Safety-oriented solutions in the industrial environment

| Themen

Functional safety (safety) and data security (security) are two aspects of safety that are becoming increasingly important in the development of devices and systems.

Strict guidelines and standards must be adhered to during development, verification, validation and throughout the entire life cycle of an assembly in distributed automation. We support you with our know-how in your development. In addition, we also offer consulting and workshops - at your site and the certification body.

We help you to make your solution SAFE!

What do the terms Safety and Security mean, what do we consider and take into account in a development?

Functional Safety

Functional safety serves to protect the life and health of people and to protect the environment from hazards that can emanate from machines and systems.

The corresponding EU directives (e.g. Machinery Directive 2006/42/EC) define the requirements to achieve a uniform level of protection within the EU. These become legally binding through transformation into national law. The annex to the Machinery Directive lists harmonized standards that must be used for development, depending on the product.

For functional safety, these are, for example, the standards DIN EN ISO 13849 and DIN EN 61062, which refer to the basic safety standard IEC 61508 for electrical, electronic and programmable electronic control systems (E/E/PE systems).

Other standards outside the scope of the Machinery Directive for various areas of application (e.g. DIN EN 50128, DIN EN 50129 for railroad applications, ISO 26262 in the automotive sector) place similar requirements on the development of functionally safe control systems.

Safety Integrity Level (SIL according to IEC 61508)

A comprehensive catalog of measures is used to define how a specific safety level can be achieved. Depending on the standard, aSafety Integrity Level (SIL according to IEC 61508) or Performance Level (PL according to ISO 13849) is determined for each safety function. This is a measure of the remaining residual risk.

The proof of the measures taken and activities performed to achieve a specific SIL or PL is of particular importance. The development process must be designed in such a way that the prerequisites are fulfilled so that a safe product is created. A QM system (e.g. according to ISO 9001) must be in place. The aim is to avoid systematic and random errors in the individual product life phases (specification, draft, design, verification and validation, production, operation, decommissioning and disposal).


The amount of documentation to be created is much higher than in a "normal" development. In the individual phases of development, the following documents are created, for example:

  • Requirements specification
  • Safety concept
  • Architecture design
  • Hardware and software specifications
  • Software component specification
  • Design documents (schematics, layout, simulations, engineering drawings)
  • Test plans and test specifications for hardware type test, software test, integration test, EMC and environmental tests
  • Verification and validation documentation
  • FSM (Functional Safety Management) documents, such as verification and validation plan (V&V plan, safety cases)
  • Operating manuals and user documentation
  • Document set for introduction in production and production test

We develop your functionally safe electronic control systems and accompany you on your entire way - from the idea to the finished solution.

We typically develop according to the V-model.

As an alternative to complete development, we can also take on subtasks of your development. For example, you can transfer the development of the safety-related software or hardware to us in isolation.

In addition, we also provide consulting services and accompany the assessment at the appropriate authorities (e.g. TÜV).

We use the document system "Polarion" for the creation of documentation. This enables us to meet and monitor the requirements of the standards for the traceability of the requirements and the traceability of the test steps to the requirements.

For the unit tests (whitebox tests) in the software we use the test system "Tessy". With the help of this tool we measure e.g. the test coverage required by the standards (e.g. Code Coverage C0, C1, C2, Branch Coverage). The test results of the test run are automatically imported into "Polarion" and are available there for documentation.

Of course we also realize black box testing, interface testing, integration testing and performance testing.

Data security

Data security is about data confidentiality and data protection. Here, for example, encryption technologies and authentication mechanisms are used to ensure the confidentiality of data or to identify a person or machine and clarify authorizations. Other standards apply in this area (e.g. DIN EN IEC 62443).

Due to Industry 4.0 and the associated increasing degree of networking, the importance of data security is growing. Thus, it is an important task to also ensure functional safety through data security. This connection is established in ISO 61508 by a reference to IEC 62443.

Priority is given to considering the attack security of a solution as early as the conception phase - potential threats are identified and defensive measures are defined.

Your solution - SECURE with us

SYS TEC electronic has the corresponding expertise from security-oriented projects in the fields of industry, railroads and medical technology.

We offer consulting, advice and workshops by our SYS TEC electronic developers at our headquarters in Heinsdorfergrund, at your site or at the certification body.

We supervise the conception and development of your solution from the idea on in all areas. You need a specialist for a subtask of your development? Of course, we are happy to help you here as well!

Do not hesitate to contact us: We will also develop an individual, customer-specific security solution for you at the highest level!