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Dell, Sony Discussed Battery Problem 10 Months Ago

InfoWorldMike writes "Dell and Sony knew about and discussed manufacturing problems with Sony-made Lithium-Ion batteries as long as ten months ago, but held off on issuing a recall until those flaws were clearly linked to catastrophic failures causing those batteries to catch fire, a Sony Electronics spokesman said Friday. Spokesman Rick Clancy said the companies had conversations in October 2005 and again in February 2006. As a result of those conversations, Sony made changes to its manufacturing process to minimize the presence and size of the particles in its batteries. However, the company did not recall batteries that it thought might contain the particles because it wasn't clear that they were dangerous, Clancy said. Dell spokeswoman Anne Camden declined to comment on the conversations with Sony in October and February, but told InfoWorld that Dell was 'confident that the manufacturing process at Sony has been changed to address this issue. Now our focus is erring on the side of caution to ensure no more incidents occur.'"

32 of 111 comments (clear)

  1. well they would have done something then by atarione · · Score: 5, Funny

    but the laptop with the response plan on it burst into flames.

    --
    actually I am happy to see you, however that is in fact a banana in my pocket.
  2. Of course they knew it was dangerous by pimpimpim · · Score: 2, Informative
    Otherwise, why would they ever start to examine these things close enough to find out there were small particles in it.

    Furthermore, I don't think they were talking about just malfunctioning of the batch of batteries, because I guess general malfunctioning was not an issue with these batteries. Otherwise the batteries that exploded would have already been returned to Dell before they could even get the chance to explode. Or where these all brand new batteries that exploded? And how many stories are there about malfunctioning batteries on Dells, except for the exploding ones?

    --
    molmod.com - computing tips from a molecular modeling
    1. Re:Of course they knew it was dangerous by RenderSeven · · Score: 2, Interesting
      Honestly, Im not sure. I have 4 LCD's - Amptron 17, 2x Dell 19, Amptron 19. I got the Dell's recently. Ive noticed my eyes dont focus anymore weekday evenings since I started using the Dell's. It may be a coincidence, or my imagination, or the angle on the desktop, but it seems like the Dell 19's hurt my eyes. Especially the more expensive of the two, although I dont spend the number of hours on the newer one to have as strong an opinion.

      Either way, if it wasnt for the price and that its hard to get a deal on a desktop without buying the monitor 'package' I would certainly have gone with another brand. First, a monitor company lives and dies by the quality (and price) of the monitor, while Dell sells them by leveraging. Its not 'Darwinian'... Second, if Dell is pushing them so hard they must be extremely profitable, meaning the margins are good, meaning they may spend less in parts than a comparably priced Viewsonic, for instance.

      OH! Almost forgot... The newest Dell 19 always autosets its parameters when the computer comes out of sleep or powers on. Its REALLY annoying and it rarely catches the first two pixels on a line. When youve spent 10+ years staring at Windows you might be surprised how out of place the desktop looks with the left two pixels missing. Its the only monitor Ive ever owned that autosets constantly, and I cant find a way to turn it off.

      But I have to repeat, Im pretty happy overall with what I got for how little I spent on a moderately loaded Inspiron 3100 + 19" panel. I love my Inspiron 6000 laptop and so does every client that sees it. The base desktop for $270 on sale is damned respectable too.

  3. Sony! by bogaboga · · Score: 5, Insightful

    When it comes to electronics, I have been one of the people holding SONY in very hight esteem. But the behavior of the company with its music, and problems with quality in its devices, have dented my approval. What is going on at SONY? Now there is this battery thing...I think it's time to look at other players in the business. SAMSUNG to me, looks very promising. No wonder SONY's market share has been diminishing since the early 90s.

  4. Direct Cause by staticneuron · · Score: 5, Interesting

    Was it that hard to find a direct cause for this? I would have imagined they would create a stress test to replicate these real-life situations in whitch the labtops caught on fire.

  5. Simple Mathematics by sincewhen · · Score: 4, Funny

    A times B times C equals X. If X is less than the cost of a recall, we don't do one.

