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Functional Safety and Cyber Security Workshops

Functional Safety and Cyber Security Workshops | TÜV Rheinland



Detailed information about trainings, course providers, certificates

Cutting-edge training from experts in functional safety

Clearly structured, up-to-date information and instruction on international standards and related issues in functional safety is valuable to those engaged in the design, management, engineering and sales of functional safety (FS) systems and components. Trying to understand the content and implications of the standards without professional guidance can be challenging.

As functional safety experts with a long and successful track record of helping industry manage, test and certify their FS systems, we have designed ten workshops intended to share our extensive knowledge of the topic with you. With or without prior knowledge and regardless of your job title, if you work with functional safety devices or components in any capacity, we have a course for you.

Looking back on decades of successful partnerships with industry leaders and a long career as providers of occupational training, we have attracted a team of talented and experienced instructors who draw on their own background in functional safety to make workshops engaging and interactive.

Sign up for a course today!

Know the international FS standards that apply to you

Our functional safety trainings and workshops | TÜV Rheinland

Understanding what the various functional safety standards require and how they relate to your organization, products or job description makes a big difference when it comes to compliance, certification or preventing dangerous incidents. Our workshops cover IEC 61508, IEC 61511, ISO 26262, IEC 62061 and ISO 13849 in depth so that you have the knowledge to do your job better and improve the performance of your organization.

A complete portfolio of functional safety training courses

We have designed ten workshops targeting various aspects of functional safety that can benefit FS professionals and organizations and industries that utilize functional safety systems and devices:

Basic principles of functional safety according to IEC 61508

This workshop introduces the general aspects of functional safety and its principles with reference to FS standard IEC 61508, including relevant terminology to facilitate understanding. There are no prerequisites for the course, and the target audience includes various management teams (general, product, project and quality) as well as marketing and sales staff.

Without going into great depth, the course addresses topics such as:

  • The safety requirements of safety components.
  • Considerations for developing safety components.
  • Understanding how the standard’s defined safety life cycle phases correspond with the manufacturer’s internal development cycles.
  • How to interpret and compare safety related parameters and specifications.

In addition to clarifying the legal status of IEC 61508 together with its terms and content, the workshop includes segments on:

Risk analysis

  • How much safety is necessary?
  • Risk assessment according to IEC 61508-5

Functional safety management

  • Definition of lifecycle-phases
  • Documentation
  • Functional safety assessment
  • Modifications
  • Competence
  • Suppliers of products or services

Safety related parameters

  • Hardware fault tolerance
  • Safe Failure Fraction (SFF)
  • Average probability of failure (PFDAV)
  • Relation between PFDAV and Proof Test Interval (PTI)
  • Probability of a dangerous failure per hour (PFH)
  • SIL claim
  • Interpretation of safety-relevant parameters (What is good, what is bad?)

Machinery standards

  • EN ISO 13849-1 range of application
  • Determination of performance level
  • EN 62061 range of application
  • Application software development

Safety-related software according to IEC 61508 – development and tests

This workshop explains in detail IEC 61508 part 3, its terms and requirements and their application and realization. A basic knowledge of hard and software testing and development according to this standard is required before enrollment. The workshop is appropriate for software developers, project managers, quality managers, testers, managers responsible for development and application of safety-related products and systems.

Using examples and exercises, our instructors provide a thorough overview of the software development process, enabling participants to better understand its complexity. This allows project planning to become more precise and cost effective. The workshop also includes a detailed survey of precise measures for fault avoidance and fault control, as well as the relevant technical knowledge of these topics to provide a practical basis for effective software development. Methods such as the determination of software complexity as well as test coverage help participants design tests and assess their results more effectively.

Participants can expect instruction on the following topics:

Overview IEC 61508 part 3

  • Application of IEC 61508
  • Risk analysis
  • Software development process
  • Safety life cycle of software


  • Safety Requirement Specification (SRS)
  • Specification of SW-architecture
  • Documentation of tests

Measures of fault avoidance

  • Test planning
  • Documentation
  • Defensive programming
  • Coding guidelines
  • Proven in use
  • Use of test and development tools

Selected methods of hardware fault control

  • RAM tests
  • ROM tests
  • Opcode tests
  • Internal processor tests

Verification and validation

  • Static tests
  • Dynamic tests
  • Software complexity

FMECA Compilation


Programmable electronics (ASICs, FPGAs, CPLDs) in safety-related applications

ASICs, FPGAs, CPLDs are increasingly used in safety-related components, which is why the current version of IEC61508 establishes requirements for fault avoidance for those designs. Knowing the requirements of IEC61508 and how they can be applied in a meaningful way is essential.

