Digitalization of Functional Safety in a Connected Supply ......experience in managing APQP/PPAP, how do we manage the Safety Plans in System, Hardware, ... SME for AQP and PPAP to

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Digitalization of Functional Safety in a Connected Supply Chain

Chad Kymal

CTO, OMNEX

June 12, 2018

Concerns• ISO 26262 requires not only system, hardware, and software teams of the organization to be in

Synch, but also all the affected suppliers. Change in one requirement or safety goal affects the entire distributed development.

• The requirements, HARA, Safety Goal, safety Requirements, System Design, Testing, DFMEA, Hardware Design, Testing, Software Design and Testing, and Supplier System, hardware and components safety requirements, testing, HIS are all linked. How to accomplish this without web based software tools?

• Not only should the Functional Safety tools be linked, but it needs to be integrated into the overall requirements: the DVP&R, DFMEA, PFMEA, Control Plans and Shop floor controls.

• How do we track this development from an overall management? While we have gained great experience in managing APQP/PPAP, how do we manage the Safety Plans in System, Hardware, Software and the supplier DIA including the safety case of the System.

(C) Omnex Systems 2018

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About Omnex & Omnex Systems

Founded in 1985

Headquartered in Ann Arbor, Michigan with offices in major global markets

In 1995-97 provided global roll out supplier training and development for Ford Motor Company establishing offices in Latin America and Asia

Enterprise Quality Solution for APQP & Functional Safety, Integrated Management System & Supplier Management System.

Served on committees that wrote QOS, ISO/TS16949, ISO9001:2000, QS-9000 and it’s Semiconductor Supplement, ISO IWA 1 (ISO9000 for healthcare)

Former Delegation Leader of the International Automotive Task Force (IATF)

On the ISO writing committees for ISO 9001, ISO 14001, ISO 45001, and ISO 13485

SME for AQP and PPAP to International Aerospace Quality Group (IAQG)

One of the first to fully integrate Lean and Six Sigma

ISO 9001-certified for training development, training delivery and consulting

Member of AIAG manual writing committees for FMEA, SPC, MSA, Sub-tier Supplier Development, Error Proofing, and Effective Problem Solving (EPS)

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About Omnex & Functional Safety

• Provided functional safety management systems training and services since 2009 making Omnex the oldest provider of Functional Safety in the USA

• Provided services to the Automotive and Electronics Industry since 1986 and the Semiconductor Industry since 1998

• Implemented management systems and new product development for 1000s of Organizations in the Automotive, Electronics and Semiconductor Industry

• Supports Automotive organizations in the US, Europe, India and China for a multi country development projects

• Implemented, audited and developed Functional Safety work products for an entire E Car, multiple battery management systems, Steering Systems, Autonomous cars, Semiconductor devices, and software


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Omnex Worldwide Offices


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Keeping a Functional Safety Project in Synch


This requires coordination of design and manufacturing in our Global Customers with the tremendous exchange of information, forms, and checklists.

How do we keep this project with Tier One with three internal development groups and 6 Suppliers in Synch?

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Functional Safety – Parts 2 Through 9

Part 3 – Item Definition Hazard Analysis and Risk Assessment and the Functional Safety Concept

source: ISO 26262 Part 2

Part 2 – Functional Safety Management System

Part 9 – ASIL-oriented and Safety-oriented Analysis

Part 4 – Technical Safety Concept, Testing, Validation and Integration – System

Part 5 – Hardware Safety Concept, Testing, Validation and Integration

Part 6 – Software Safety Concept, Testing, Validation and Integration

Part 7 – Process Control in Pre-production, Production, Service (maintenance and repair)

and Decommissioning

Part 8 – Support Processes

Parts 4-6 – Hardware Software Interface


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Safety Plans and APQP/Project Plans Need to be Linked

