Using genealogy to crack cold cases is becoming a more frequently used method across the U.S with the identification of

The cell supplier for the affected Ford and BMW vehicles is making process changes to prevent this sort of contamination from happening again. Still, in manufacturing, there are rarely any guarantees that nothing has gone wrong. That’s why there are quality assurance departments, to make sure that the processes are right to begin with, that they are properly followed, and that any discrepancies are caught early.

“It is nice to be able to speak for her after all this time. The big headline was ‘Go-go girl found dead.’ There was a little more to her than a ‘go-go girl,’” — Rosalie Sanz in The San Diego Union-Tribune

Due to Covid-19, it may be a while before Sipos is sentenced but his arrest is a step in the right direction, to get another cold case off the table. He awaits extradition in Lehigh County jail, Pennsylvania.

This is by no means the first time that cell manufacturing flaws have resulted in fires, and many cell manufacturers have experienced problems. Back in 2011, the original Fisker Karma experienced issues with cells catching fire and in 2013, the Boeing 787 was temporarily grounded following battery fires on two aircraft. In the 1990s, multiple manufacturers of laptop computers had recalls in the wake of battery fires.

Sources familiar with the situation at both Ford and BMW have confirmed that the fires that began while the plug-in hybrids were charging have traced the root cause back to a manufacturing issue with the cells. Both automakers use cells produced at the same supplier plant. Aluminum and copper particles from the welding process for the cell containers have been contaminating the interior of the cell, which in turn is leading to short circuits while charging the batteries.

Leaving high school at 17, Mary married her Navy husband and they had two daughters. The family moved to Louisiana and then out to California where they settled. The couple’s marriage fragmented and they divorced soon after, with Mary leaving the family home.

Concerned with her absence, Mary’s friend went to her apartment, which was a few blocks away from the Star and Garter club. She found the door to her apartment kicked in and Mary’s naked and lifeless body lying on the floor, amongst overturned furniture. She had been viciously raped before she was strangled to death.

Ultimately, while any verification method is important, it is a band-aid. Optimizing quality requires getting back to the root of the problem whether that is a product design issue or a manufacturing process flaw. Quality has to be baked in from the start, and as we grow the number of electric vehicles in the coming years, we’ll be building billions of cells and battery packs. Every step in the value chain has to work to minimize the number of dangerous and difficult to extinguish battery fires.

Sipos, who was in his mid-twenties when he raped and killed Mary, left behind evidence at the crime scene. His preserved DNA was run through genealogy databases and investigators quickly found a match.

Ford isn’t taking any chances, though. It has developed its own battery stress test. Once the cells are assembled into a battery pack for the plug-in Kuga and Escape, it will go through a new testing regimen before the pack is installed in a vehicle. European and North American plants are both implementing this testing procedure where they assemble the battery packs. BMW will likely do something similar with its battery packs.

On Tuesday the 27th October, San Diego police announced that they had arrested a 75-year-old man on suspicion of Mary’s murder. John Jeffrey Sipos from Schnecksville, Pennsylvania had just left the Navy and was living in San Diego when he attacked Mary.

Anyone that enters this area has to wear a “bunny suit” that covers their entire body including the head and face. Most of the processing is completely automated to limit any interaction with the equipment or the cells.

If you ever visit a cell manufacturing facility, you’ll find the environment is more like an infectious disease laboratory than a traditional car parts plant. The areas of the factory where electrodes are processed, rolled, or folded and packaged are all pristine. The cell assembly area is in a positive pressure room where the inside air pressure is kept above the ambient pressure outside to prevent contamination.

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dly, I stayed. If you’ve ever inched through L.A. traffic to get somewhere, you might understand. It took me an hour to reach this coffee shop. I wasn’t raring to get back into my car just to drive home. But that meant waiting there like an idiot for Justin to finish up with his meeting with another woman.

Ultimately, while any verification method is important, it is a band-aid. Optimizing quality requires getting back to the root of the problem whether that is a product design issue or a manufacturing process flaw. Quality has to be baked in from the start, and as we grow the number of electric vehicles in the coming years, we’ll be building billions of cells and battery packs. Every step in the value chain has to work to minimize the number of dangerous and difficult to extinguish battery fires.