This one-day workshop presents the normative requirements of ASIC, FPGA and CPLD development in safety-related applications and shows various measures and techniques for fault control. Component developers who use programmable electronics in safety-related operations and who have a basic familiarity with IEC 61508 will benefit from this course, which has a maximum enrollment of 15 participants.

All topics related to developing programmable electronics for safety-related applications are covered, including practical applications. Specifically, the workshop includes:

Amendments in IEC 61508:2010

Management of Functional Safety

  • Safety plan
  • Verification and validation
  • Documentation

Fault avoidance

  • Life cycle phases
  • General requirements
  • Tool requirements
  • Measures and techniques for fault avoidance
  • Implementation of test structures
  • Requirements for production
  • Aging

Fault control

  • Differences between µC and ASIC based systems
  • Requirements for architecture
  • Fault models
  • Techniques for fault control
  • Implementation of test structures
  • Examples for diagnostics and tests
  • Exercises and examples of fault control

Requirements for on-chip redundancy

  • Measures to avoid mutual interferences
  • Additional requirements for on-chip redundancy
  • Determination of common cause failures

Safety-related parameters

  • PFD/PFH calculation and estimation of failure rates
  • Distribution of fault values in a design

Detailed example of fault control measures

  • Application of various measures for fault control

Development of safety-related hardware according to IEC 61508, EN ISO 13849-1 and IEC 62061

This workshop presents the normative requirements for the design and development of safety-related hardware and incorporates practical examples to demonstrate the structural requirements as well as possible measures for fault detection and control. The course is intended for hardware designers as well as project and product managers responsible for the design and development of safety-related products. A basic knowledge of IEC 61508, EN ISO 13849-1 and their application is required prior to enrollment.

While all aspects related to the design of safety-related hardware are considered, requirements and practical implementation of SIL 3 according to IEC 61508, IEC 62061 and EN ISO 13849-1 are the main focus.

A detailed list of course topics follows:

Normative fundamentals of functional safety: IEC 61508, IEC 62061, EN ISO 13849-1

Safety-related structures according to:

  • IEC 61508, IEC 62061
  • EN ISO 13849-1

Safety-related requirements

  • Normative requirements
  • “Good safety engineering practices”
  • Handling of fault exclusions

Presentation of various diagnostic techniques

  • Digital DC inputs
  • Digital DC semiconductor outputs
  • Analog inputs
  • Reset circuits
  • Microcontroller
  • Power supplies

Practical example and role-play

  • Self-contained assessment of a µC based circuitry
  • Common discussion of results

Application of failure mode and effect analysis (FMEA) during product development

This workshop, with its emphasis on practical exercises, is an introduction to the failure mode and effect analysis (FMEA) applied during the development of safety-related products. Basic principles of an FMEA are introduced and their application is illustrated through comprehensive, practical activities. IEC 61508 and EN ISO 13849-1, category 4 are the relevant standards that form the background to the course, and a basic knowledge of these norms and their application in safety-relevant products is a prerequisite. The workshop targets hardware developers and project managers and others responsible for product development and application of safety-related systems.

The topics include all aspects necessary to perform an FMEA at the system, bloc and component level. The course contents in detail are:

General introduction and approach of the FMEA method

Introduction and presentation of FMEA procedures at different development levels:

  • System level (application and operation of a safety-related product)
  • Bloc level (functional discrete units of a safety-related product)
  • Component level (of selected function units)
  • Software FMECA

Exercises incorporating real-life examples illustrate the different FMEAs and the results are discussed with participants.

Cyber Security in industrial automation

In this workshop our experts introduce and discuss the fundamental contents and requirements of IEC 61508 and IEC 62443 regarding the development of programmable, electronic safety systems while also focusing on cyber security in industrial automation. In addition, the course clarifies and compares functional safety and cyber security aspects as they relate to these standards. Developers, marketing and sales managers, product/project/quality managers and testers are invited to participate and bring along questions and topics for discussion.

