How often should you test safety systems in automotive manufacturing?

1 Why test safety systems?

Testing safety systems is not only a legal requirement, but also a good practice to maintain the quality and efficiency of your automotive manufacturing operations. By testing safety systems, you can identify and fix any faults, errors, or malfunctions that could compromise the safety of your workers, equipment, or products. You can also verify that your safety systems meet the specifications and regulations of your industry, such as ISO 26262, IEC 61508, or OSHA. Testing safety systems can also help you reduce costs, waste, and downtime by preventing or minimizing the impact of accidents.

2 When to test safety systems?

The frequency of testing safety systems depends on several factors, such as the type, complexity, and age of the system, the level of risk involved, the environmental conditions, and the manufacturer's recommendations. Generally, you should test safety systems at least once a year, or more often if required by law or standards. However, some safety systems may need more frequent testing, such as monthly, weekly, or even daily, depending on their usage and criticality. For example, you may need to test emergency stops every shift, or safety PLCs every month.

3 How to test safety systems?

Testing safety systems requires different methods and procedures depending on the system and the testing objectives. Functional testing involves checking the functionality and performance of the safety system by simulating normal and abnormal operating conditions and verifying the expected outputs and responses. Fault injection testing involves introducing faults or errors into the safety system to evaluate its robustness and fault tolerance. Compliance testing verifies that the safety system conforms to the relevant standards and regulations by using certified tools and techniques. Lastly, regression testing retests the safety system after any changes or modifications to ensure that no new defects or issues have been introduced.

4 What to document?

Documentation is a key element of testing safety systems, as it provides proof and records of the testing activities and results. The test plan should be documented, which outlines the scope, objectives, methods, criteria, and schedule of the testing process. Additionally, the test cases must be documented, specifying the inputs, outputs, and expected outcomes of each test scenario. The test results should also be documented, which report the actual outcomes and observations of each test scenario along with any deviations, errors, or failures. Finally, the test report should be documented to summarize the overall findings and conclusions of the testing process and any recommendations or actions for improvement.

5 What to avoid?

Testing safety systems is a complex and critical task that requires careful planning, execution, and evaluation. To ensure success, it is important to avoid testing without a plan, backup, team, or review. Without a clear and detailed plan, testing can be inconsistent and incomplete. Without a backup or recovery plan, fault injection or high-risk scenarios can cause irreversible damage or data loss. Testing without a qualified and experienced team can compromise the quality and reliability of the process, as well as the safety of the testers and the system. Finally, without a review or verification, any defects or issues may be overlooked and standards or regulations may not be complied with.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?