Automotive System Safety Critical Considerations for Engineering and Effective Management

Contains practical insights into automotive system safety with a focus on corporate safety organization and safety management

Functional Safety has become important and mandated in the automotive industry by inclusion of ISO 26262 in OEM requirements to suppliers. This unique and practical guide is geared toward helping small and large automotive companies, and the managers and engineers in those companies, improve automotive system safety. Based on the author’s experience within the field, it is a useful tool for marketing, sales, and business development professionals to understand and converse knowledgeably with customers and prospects.

Automotive System Safety: Critical Considerations for Engineering and Effective Management teaches readers how to incorporate automotive system safety efficiently into an organization. Chapters cover: Safety Expectations for Consumers, OEMs, and Tier 1 Suppliers; System Safety vs. Functional Safety; Safety Audits and Assessments; Safety Culture; and Lifecycle Safety. Sections on Determining Risk; Risk Reduction; and Safety of the Intended Function are also presented. In addition, the book discusses causes of safety recalls; how to use metrics as differentiators to win business; criteria for a successful safety organization; and more.

• Discusses Safety of the Intended Function (SOTIF), with a chapter about an emerging standard (SOTIF, ISO PAS 21448), which is for handling the development of autonomous vehicles
• Helps safety managers, engineers, directors, and marketing professionals improve their knowledge of the process of FS standards
• Aimed at helping automotive companies—big and small—and their employees improve system safety
• Covers auditing and the use of metrics

Automotive System Safety: Critical Considerations for Engineering and Effective Management is an excellent book for anyone who oversees the safety and development of automobiles. It will also benefit those who sell and market vehicles to prospective customers.

JOSEPH D. MILLER of J. D. Miller Consulting, Inc, USA, was Chief Engineer of System Safety where he established and directed the system safety process for TRW Automotive worldwide. He led the US Technical Advisory Committee (USTAG) for Functional Safety (ISO26262) for 12 years and served as an ISO expert voting the US position. He also led the US delegation for the Safety of the Intended Function (SOTIF) ISO PAS 21448.

Series Editor’s Foreword ix

Preface xi

Abbreviations xv

1 Safety Expectations for Consumers, OEMs, and Tier 1 Suppliers 1

Trustworthiness 1

Consumer Expectations 3

OEM Expectations 4

Supplier Expectations 6

2 Safety Organizations 11

The Need for a System Safety Organization 11

Functions of a Safety Organization 12

Critical Criteria for Organizational Success 13

Talent to Perform the Safety Tasks 14

Integral to Product Engineering 14

Career Path for Safety Personnel 15

Safety Process Owned by Program Management 15

Executive Review 16

Pillars of a Safety Process 18

Alternatives, Advantages, and Disadvantages 26

3 System Safety vs. Functional Safety in Automotive Applications 41

Safety Terminology 41

Functional Safety Standards vs. System Safety 42

Background 42

Application of Functional Safety Standards 42

Safety of the Intended Function (e.g. SOTIF, ISO PAS 21448) 44

Triggering Event Analyses 45

Background 45

Systematic Analyses 46

Validation 49

Validation Targets 49

Requirements Verification 50

Release for Production 53

Integration of SOTIF and Functional Safety and Other Considerations 55

Background 55

Analyses and Verification 57

Validation 58

4 Safety Audits and Assessments 61

Background 61

Audits 61

Audit Format 63

Use of External Auditors 65

Assessments 67

System Safety Assessment 67

Work Product Assessment 67

5 Safety Culture 71

Background 71

Characteristics of a Safety Culture 71

Central Safety Organization 72

Safety Managers 74

Joint Development 75

Enterprise Leadership 75

Liability 75

Customers 77

Safety Culture vs. Organization 77

6 Safety Lifecycle 79

Background 79

Concept Phase Safety 80

Preliminary Hazard Analysis 80

Preliminary Architecture 81

Requirements 83

Design Phase Safety 84

Design-Level Safety Requirements 84

Verification 86

Manufacturing

Phase Safety 86

Safety in Use 87

Safety in Maintenance 88

Safety in Disposal 90

7 Determining Risk in Automotive Applications 91

Analyze What the Actuator Can Do 91

Analyze Communication Sent and Received 93

Determine Potential for Harm in Different Situations and Quantify 94

Exposure 95

Priority 96

Consider Fire, Smoke, and Toxicity 97

8 Risk Reduction for Automotive Applications 99

History 99

Analysis of Architecture 99

System Interfaces 100

Internal Interfaces 101

Requirements Elicitation and Management 102

Three Sources of Requirements 102

Cascading Requirements 104

Conflicts with Cybersecurity 105

Determination of Timing Risks in an Automotive Application 106

Milestones 106

Samples 107

Program Management 108

Design and Verification 109

Sample Evaluation 109

Verification 111

9 Other Discussion and Disclaimer 113

Background 113

Three Causes of Automotive Safety Recalls – Never “Random” Failures 114

Failure Rates 114

Recalls Due to Random Hardware Failures 115

Causes of Recalls 116

Completeness of Requirements 117

Timing Risk 118

“But It’s Not in the ‘Standard’” 118

Competing Priorities 119

Audits and Assessments 120

Disclaimer and Motivation for Continuous Improvement 121

Policy Statement 122

Governance 122

Metrics 123

Process Documentation 124

Tiered Metric Reporting 125

Use of Metrics 126

10 Summary and Conclusions 131

Background 131

System Safety is More than Functional Safety 131

Safety Requirements 132

Safety Process 133

Five Criteria for a Successful Safety Organization are Key 134

Auditing and the Use of Metrics 135

Auditing 135

Metrics 135

Future Considerations for SOTIF 137

Machine Learning 138

Appendix A IEC 51508 Compared to Typical Automotive Practices 139

Appendix B ISO 26262 – Notes on Automotive Implementation 167

References 215

Index 217

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