    --
    -- Braden's law of data: All data spends some of its lifetime in an excel spreadsheet.
    1. Re:Simple Mathematics by Rosco+P.+Coltrane · · Score: 3, Funny

      If X is less than the cost of a recall, we don't do one.

      Are you saying Sony execs watch porn instead of working?

      --
      "A door is what a dog is perpetually on the wrong side of" - Ogden Nash
    2. Re:Simple Mathematics by kjart · · Score: 2, Insightful

      A times B times C equals X. If X is less than the cost of a recall, we don't do one.

      I know what you're paraphrasing and it does apply, but I have to ask, so what? Of course an equation like this is going to be used and research is going to be done. If a single catastrophic failure occurs, do you recall all 10,000,000 of your product? How about after 10? 100? There will always be freak occurences where horrendous events happen in unexpected ways - you have to figure out whether it's just that or part of a larger trend.

      Speaking of which, I'm curious about how many incidents of battery fires have actually been reported. I'm aware of the famous one obviously, but how many others have been reported? Is this actually a case where dozens/hundreds of batteries are bursting into flame, or merely a case of one hugely publiscized incident? I wouldn't be surprised if Dell was issuing the recall to save face after the huge publicity of that one fire, even if the incidences dont merit it.

    3. Re:Simple Mathematics by Anonymous Coward · · Score: 2, Interesting

      at least give credit!

      "A new car built by my company leave somewhere traveling at 60 miles per hour. The rear differential locks up. The car crashes and burns with everyone trapped inside. Now, should we initiate a recall? Take the number of vehicles in the field (A) multiply it by the probable rate of failure (B) then multiply the result by the average out of court settlement (C). A times B times C equals X. If X is less than the cost of the recall, we don't do one."

          -- Tyler Durden, Fight Club

    4. Re:Simple Mathematics by morgan_greywolf · · Score: 4, Interesting
      Speaking of which, I'm curious about how many incidents of battery fires have actually been reported. I'm aware of the famous one obviously, but how many others have been reported? Is this actually a case where dozens/hundreds of batteries are bursting into flame, or merely a case of one hugely publiscized incident? I wouldn't be surprised if Dell was issuing the recall to save face after the huge publicity of that one fire, even if the incidences dont merit it.


      According to the original CNN story that was broadcast/published when the story broke, Sony's Rick Clancy had told the AP that about "a half-dozen or so fires in the United States" had occurred, causing Dell and Sony to study the problem for "more than a month." That's on top of the highly-publicised fire in Japan. Of course, 10 months is more than a month, right?

      But the manufacturing defect that's causing the problem would obviously cause such problems. In TFA, a Dan Doughty from Sandia National Labratories describes the condition that occured -- metal flakes causing a short between the anode and cathode -- as causing the battery to discharge ALL of it's energy at once. Now, if you have a laptop manual handy, read the part about where it says how many Watt hours (WHr) the battery holds. A Dell Inspiron 8500 has a 72 WHr battery.

      We know that by definition a Watt is the amount of joules/second. So, a 1 Watt hr = 3600 Joules per energy. Now doing the math (3600 * 72) we get 259,200 joules of energy in that Inspiron battery. Keep in mind that there is other heat around the battery as well. Now discharge those 259,200 joules all at once with all that heat around it. Putting that in perspective, a firecracker only discharges about 3900 joules of energy, while a 100g stick of dynamite discharges about 400,000 joules.

      <sarcasm> But no, I'm sure they had no idea. </sarcasm>

    5. Re:Simple Mathematics by morgan_greywolf · · Score: 2, Informative

      s/joules per energy/joules per second

  6. Dell - The best Bang for your buck !! by Anonymous Coward · · Score: 5, Funny


    Dell - The best Bang for your buck !!

