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Merging ISO 26262 FuSi process and FMEA review for HMI components

  • Gehrung & Partner was asked by a well-known automobile premium manufacturer (OEM) to contribute their proven technical and methodological expertise in the field of ISO 26262 FuSi and FMEA to an extensive new development project. The development project for a new series consists of over ten different HMI (Human Machine Interface) components, some with ASIL safety goals.

    A new OEM overall process for ISO 26262 FuSi workshops and FMEA reviews was set up. The objective of the supplier FuSi workshop process was the early coordination of the required ISO 26262 FuSi work products (DIA, FuSi planning, FSK/TSK, HSI, verification & validation concept, etc.) together with the respective suppliers. For this purpose, FuSi workshops were held at the supplier's premises at previously defined milestones. The objective of the supplier FMEA review process was to ensure the consistent application of preventive system / risk analysis by means of FMEA. For this purpose, FMEA reviews were also carried out at the supplier for milestones defined above. This ensured a harmonization of the ISO 26262 FuSi workshop process with the respective work products, including the ongoing FMEA risk analyses, both at the OEM and the respective suppliers.

    With the help of this multi-year project implementation, both the ISO 26262 FuSi process and the FMEA risk analyses at the OEM and the respective suppliers could be carried out, optimized and established in a targeted manner. The early identification of risks from the harmonized processes made it possible to solve them efficiently and sustainably. With a lower total effort, a higher quality and safety of the more than ten different HMI operating components, partly with ASIL safety goals, could be achieved.

New development ADAS front camera at well-known Tier 1

  • In this project, the required ADAS front camera (Advanced Driver Assistance Systems) with Ethernet and CAN connection had to be developed in an extremely cost-optimized way, since it is to be used as an OEM group camera with a very high number of units per year. It was a further development of an existing ADAS front camera. Because an Ethernet network was used for the first time, the EMC requirements and the Ethernet conformity test with regard to hardware and software had to be ensured. In addition, the OEM required much stricter tests in the environmental tests than in the previous camera.

    Gehrung & Partner was able to employ a very experienced interim project manager with the appropriate technical background for this challenging task. Based on the requirements, a specification with corresponding test plans was created and agreed with the OEM. The first DV tests with B1 samples showed that the selected development focuses were correctly recognized, but that further optimization measures were necessary. Critical factors here included temperature changes and EMC. After approx. 12 months, with the start of the PV tests, the project could be handed over with complete documentation to a permanently employed project manager.

Functional Safety and Cyber Security result in combined safety

  • In this concept stage, the project was successfully handed over to a permanently employed project manager after approx. 10 months and the A-sample phase could begin without any interruption.

  • The terminology alone illustrates the differences between Functional Safety and Cyber Security. Functional Safety assumes that the technical system is potentially harmful and addresses the reduction of the risk that the system poses to humans. Roughly speaking, Functional Safety therefore addresses the effect of the system on human. Cyber security contrasts the effect of humans on the system.

  • Gehrung & Partner offers various consulting services such as hazard & risk analysis (G&R), safety goals, safety planning, functional / technical safety analyses (FSK, TSK), FTA, FMEDA, FMEA safety case, etc. in the field of functional safety. In addition, we can work out an individual solution approach for you to harmonize the safety / security development processes.

Integrated sensor / actuator ADAS front camera at OEM

  • Gehrung & Partner (G&P) was asked by a German OEM to temporarily take over the project management for the hardware and basic software for an integrated sensor / actuator ADAS front camera (Advanced Driver Assistance Systems) from the beginning of the project. It was the first front camera where all data from other sensors (radar, lidar, etc.) and the outputs for actuators (ESP, steering, etc.) were merged by the ADAS camera.

    The challenge was that this was a completely new development, with many unknown parameters. Because the camera had to be very small, the hardware concept and the associated thermal management were unknown. Due to the first use of an Ethernet network, the EMC behavior was associated with high risks. The test strategy also had to be restructured because of the significantly increased complexity. The main tasks for G&P were therefore to check the extensive requirements together with TIER 1 for completeness and plausibility. A lean process was set up and successfully implemented for this purpose. For the thermal management and the EMV aspects extensive simulations were arranged. Furthermore, the experiences of experts from comparable projects in the company were exchanged. Finally, the test strategy was redesigned together with the test department and the first basic investigations were carried out.

