Functional safety testing

Deliver safer, more reliable products that fulfil regulatory requirements.

Pictogram in .SVG for Functional safety certification safety kit

What is functional safety testing?

Functional safety testing ensures that your systems and equipment operate correctly in response to inputs and environmental conditions, especially in critical applications like automotive, industrial machinery, and energy sectors. It prevents hazards caused by system failures, ensuring reliability and safety for users and operators. TÜV SÜD offers proven capabilities backed by international recognition and understands the complex requirements in the field of functional safety testing and certification.

By rigorously testing according to relevant industry standards, manufacturers and operators can ensure safer, more reliable products. Even when failures or malfunctions occur, a tested and certified product can minimise the likelihood of safety risks for people, property and environment.

Why functional safety testing is important

Functional safety has become a critical issue across all areas of industry. With the expanding digitalisation and automation of life and industry, new challenges and requirements for functional safety arise. This is especially important in industries with high safety requirements and critical applications like automotive, industrial machinery, medical devices and energy.

Functional safety is part of the overall safety of the machine and the machine control system that depends on the correct functioning of the Safety-related Control System (SCS) and other risk reduction measures. This is going beyond traditional product safety assessments to identify the new types of hazards brought about by modern manufacturing methods and providing protection against them.

Thorough testing and certification ensure the safe operation of products thereby reducing any technology-related risks to people, property and environment. Compliance according to relevant functional safety regulations and standards is essential for ensuring that your product fulfils a relevant Safety Integrity Level (SIL). To export machinery or electrical/electronic programmable devices to other countries, compliance with relevant safety regulations is often a mandatory requirement.

Functional safety testing and certification not only enhances your product reliability and mitigates possible financial risks, but it also builds customer trust and supports the efficient functioning of complex systems.

How TÜV SÜD can help you with functional safety testing

TÜV SÜD offers proven capabilities backed by international recognition. From chip design to full plant assessment, we can help you across a range of industries. We are accredited by many national and international organisations including ZLS, DAkkS, European Commision, IECEE, NRTL, and UKAS.

Our multidisciplinary team understands the complex requirements in the field of functional safety testing and certification. The wide range of relevant standards creates a complex regulation landscape. This sometimes makes it difficult to find the appropriate product or system-related standard. TÜV SÜD can help you simplify that complexity by identifying and interpreting the applicable standards.

We offer TÜV SÜD certification marks that are globally recognised and synonymous with quality and safety, helping you gaining a competitive edge worldwide with trusted products. By assessing systems for reliability and functionality, our services strengthen the confidence of your business partners and end users by improving your processes and product quality and minimise risk of downtime and damage.

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What our functional safety testing service include

TÜV SÜD provides support in a wide variety of fields including:

Automotive
Tractors, agriculture and forestry machines
Intelligent transport systems
Consumer goods
Conveyor technique, mobile constructions and stage technology
Furnace systems and products
Safety components
Generic components for embedded systems
Household devices for industrial use
Industrial machines
Industrial robotics
Lifting equipment in nuclear power plants
Medical equipment
Mobile machinery
Power plants
Process technology
Rail rolling stock
Rail signalling
Steam and pressure installations

Our functional safety service portfolio includes but is not limited to:

Assessment during development
Our experts conduct assessment of the functional safety management process during development of protection devices and systems.
Testing
TÜV SÜD offers testing of safety-related components, devices, protection systems, machines, industrial plants, etc.
Certification
Our certification services cover device certification and type certification. Our experts can certify your products to IEC 61508 and all relevant industry safety standards, including CENELEC EN 50129, CENELEC EN 50128 and CENELEC EN 50126, EN ISO 13849, ISO 26262 and IEC 61511.
Training
We provide various trainings to instruct your staff regarding all the relevant functional safety norms, both generic and for different application fields. Topics include IEC 61508, ISO 26262, EN ISO 13849-1, IEC 62061 and the EN 5012X series or the equivalent IEC standards. We can also customise in-house training to suit your needs onsite.

How functional safety testing applies to industries 

Functional safety testing for medical devices 

Medical devices are among the most highly regulated products in the world today. A single functional failure can mean the difference between life and death for patients. Ensuring the functional safety of medical devices is critically important for manufacturers, importers and resellers, as these devices can impact the health and wellbeing of the operators and patients that use them.

Functional safety testing for automotive

The ISO 26262 standard was developed to address the growing complexity of safety-relevant electrical and electronic (E/E) systems in vehicles. Complementing this, ISO 25119 outlines general principles for the design and development of safety-related parts of control systems (SRP/CS) in tractors, municipal equipment such as road sweepers, and other agricultural and forestry machinery.

Functional safety testing for rail

This form of testing is vital for the rail industry because it ensures the reliable and safe operation of complex rail systems. This helps protect passengers, crew, and cargo from potential hazards. This testing validates that safety-critical components, such as signaling systems, braking mechanisms, and communication networks, function correctly even in the presence of faults or failures.