FRONT IMPACT AIRBAG SYSTEM

CAN BUSS - TROY - SUPPLIER A

CONTROL UNIT - TROY - SUPPLIER B

DRIVER AIRBAG INITIATOR: HARDWARE - SWEDEN / SOFTWARE – INDIA - SUPPLIER C

FRONT CRASH SENSOR - MICHIGAN - SUPPLIER D

PASSENGER AIRBAG INITIATOR: HARDWARE - SWEDEN / SOFTWARE- INDIA- SUPPLIER C

RIGHT IMPACT SENSOR - MICHIGAN - SUPPLIER E

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Not only do Safety Plans throughout the distributed development need to be linked but the Safety Plan and APQP Project Plan also need to be linked


NPD Project Plan Integrated with Safety Plan10


NPD Project Plan Integrated with Safety Plan11

• How do we keep Safety Plan Versions aligned?

• How to link Key Deadlines – System Testing timing, Hardware and Software timing which are dependent on each other. Other timing linked to each other

• Release of Safety Requirement, Integration Test Plan, and related Hardware and Software Technical Requirements releases?


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Linked Safety Plans in Connected Supply Chain


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NOTE: This slide has embedded video content.

Integrated NPD & Safety Plans in Connected Supply Chain

Slide 2- Ask Questions to emphasize the profoundness of what they just saw…


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NOTE: This slide has embedded video content.

Linked Documents – HARA to Requirements to Test Plans

The requirements, HARA, Safety Goal, Safety Requirements, System Design, Testing, DFMEA, Hardware Design, Testing, Software Design and Testing, and Supplier System, Hardware and Components safety requirements, testing, HSI are all linked. How to accomplish this without web based software tools?


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HARA

Safety Goals, Safety States

Safety Requirement Allocations

DFMEA

Testing

Hardware & Software Interface


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HARA to Requirements to Test Plans – across the connected Chain

The requirements, HARA, Safety Goal, safety Requirements, System Design, Testing, DFMEA, Hardware Design, Testing, Software Design and Testing, and Supplier System, Hardware and Components safety requirements, Testing, HSI are all linked. How to accomplish this without web based software tools?

Front Impact Airbag System

Can BussTroy - Supplier A

Control UnitTroy - Supplier B

Driver Airbag InitiatorHardware – Sweden

Software- IndiaSupplier c

Front Crash Sensor Michigan

Supplier D

Passenger Airbag InitiatorHardware – Sweden

Software- IndiaSupplier c

Right Impact SensorMichigan - Supplier E


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HARA, Requirements, DFMEA, Test Plan(DVP&R), PFMEA, Control Plans and Shop floor controls.


These documents are typically done by teams outside off Functional Safety. These documents need to be linked to the Functional Safety requirements and overall requirements

HARA

REQUIREMENTS

DFMEA

DVPR

PFMEA

Control Plan

Shop Floor Control

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60%

40%

Functional Safety & IATF Documents

Overlap

Unique

Functional Safety and Other IATF Documents


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PART 2PART 3PART 4PART 5PART 6PART 7PART 8

PART 9

Manage an Overall Program

• Safety Goal and Safety Requirements have been successfully verified and validated in the Test Plan (DVP&R) of the Airbag at the Hardware, Software and integration level

• This culminate into the safety case


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An Extract from a Safety Case

4. Main Safety Argumentation4.1 Nominal Performance of Functionality is Safe4.2 Implementation is Safe

4.2.1 Defined Safety Goals4.2.2 Functional Safety Concept4.2.3 Technical Safety Concept4.2.4 Software Safety Requirements4.2.5 Hardware Safety Requirements4.2.6 Verification & Validation4.2.7 Safety Analyses

4.3 Sufficient Confidence in Development Effort4.3.1 Company Development Process Compliance with ISO-26262 Audit4.3.2 Project Compliance with Development Process Audit

4.3.2.1 Project System Safety Plan4.3.2.2 System Safety Test Plan4.3.2.3 Gate Review Protocol

4.3.3 Sufficient Competence

New Product Development & Functional Safety Project Dashboards


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[email protected]?


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Thank You

mailto:[email protected]