  • In this concept stage, the project was successfully handed over to a permanently employed project manager after approx. 10 months and the A-sample phase could begin without any interruption.

Automotive Cyber Security Symposium 2017

  • Gehrung & Partner participated with other experts at the "Automotive Cyber Security Symposium 2017" in Stuttgart. The intensive exchange of experiences and the detailed discussions show the many open challenges on this topic.

    The fast-growing connectivity of vehicles opens up many possibilities for new functions. This increases the potential for cyber-attacks on different vehicle networks. These attacks involve high risks, especially with regard to functional safety. During the Automotive Cyber Security Symposium different topics like Security Integration in E/E Architectures, Vehicle Key Management, Security of Connected Autonomous Cars, Security Check, Automotive Penetration Testing, etc. were presented and discussed controversially. It was indicated several times that the conventional development V-model must be extended in parallel by functional security and cyber security. The topics "End of Line Programming" in production and "After Sales Handling" were only mentioned, but also represent a big, still open challenge.

  • Gehrung & Partner offers a wide range of consulting services in the area of Cyber Security and Functional Safety. We would be pleased to develop an individual solution for you to harmonize the safety and security development processes.

G&R for pose / gesture recognition

  • The challenges in this project resulted from the highly innovative pose / gesture recognition system with a multitude of features, high complexity, many use cases and various interfaces to other systems..

    The objective was to develop the pose / gesture recognition system according to the ISO 26262 FuSi management process for potential ASIL relevant components / systems. The Hazard and Risk Analysis (G&R) was created with the help of Medini Analyze. To this purpose, the use cases were rated in workshops with regard to the risks involved. The relevant security goals / hazards with corresponding ASIL classification (attributes, probability of occurrence, effects and controllability) were discussed especially for the various use cases, which were then determined and documented in the course of the project in accordance with the ISO 26262 FuSi Management Process. Herewith the basis for the following functional / technical safety concept (FSK/TSK) was worked out and the following technical implementation was realized.

Presentation on 2017

  • For the sixth time in a row, took place in Munich in April 2017. The forum serves as an exchange of experience for all who work in the field of automotive, railway technology or automation in the area of functional safety. Together with Prof. Butzmann (Bergische Universit├Ąt Wuppertal) and Dr. Edler (elbon), Gehrung & Partner presented a new simulation methodology FuSim.

    With the simulation methodology FuSim, failure-effect analysis of electronic and mechatronic systems can be integrated directly into the development environment of MATLAB / SIMULINK. Instead of the common analysis by means of separate tools, potentially safety-relevant failures can be identified and evaluated in a targeted manner by a largely automated, virtual error injection in an integrated environment. This provides a much more extensive test depth compared to the methods used so far and thus significantly better analysis results with reduced human resource use compared to safety analysis such as FMEDA and FTA. Last but not least, the reduction of tool breaks also makes the consistency between system development and safety checks much easier to ensure.

  • With the increasing complexity of electronic systems and short development cycles, the presented approach promises a fundamental innovation. Ask us, we will advise you. Link to presentation.

Successful audit 9001:2015

  • Gehrung & Partner have already a well established QM-System according to ISO 9001. The basic for the maintenance and further development are fully given. It contains a extensive Web based quality management manual, quality policy, measurable goals and documented procedures. The consistency of the requirements of ISO 9001: 2015 are already given at all levels. Possible complaints, internal audit results, target specifications and target deviations are summarized and verified in regular management reviews. Corrective actions are initiated, enforced and evaluated for their effectiveness within the continuous improvement process.

    The management of Gehrung & Partner encourages and supports the maintenance and further development of the introduced QM-System. If any need for improvement is identified, root cause analysis are carried out and documented, and the implementation of the actions is verified. Therefore we can offer our customers as usual our high quality consultancy.

Preventive Risk Analysis for Integrated Frame Enclosure

  • Since many years, Gehrung & Partner is supporting with its technical and methodological expertise successfully a well-known manufacturer in the field of fuel cell vehicles. Within the scope of the Common Fuel Cell Program (CFCP) project Gehrung & Partner was asked to support the preventive risk analysis of an Integrated Frame Enclosure for fuel cell stacks.