  7. Story? by JabberWokky · · Score: 4, Insightful
    Um, what exactly is the story here? They talked about and researched the issue before issuing a recall. I have a feeling that could be said about every recall... pretty much every business action that occurs. Seldom are the dart or "mouse with ink on it's feet" methods used anymore. They were alerted to the problem, got confirmation and addressed the problem.

    So what exactly is the story?

    --
    Evan

    --
    "$30 for the One True Ring. $10 each additional ring!" -- JRR "Bob" Tolkien
    1. Re:Story? by Snover · · Score: 2

      The story here is that they knew that their batteries were defective and had the potential for damage or loss of life but they didn't do anything about it when they found out.

      "A times B times C equals X. If X is less that the cost of a recall, we don't do one."

      --

      [insert witty comment here]
    2. Re:Story? by Minwee · · Score: 3, Informative

      "The story here is that they knew that their batteries were defective"

      Define "defective".

      Never mind, I'll read the article and do it for you.

      "Discussions were about the problem of small metal particles that had contaminated Lithium-Ion battery cells manufactured by Sony, causing batteries to fail and, in some cases, overheat."

      They were aware that some batteries could fail. "Fail" and "In some cases, overheat", do not mean "OHMYGODALLTHEBATTERIESAREGOINGTOKILLPEOPLE!" It means "There is a problem with the batteries and we should look at them."

      Unless of course you think that that clearly means they were dangerous.

      "[...] the company did not recall batteries that it thought might contain the particles because it wasn't clear that they were dangerous. [...] "We didn't have confirmation of incidents [involving fires] until relatively recently.""

      The story here is that they knew the batteries were defective, investigated what was happening, and did something about it when they found out what was happening. Look closely at your, sorry, Chuck Palahniuk's equation. When you have no reason to believe that B or C are any greater than zero, then X equals zero. It doesn't take a genius to figure that part out.

  8. Lies, damn lies, and PR by Zocalo · · Score: 5, Interesting
    That's pure crap. Why else would they have registered the "dellbatteryprogram.com" domain name back on 10th November of last year if they didn't think that a recall was going to be required? You might also notice from the WHOIS information that they are not hosting the domain on their own DNS servers like they do with their other domains. I think it far more likely that they had their discussions with Sony, but decided not to risk a PR disaster by performing a complete recall unless failures made it absolutely necessary to do so.

    My company made the decision to dump Dell just before this latest fiasco broke. Between regular failures of wireless modules in the D600 laptops, having to replace the motherboards of every one of GX270 desktops (OK, not really Dell's fault that one, but it's their badge up front for management to see) and totally abysmal support we've had enough. From their recent earning reports, I guess we're not alone in that.

    --
    UNIX? They're not even circumcised! Savages!
    1. Re:Lies, damn lies, and PR by sharkey · · Score: 4, Informative

      IIRC, Dell had a battery recall in December 2005 for a different issue.

      --

      --
      "Outlook not so good." That magic 8-ball knows everything! I'll ask about Exchange Server next.
    2. Re:Lies, damn lies, and PR by Anonymous Coward · · Score: 5, Informative

      You recall correctly. In december 2005, Dell recalled about 20000 batteries in the US, and about 35000 worldwide. I can still remember checking my own laptop's battery on dellbatteryprogram.com, and beeing dissapointed that I didn't get a fresh one for free. This time however, my old and worn battery will be replaced.

  9. How much proof is necessary? by NexFlamma · · Score: 3, Interesting

    IANAL, and I'm really curious about this: How much evidence would be necessary to convict them on something akin to endangering the public by releasing notebooks that they knew could combust in a literal fireball?

    I'm really hoping there is at least some legal protocol to protect consumer's from things like this that are rushed out the door at the (potential) expense of people's lives, other than class action suits.

    1. Re:How much proof is necessary? by blixco · · Score: 2, Interesting

      You would "only" have to prove negligence, that Dell willfully ignored data pointing to batteries that catch fire. They'd have to have documented that somewhere along the line, someone emailed someone else with orders to go ahead and sell the batteries despite the danger.