Workshop segments include:

  • Introduction of relevant definitions related to security and safety
  • Difference between IT-security and cyber security (industrial security)
  • Overview of internationally relevant security standards
  • Introduction of safety level definitions
  • Attack vectors
  • Functional requirements of industrial components
  • Security risk assessments and threat modelling
  • Secure software development in a nutshell
  • Security module verification

Validation of functional safety in the manufacturing industry

According to the Machinery Directive and EN ISO 13849 and EN 62061 harmonized standards, machine builders are required to validate their machines, including safety technology. After presenting a theory of validation, instructors illustrate individual validation steps by way of interactive tasks. The course also answers practical questions about how and what to validate, when to know that validation is completed and how it must be documented. The workshop, intended for commissioners, test personnel, developers/designers, programmers and project managers/planners, requires a basic knowledge of safety engineering. Helpful preparatory courses include:

  • The way to a safe machine according to current standards
  • Safety of machinery – CE marking and standards
  • Risk Assessment Management – methodology for the standard-compliant implementation of the risk assessment

The following topics are covered:

  • Theory of Validation
  • Validation of specifications
  • Validation of implementation concept
  • Validation of hardware implementation
  • Validation of software implementation (application software)
  • Validation of safety parameters (PFHD, SIL, MTTFD, PL) calculations
  • Validation of the overall application

Functional safety of mechanical, pneumatic and hydraulic actuators according to IEC 61508

This workshop, incorporating detailed examples and exercises, focuses on the functional safety requirements for actuators. Its main objectives are:

  • Transferal of normative requirements of IEC 61508 to actuators
  • Possible solutions for SIL classification of actuators

Instructors explain the fundamentals of the standard and interpret its relevant requirements as well as discussing safety-related parameter calculations for actuators and the applicability of those calculations. Participants should already have basic knowledge regarding testing and development of hard and software according to IEC 61508. Component and product manufacturers, developers / design engineers, plant designers, plant operators, quality managers and functional safety managers are all encouraged to attend.

Course content covers:

  • Reasons for failures in safety-related systems
  • Definition of safety functions
  • Fault exclusion - reasons and proof
  • Current methods for SIL-assessment
  • FME(D)A – application for actuators
  • Determination of failure rate from:
    • Statistical test procedures
    • Proven-in-use

  • Operating modes (high / low demand)
  • Proof test interval – contents and scope
  • Limitation of conditions of use due to structural requirements of the system
  • Documentation

Basic principles of functional safety in process technology according to IEC 61508 and IEC 61511

In this workshop, participants learn basic principles and FS information related to protection equipment as well as the details and terms of IEC 61508 and IEC 61511. There are no prerequisites for the course, which has been designed for system integrators, designers, marketing and sales staff, product / project / quality managers, test authorities and general managers.

After introducing the legal status and contents of IEC 61508 and IEC 61511, the instructor will cover:

Risk analysis

  • How much safety is needed?
  • Risk graph acc. to IEC 61508-5 / IEC 61511

Management of functional safety

  • Definition of life-cycle phases
  • Documentation
  • Validation (assessment) of functional safety
  • Modifications
  • Competencies
  • Suppliers

IEC 61511

  • Application area
  • Proven in use
  • Normative requirements to SW-development
  • Validation
  • Verification
  • Safety-related parameters
  • Hardware fault tolerance
  • Safe failure fraction (SFF)
  • Probability of failure on demand (PFDAV)
  • Coherence of PFDAV and proof test interval (PTI)
  • Structural requirements of subsystems
  • Validation of safety-related parameters

ISO 26262 – revised and brand new

The intention of this workshop is to give a clear overview of the major changes and resulting impact of the second edition of ISO 26262, which is recognized worldwide as the functional safety standard for the automotive sector. Instructors provide an up-to-date interpretation of its contents and discuss in detail the implications for companies and products.

The workshop targets safety managers, product design engineers (HW design, SW design, system design) of OEMs, suppliers and service providers as well as decision makers who would like to see new challenges and opportunities in a fast changing market.

The course syllabus includes:

  • Changes in ISO 26262, 2nd edition
  • Functional safety management-related changes
  • Functional safety concept level changes
  • Additional aspects for motorcycles (part 12)
  • Additional aspects for trucks, buses, trailers and semitrailers (T&B)
  • System level changes
  • Hardware level changes
  • New aspects for semiconductors (Part 11)
  • Software level changes
  • Changes in support processes
  • Analysis of dependent failures
  • New aspects for cyber security
  • Discussion

Global leaders in functional safety

With a reputation for excellence and expertise, we are the chosen partner for many of the world’s largest and most reputable organizations. As challenges such as cyber security arise, we have the resources to learn how to overcome them and to incorporate those lessons in our courses and workshops. Working globally and in nearly every industrial sector, our instructional personnel are among the most respected in the field of functional safety.

Speak with one of our experts to learn more!

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