Adaptive safety and security

Event-triggered risk assessment and automated safety validation in smart manufacturing

Event-triggered risk assessment and automated safety validation in smart manufacturing

Safety risk assessment in Industry 4.0

While the introduction of adaptive and interconnected configurations can vastly improve facilities’ performance and efficiency levels, the complexity of the risk landscape increases. In a dynamic Industry 4.0 production environment, safety hazards and cyber threats emerge dynamically in line with the adaptive set-up. Changes can be new assets, e.g. machines or components added into the system; new properties of existing assets, e.g. new workpieces or products, new material properties; new environmental conditions (operating space, barriers, clearances, human presence, etc.).

Effective risk assessment, determined by actual interdependencies, shall be performed for each new configuration to reduce liability risk. How can changes in the system be handled timely and effectively while minimising both safety-critical downtime and operational stops? The answer is embedded in the digital representation of the manufacturing system.


Event-triggered risk assessment and automated safety validation

To ensure stable and safe operations in a dynamic production environment, the manufacturer would need new and holistic solutions.

  • Reduce downtimes for planned changes (e.g. new equipment): simulate new configurations prior to installation to allow for smooth integration and commissioning.
  • Reduce safety-related downtimes and stops during operations: anticipate possible changes to automatically assess and validate any interaction within the system at runtime; enable optimized safety configurations based on real environment and application-specific limits, rather than worst-case assumptions according to the conventional safety assessment approach.

Preparation based on a thorough set of data is key. Furthermore, these solutions require suitable supporting platforms and digital representations characterizing the specific use-case.

Today, supporting platforms for operators of smart manufacturing systems are focused on functional optimisation to make the most of I4.0 advantages in terms of increased flexibility and efficiency. However, if the underlying safety and security gaps that arise in dynamically changing I4.0 environments are not taken into consideration, the operator does not have the full picture, hence exposed to liability risk and loss of productivity. 

The current I4.0 information models for Asset Administration Shell (such as RAMI 4.0) pose a similar challenge as they lack the safety and security layers.


Adaptive safety AND SECURITY by TÜV SÜD

To improve the speed and flexibility of risk assessment in a smart manufacturing context, TÜV SÜD has developed and patented a method to automatically evaluate compliance to safety and security requirements: Adaptive Safety & Security. By embedding pre-defined safety and security profiles in the system’s digital twins, the solution facilitates automatic and event-triggered risk assessment based on actual hazards and cyber threats at the time of interaction. Furthermore, the solution can be used to simulate planned changes to the system, thereby conducting risk assessment and safety validations prior to installation. In other words, the adaptive safety and security solution can be used offline as a safety simulation tool, or at runtime during operations. 

The TÜV SÜD solution for adaptive safety and security is designed for Industry 4.0 optimisation. Leaving behind the traditional static and worst-case risk assessment which - through its generic approach - is disconnected from the application reality, we take machinery safety compliance to a new level with our dynamic and application-context solution. This approach allows us to link safety and security requirements to our customers’ ultimate goal of achieving higher productivity through increased flexibility.


Our services

Depending on the individual needs of the customers, the Adaptive Security and Safety services of TÜV SÜD can include the following steps:

  • Evaluation of system/machine/component based on the selected use case
  • Modelling of relevant safety and security properties
  • Creation and integration of TÜV SÜD safety and security profiles, based on system-specific requirements
  • System documentation
  • Simulation assessments 
  • Runtime risk assessments
  • Generation of safety & security assessments reports for each new configuration in case of liability claims with insurance companies and/or supervisory authority



Why choose TÜV SÜD?

By combining interdisciplinary expertise including machinery safety, functional safety, industrial security, risk assessment and automated processes, TÜV SÜD is actively contributing to the safe integration of advanced manufacturing and Industry 4.0 technologies. We work with customers across the globe to reduce downtimes, enhance resilience and verify product quality, thereby releasing the full potential of smart manufacturing. Our methodology for risk analysis, applying both cybersecurity and safety aspects, is proven in the field. TÜV SÜD experts also actively participate in international standardisation committees, gaining valuable insights on the latest regulatory developments. Due to our experts’ relentless commitment to instil safe operations across industries, the TÜV SÜD certification mark has become a globally renowned symbol for safety, security and trust.

Your benefits at a glance

  • Reduced downtimes - Ensure safe and stable operations by facilitating event-triggered risk assessment at runtime
  • Continuous safety compliance - Mitigate risk and maintain safety compliance in dynamic environments
  • Improved performance - Enhance productivity through automated safety validations and runtime decision support


Adaptive safety and security whitepaper
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Adaptive Safety and Security

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