      You won't find that evidence. Dell didn't know that the things would catch fire because they don't test as well as they should. Their own incompetence would protect them from such a suit.

      That doesn't mean it won't be tried. Dell is sued every day of every week for something.

  10. forgotten the TV lawsuits by Wansu · · Score: 2, Insightful



    I suppose SONY and Dell either forgot all the lawsuits in the 60s and 70s stemming from TV sets burning down houses or they just didn't think the same kind of thing could happen to them. They will pay a hefty price.

    --
    Wansu, th' chinese sailor
  11. Hah!! by vistic · · Score: 4, Interesting

    Why on Earth would you hold Sony products in high esteem? I could understand that thinking back in the 1980s... but since the 90s came Sony has always had poor-quality problems except in their professional gear. There's nothing "high-end" or quality about them.

    Personally I think it's because they've stopped manufacturing their things in Japan. Now it's all about Malaysia or Indonesia or Taiwan or China or something.

    Check where things are manufactured, it can tell you a lot about what level quality to expect. Different countries have different cultures and different governments and different labor laws and quality assurance programs and work ethics and wages, etc.

    Then again I also can't believe you're starting to think Samsung is looking good. They've improved a lot, thanks to improvements in South Korea itself, but they're still kind of crap and have a long way to go. South Korea used to be one of the WORST countries in as far as quality manufacturing goes, but they've done a lot in the past 5 years or so to try and fix things.

    1. Re:Hah!! by multipartmixed · · Score: 2, Informative

      I agree wholeheartedly.

      Ask any TV repair professional; back about 1990 when the Sony TVs started saying "Made in Mexico", the quality dropped like a stone.

      --

      Do daemons dream of electric sleep()?
    2. Re:Hah!! by Abreu · · Score: 3, Informative

      Sony TVs "made in Mexico" were only assembled in Mexico, from low quality chinese components... The blame lies in China, not across the Rio Grande.

      --
      No sig for the moment.
    3. Re:Hah!! by pheede · · Score: 2, Interesting

      I don't know enough about the quality of Sony products in general to agree or disagree with your comment. But I find it just a little bit funny, that the two Dell batteries I have, which are part of this recall, were both manufactured in Japan.

    4. Re:Hah!! by pete6677 · · Score: 2, Insightful

      Agred. Sony has been living off their name for the better part of 20 years now. What successful and truly innovative product have they really had since the CD? Charging more money while steadily degrading quality and useability is a recipe for short term success but long term failure. In fact I am surprised they're still doing as well as they are.

      Once the PS3 ends up being the disaster that everyone thinks it will be, they will file Chpt. 11, or whatever they call that kind of Bankruptcy in Japan.

    5. Re:Hah!! by Quino · · Score: 2, Interesting

      Exactly; with mass production quality comes from design (of the product, manufacturing processes), quality control, etc. and not the ethnicity of the people pressing buttons of the manufacturing equipment.

      It made me laugh when I heard, for instance, that there were concerns about Toyotas made in the US (could they possibly be of the same quality as Toyotas made in Japan?). It seemed naive, as one of the key points about mass production is making products out of identical, interchangable, parts and taking the "human element" out of it. We're not talking about hand-made shoes here after all! One part of Toyota lean production methods (Toyota pretty much wrote the book on quality mass production btw) is studying and controlling small variations of your widgets as tool age, and designing products so that mistakes are impossible during assembly (error-proofing), etc.

      I still hear comments,even from colleagues (who should know better!), about the quality of stuff made in China -- as if something in the water makes anything manufactured there bound to be of low quality. People still show surprise that quality stuff can come out of Korea (again, I'm not sure what the rationale is, makes me wonder how certain people view the world ).

      Japan, early in its industrialization, was also synonymous with cheap low quality crap that'd fall apart if you looked at it funny or that would dissolve in the rain -- funny how perceptions change.

      I will guarantee you that a car manufacturer in China building quality designs and manufacturing processes can turn out cars of Toyota quality (and the time can still come and maybe not too far in the future). Ironically enough, all they have to do is embrace Deming and study Toyota manufacturing methods.

