Adaptive safety and security


Trustworthiness in Industry 4.0

Trustworthiness in Industry 4.0

Taking safety to a new level


Industry 4.0 (I4.0) marks a profound paradigm shift in which humans, machines and systems are digitally interconnected and interoperate via IIoT devices. This enables increased levels of automation with new functionalities - two key ingredients for improving operational efficiency and generating new business value.

However, accidental and/or malicious incidents involving humans, machines and networks are increasingly common, jeopardising the core mission of I4.0 stakeholders. Root causes lie mainly in insufficient understanding of the interdependencies between critical control functions and processes, and the associated underlying cyber-physical risks.


It is defined as the capability of an I4.0 engineering solution to achieve its operational and business objectives in a safe, reliable, secure, and resilient manner throughout its entire life cycle. This is a complex task to be tackled by system designers, integrators, and operators from the design phase. On the one hand, new functionalities are needed to add flexibility, increase efficiency, optimise performance, improve quality etc.; on the other, they must be reliable and shall not trigger unexpected events leading to accidents and/or downtime, thus undermining both operational and business objectives.

Dynamic risk approach

Digital systems demand a dynamic risk approach that aids in optimising performance and maximising uptime without compromising compliance. TÜV SÜD's Adaptive Safety and Security System (AS3) is a patented solution that overcomes the limitations of conventional, static risk assessment enabling automatic, in-situ and runtime assessments and validations of critical controls and safety functions. This novel technique lies in the digital safety-security twins (profiles) describing human-machine and machine-machine interactions in a specific application context. It remains relevant across a system's technical lifetime, spanning the processes of design, commissioning, operation, and maintenance.

Core value

AS3 is a joint engineering effort by our experts in close collaboration with the end-user.

It embeds TÜV SÜD safety and industrial cybersecurity expertise modelled digitally that can be deployed as a built-in feature of end-user tools and platforms. Whether used for virtual simulations or during operations, AS3 helps navigate complex risk landscapes dynamically and efficiently, enhancing system safety, security, reliability, and resilience. This translates into stable operations, reduced downtime, and greater productivity.


Support I4.0 stakeholders in their quest to deliver high-performance and trustworthy engineering solutions. 



AS3 - Revolutionising Risk Assessment 

Backed by decades of extensive safety and security expertise, TÜV SÜD's Adaptive Safety and Security System (AS3) is a revolutionary digital risk solution that integrates machine standard requirements with system's operational objectives into digital safety-security profiles to generate a zero-accident, zero-downtime strategy.

Safety and industrial cybersecurity in IIoT architectures are intertwined, therefore dependencies must be carefully analysed and assessed. AS3’s guiding principle is the Enhanced Risk Assessment (ERA), a TÜV SÜD methodology merging both aspects into one, holistic assessment.

The identification and prioritisation of cyber-physical risks leading to critical consequences (HSE, legal, operational, financial, reputational, etc.), and the assessment of the relevant protective safety-security measures will be conducted jointly with the customer during the Enhanced Risk Assessment. The outcomes will be translated into digital safety-security profiles which are then processed by AS3 inference engine to determine the safety state of the system.

Ultimately, it’s safety on the shop floor, reliability of production processes, OT security posture and resilience that will determine the trustworthiness of an I4.0 solution.

AS3 dashboard provides detailed information and will eventually raise warnings when a safety/reliability gap is detected. This can happen at runtime, or offline when checking system reconfigurations.     


AS3 is NOT a control tool and does NOT execute control functions. Its scope is limited to the assessment of critical controls and safety functions at runtime (monitoring), or offline (simulations).

AS3 outputs indicate the state of a system based on the safety/reliability of human-machine and machine-machine interactions. They are not valid for certification purposes. 

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