Functional Safety Testing - FMEA Analysis

Reliable Systems with Functional Safety Testing and Certification

Functional safety testing is important for businesses seeking to expand internationally, as many markets require compliance with standards such as IEEE 802.15.14, IEC 61508, IEC 61511, and many more. As a world leader, providing solutions for functional safety testing and certification, TÜV Rheinland can provide Failure Mode and Effect Analysis for products to examine the consequences of possible failure conditions in different components of machinery. FMEA testing allows companies to identify areas of concern and take steps to implement safety controls in the case of failure. Our experts work with you to ensure the safety, quality and reliability of software, electronic measuring and control systems, industrial machinery, programmable electronic systems, and process automation.

Benefits at a Glance

With Functional Safety Testing and Certification from TÜV Rheinland you can:

  • Ensure compliance with domestic and international standards and requirements
  • Reduce your liability risk with documented safety standards
  • Competitively position your products in the global marketplace with our independent third party certification
  • Effectively utilize our network of experts for integrating safety related products into the safety instrumented systems and applications
  • Benefit from fast audit times and our many years of experience and expertise

Our Functional Safety Testing Services

We support manufacturers from concept design through the development process to ensure compliance with Functional Safety requirements for products and systems. The following provides an overview of our “Functional Safety” services:

Product Testing and Certification

Products and Systems have to adhere to high standards for safety, reliability and quality. If it fails to function, due to technical defects, faulty sequence of events or human failure, environment and technology may well be endangered. TÜV Rheinland experts offer you the expertise and attention to detail, in the planning and execution of testing for electrical, electronic and programmable electronic safety-related components and systems.

Type Approvals

TÜV Rheinland experts provide type approvals to ensure safety related products contain sufficient functional safety to meet their intended Safety Integrity Levels (SIL). Conformance to the requirements of domestic and international standards is critical to ensure a product's suitability for its intended applications. TÜV Rheinland's type approval provides proof that the product meets the requirements of the relevant product standards and it can be used for the specified range of operations.

Because of the complexity of today’s devices, tests should be carried out parallel to product development. Streamlining development efforts is an important advantage for the manufacturers.

Performance Testing

We can test your products and components to a variety of performance and environmental criteria. Our modern, well-equipped laboratories and testing facilities provide cost effective solutions to a wide range of performance and environmental issues. Benefit from effectively utilizing our subject matter experts during your development activities or for the qualification of your components.

Some of the performance testing we offer includes:

  • Vibration Testing
  • Shock Testing
  • Climate and Temperature Testing

Failure Mode and Effect Analysis (FMEA)

One of the essential safety requirements concerning protection and monitoring systems refers to the behavior in case of failure conditions. It is a requirement that failures in the control, as well as in the peripheral should not lead to a failure of the defined safety functions. A possible method to prove, that failures cannot react critical to safety, is the Failure Mode and Effects Analysis (FMEA).

The FMEA examines the behavior of a product during development or existence of internal or external faults. This is done by the detailed analysis of the circuit diagram and documents and/or by practical simulations of fault and examination of the behavior of the device (component, unit). The possible instant indicating the occurrence of failure and the temporal requirements for fault detection always have to be considered and respected.

FMEA provides proof that even in case of failure, a control can carry out the safety function according to the standard's requirements.

Risk and Reliability Analysis

Safety-related requirements are defined in application dependent and independent standards, which determine the definitive test principles of type approvals. In the risk analysis of the applications, where levels or categories are not binding, the independent international application standard IEC 61508 offers methods and support to determine the risk and the requirements referring to the risk of the safety or protection equipment.

The determination of risk is made by inspecting the combination of effect and occurrence probability of damage of the process including the automation devices without safety or protection devices. The result is a safety integrity level (SIL). The safety and protection devices have to apply to the SIL requirements, which reduce the risk of the application to a tolerable risk.

Additional Functional Safety Services and Resources

Functional Safety Certification Services

In addition to our Functional Safety Product Certifications, we also offer our customers Functional Safety Management (FSM) systems certifications according to the requirements of international standards, such as IEC 61508, IEC 61511, IEC 62061, EN 954, ISO 13489 and many more.

The existing structural organization and procedures of the certification body are based on the criteria determined by EN 45012. The organization and certification procedures follow quality management procedures accordingly.

Our experts and auditors are not only competent in auditing FSM organizational measures, they are also able to judge the organizational measures for their technical effectiveness, because of their own practical experiences.

Our Functional Safety Certification Marks

At TÜV Rheinland, we offer two types of Functional Safety Certification Marks:

Type Approved

The Type Approval Mark provides proof that your products were tested and meets the requirements of the relevant product standards.

The type approval is a basis for the producer's CE declaration of conformity, as all regulations are applied as the base of testing, which is necessary to show proof of conformity according to the relevant domestic and international directives such as low voltage and EMC directives.

The test mark "Functional Safety FS" is applied to products, which - according to the product standards - require functional safety (fail-safe behavior) and which are used in safety related applications.

Functional Safety - FS Mark

The safety design of the product according to the relevant standards, including the EN 954 and/or the IEC 61508, has to be approved. Together with the product's implemented measures to ensure fail safe behavior, the complete documentation concerning the overall life-cycle of the product, as well as the implemented Functional Safety Management, which is being applied to all life-cycles of the product to the standard requirements, has to be surveyed and assessed. A certificate and test mark "Functional Safety FS" includes the mark "Type approved".

Products Covered

  • Programmable Systems
  • Drives with Integrated Safety Functions
  • Safe Bussystems
  • Software Qualification
  • Electro Sensitive Protective Equipment (ESPE)
  • Sensors, Actuactors and Logic Units