Functional safety testing for consumer products and retail

It is essential for consumer products to ensure that they operate reliably and safely, protecting users from potential hazards. This testing verifies that safety mechanisms effectively prevent malfunctions that could cause injury or damage, ensuring compliance with stringent safety regulations and standards.

Functional safety testing for manufacturing

In industrial manufacturing, it is vital to safeguard the integrity and reliability of complex machinery and automated systems. By rigorously testing critical components and safety functions, you can identify and mitigate potential hazards. Our experts apply EN ISO 13849-1 and EN 62061 to reduce machinery safety hazards through a comprehensive risk assessment. We do this according to EN ISO 12100 for the relevant phases of a machine’s life cycle.

Functional safety testing for energy

This form of testing ensures the safe and reliable operation of energy generation, distribution, and control systems. It verifies that safety-critical components, such as control systems in power plants, electrical grids and renewable energy installations, function correctly under normal and faulty conditions.Testing helps meet stringent safety standards and prevent catastrophic failures, protecting not only human life but also the environment.

Frequently Asked Questions (FAQs)

How does functional safety enhance the reliability and lifespan of my products?

It ensures that products operate correctly under specified conditions, reducing the risk of failures and accidents.

Hazardous states in systems or components can be minimised to limit damage to people, property and environment. Additionally, manufacturers, suppliers and operators can benefit from increased market acceptance and positive brand associations.

It also demonstrates your commitment to high safety standards, enhancing your company’s reputation and credibility. This certification can differentiate your products in the market, build customer trust, and potentially open up new business opportunities by meeting stringent safety requirements.

Why is functional safety certification important?

In many instances, regulatory authorities require certification. Products often cannot enter a market without certification. There may be local, national, or international requirements depending upon your product, its intended use, and where it is to be marketed.

However, even when there is no legislative requirement for certification, many end users require it. Some insurance companies may also require it before they offer coverage. In terms of product liability, compliance with standards serves as proof that product/application meets state-of-the-art safety requirements.

Some regulatory authorities and end users may demand that certification be carried out by an independent, third-part qualified certifier. Demonstration of independent review is important to users’ acceptance of a product; a lack of may lead to questions of whether the product has been looked at with a fully critical eye.

When should you conduct a functional safety assessment?

Getting a product certified is a process that should ideally start in the early development stages. You should involve your developers, your assembly teams, and your certifying organisation. Starting early allows you to build robust development plans in which the assessment process will follow through the product development lifecycle.

Leaving testing to the end of your product development can be risky. You may learn too late that your product does not meet safety criteria and you must go back to the drawing board. Planning early can mitigate costly reworks or recalls.

What specific standards and regulations apply to my industry?

The applicable standards depend on your industry: IEC 61508 as generic standard, ISO 26262 for automotive, IEC 62061 and ISO 13849 for machinery, and EN 50126/50128/50129 for railways. Our services ensure your products comply with these standards, providing peace of mind and meeting regulatory requirements.

The applicable standards are:

Buildings
EN 81 / EN 115 – Lifts

Industrial
IEC 61496-1 – Programmable controllers
ISO 13849 – Safety control systems
IEC 61800-5-2 – Electrical power drive systems
ISO 13850 – Emergency stop
IEC 62061 – Machinery
ISO 10218 – Robots

Transportation
EN 5012x – Railway applications
ISO 26262 – Road vehicles
ISO 25119 – Tractors and machinery for agriculture and forestry
ISO 15998 – Earth-moving machinery

Medical
IEC 60601 – Medical devices
IEC 62304 – Medical device software

Household
IEC 60335 – Household appliances
IEC 60730 – Motor control

Energy
IEC 62109 – Energy delivery
IEC 61513 – Nuclear power
IEC 50156 – Furnaces
IEC 61511 – Industrial processes

Download here for more information on the basic functional safety testing standard IEC 61508 applicable to various industries.

Functional safety complexity: Basic functional safety testing standard IEC 61508 applicable to various industries like manufacturing, medical, buildings, energy, transportation and household.

Can functional safety assessment help us reduce development costs and time to market?

Yes, by identifying potential safety issues early in the design phase, functional safety testing and assessments can prevent costly redesigns and delays. To avoid business losses and time-consuming reworks, it is important that manufacturers ensure that their products adhere to the quality and safety guidelines from the onset.

Our experts you help you to simplify the complex regulation landscape for functional safety by identifying and interpreting the applicable functional safety standards. We also work with you to streamline the development process, ensuring your product meets safety standards efficiently, reducing overall costs and time to market.

What role does functional safety play in integrating new technologies such as automation and IoT into my products?

It plays a crucial role in the integration of new technologies like automation and IoT into products. As these technologies often introduce complex interactions and new operational risks, functional safety ensures that all systems and components operate safely under all conditions.

By identifying potential hazards early and implementing appropriate safety measures, it mitigates the risks associated with automated processes and interconnected devices. This not only protects users and operators but also enhances the overall reliability and performance of the products. This ensures that they meet stringent safety standards and regulatory requirements.

Furthermore, it facilitates the seamless and secure integration of advanced technologies, enabling innovative solutions without compromising safety.