that age is a hazard and a factor in tire-related crashes. While there are no state or federal tire age regulations, there is general consensus on when a tire’s useful service life is over. 

Despite decades of acknowledgement among all of the major players, the critical information about tire age has not been adequately conveyed to those at the retail level – consumers, and tire sellers and the tire and service technicians on whose advice and guidance the average motorist relies. Neither industry has taken responsibility for nor taken action to alert and train tire service professionals or consumers, which is why we continue to see old tires rotated into service with deadly results

The symposium was also marked by a rare open dispute between the RMA, which represents manufacturers, and the Tire Industry Association, which represents tire sellers. RMA chose the symposium to roll out its lobbying effort to implement a mandatory registration system requiring retailers to electronically register the tire at the time of the sale. Ever since, the RMA has been busy trying to get language to that effect wedged into a transportation bill. The TIA has argued that tire registration is already too big of a burden for retailers to have to stock registration cards from several manufacturers. Retailers should just provide the customer the TIN and tell them what website they can use to register the vehicles.

TIA Executive Vice President Roy Littlefield says that 80 percent of the tires retailers sell are registered and the group has been trying to keep any such mandates out of federal legislation. The TIA does support any effort to “take advantage of current technology. The industry can do a better job, and not only improve the tire registration system, but also focus on the more serious issue of recalls.”  

Safety Research & Strategies is hopeful that the NTSB will, at long last, move the ball forward. The Tire Identification Number (TIN) system is forty years old and showing its age. Just about every retail product can be and is tracked via automation – except for passenger car tires, and there is no good reason why techs and consumers are still relying on cards and complicated web searches to find out if a particular tire has been recalled and why isn’t the full TIN on both sides of the sidewall?  The excuses are as tired as the system itself.

See also The Run Down on NTSB Tire Symposium