      If Sony's cutting corners with their quality control then issues like these are bound to come up. But these quality concerns have zero to do with the language of the workfoce.

  12. I worked at Dell by blixco · · Score: 5, Interesting

    for six years, and the one thing you, as a consumer, have to know about Dell (and possibly companies like it) is that there are two forces that drive their decisions: money and litigation. Dell has cut cost to the bone, not just in their supply chain but throughout their enterprise. Every dime is scrutinized, every step planned to the Nth to determine if the cost / benefit hits a sweet spot. The main driver behind product launches is schedule, and not quality. With the right schedule, Dell can be to the market at a price that makes profit.

    If there are problems with the equipment, those problems are weighed against the overall cost they contain. If Dell determined that their notebooks blew up, they'd have to weigh the odds, the cost of litigation, and the cost of bad press versus the cost of fixing the problem.

    The only bad thing about this way of thinking from a business perspective is that economy overrides lesson learned. Dell has had battery recalls more than a few times in the past, and this latest may cement the idea with people that Dell = exploding batteries. But rather than proactively develop test plans and more rigorous standards for their suppliers, they simply look at the bottom line.

    Ultimately this has served them well from a cash perspective, but this past year has seen a lot of their karma catch up with them; their process (which is King at Dell) has run out of wiggle room for cost cutting, and bad press like this (combined with the cost to replace those batteries) may start to chip away at their altar of the almighty dollar.

    You'd be amazed, though, how myopic quarter to quarter thinking makes a corporation.

    1. Re:I worked at Dell by DerekLyons · · Score: 3, Insightful
      I worked at Dell for six years, and the one thing you, as a consumer, have to know about Dell (and possibly companies like it) is that there are two forces that drive their decisions: money and litigation.

      No news there - it's the same at pretty much any other corporation.
       
       
      If there are problems with the equipment, those problems are weighed against the overall cost they contain. If Dell determined that their notebooks blew up, they'd have to weigh the odds, the cost of litigation, and the cost of bad press versus the cost of fixing the problem.

      Again, the same as at virtually every other manufacturer, from baby food to SUV's.
  13. Re:What were they thinking? by blixco · · Score: 2, Informative

    Failure analysis is a pretty well established science, and when every failure leads to a lawsuit, the analysis is done with a very specific intent.

    In this case, Dell will be able to point at Sony as the cause of the problem, unless Sony can produce a demand by Dell for cheap batteries that used inferior design.

    Now so far as the science behind exploding batteries, it is hinted at that the battery cells were filled with an inferior product. The particles that carried the charge were too large, which allowed them to carry more energy (heat, in this case) in a concentrated space. Maybe. My bad but best guess.

  14. VBScript to find Dell Battery Part # by PoitNarf · · Score: 2, Informative
    I'm sure there are plenty that were in my situation. Large organization, many Dell Latitude laptops, and many users that probably won't check the part # on their batteries to see if it's included in the recall. I included the following lines to an inventory script we run on all the computers on our Windows domain to collect hardware information which is stored in a SQL database. It is able to get the battery manufacturer and part # from the BIOS. Here's the code for all who are interested:

    strComputer = "."
    Set objWMIService = GetObject("winmgmts:" _
    & "{impersonationLevel=impersonate}!\\" & strComputer & "\root\cimv2")

    Set colItems = objWMIService.ExecQuery("Select * from Win32_PortableBattery")

    For Each objItem in colItems
    Wscript.Echo "Manufacturer: " & objItem.Manufacturer
    Wscript.Echo "Name: " & objItem.Name
    Next
    --

    "0101100101? It's just jibberish. *looks in mirror, gasps* 1010011010@!? AHHHHHH!!"
  15. Re:Why Sony Products Should Be Held in High Esteem by RotHorseKid · · Score: 2, Informative

    The Ad comes from the 1990 movie Crazy People, starring Daryl Hannah.

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    Nobody writes jokes in base 13. - DNA