    The focus of the risk analysis was on verification the use of aluminum in consideration of manufacturability, structural stiffness, HV contact protection, tightness towards water / dust, requirements of crash and assembly. Another focus was on the coordination of the internal / external interfaces with the respective suppliers.

  • The product FMEA could be handed over to the customer within the timeline and the expected high quality. Gehrung & Partner was assigned to support further risk analyzes within the projects of the CFCP.

Process Analysis Contact strip

  • Based on the positive feedback from our customer during the preventive risk analysis of complex electrical / electronic components, Gehrung & Partner was asked to support the process analysis of an assembly process for contact strips.

    The work was to determine the current production process by using the provided process qualification plan (PQP) and to complete the already by the customer started the Process-FMEA according to our distinctive methodological and technical knowledge.

  • Within the tightly specified time frame the FMEA successfully succeeded in illustrating the sequence of the production process. Also the moderation participants got a better understanding in the FMEA method and providing the jointly generated actions for the further procedure or possible decision to optimize the process sequences.

Project management for control unit of an adjustable differential locks SG for at an international manufacturer of drive shafts and differential gears

  • For the new, innovative product of an adjustable differential lock (Torque-Vectoring with ‚disconnect‘all-wheel drive system) an experienced interim project manager was needed by an international manufacturer of drive shafts and differential gears.

    The challenges have been the given extremely tight deadlines and the little experiences with this subassembly at the transmission manufacturer as well as at the electronics supplier.

  • For this challenging task, Gehrung & Partner was able to provide a very experienced interim project manager at short notice. Initially, the imprecise requirements provided by the OEM proved to be a major problem. To solve this problem a corresponding requirements-optimization process was established by Gehrung & Partner and lead to a lasting improvement of the customer requirements. The during tender process given unrealistic deadlines were more or less maintained by meticulous scheduling and capacity tracking and as well by close and coordination between OEM and sub-contractor. Because the customer could not keep his deadlines, based of other rea-sons, he accepted this.

    Despite of the challenging deadlines and quality targets by the OEM and also the project specific difficulties the project could be lead to the desired targets after approximately 1 year. The introduction of serial production will now be taken over by internal experts.

Preventive risk analysis to ensure the development quality of H2 sensors for fuel cell vehicles

  • For many years, Gehrung & Partner is successfully supporting a well-known manufacturer in the field of fuel cell vehicles. Among other things, preventive risk analyses of alternative drive concepts were carried out in this context. Within this scope, Gehrung & Partner was asked to support the sensor system suppliers methodically in the risk analysis of a H2 sensor which is necessarily required for the safety concept of fuel cell vehicles.

    The challenge in this project is mainly the complexity of the H2 sensor system algorithms and the different applications of the H2 sensors (in the exhaust system, on the underbody in the area of the hydrogen tank and un-der the hood in the area of the fuel cell system) where in each location the smallest H2 concentrations must be monitored. Resulting from the superordinate hazards and risk analysis, the H2 sensors has additional a max. ASIL B classification.

    In corporation with the H2 sensor system experts and in regular coordination meetings with the sensor algorithms experts, the risks were analyzed by means of Product FMEA with the focus on safety-related functions, electronic functions, software, hardware, media and mechanical interfaces, EMC/EMI, etc.

Specialization CAQ-System BABTEC at the manufacturer of metal casting systems

  • Within the scope of the migration of the current software release into BABTEC CAQ system Gehrung & Partner was asked to implement and adapt the relevant documents of the quality assurance at an international developer and manufacturer of metal casting systems for automotive, mechanical engineering and valves. The main task was that not all previous BABTEC releases were implemented and older quality documents should also be updated to the current release level..

    Based on the example of an production control plan of the Process FMEA for a intake manifold module (light metal cast), in a two-day on-site workshop selected employees were trained in the application and practical implementation of the new system release, especially in the FMEA module. Important topics for the creation of the norm conforming production control plan acc. ISO TS 16949 (Appendix A.25) were the completeness of the test-relevant product and process characteristics, as well as applied test methods, test frequency, test equipment and the correlation with the related development documents (e.g., product FMEA Design). This built up a profound basis for the further efficient application of the BABTEC CAQ system.

    In the subsequent process auditing according to ISO TS 16949 by an external certification company, the production control plans were explicitly evaluated positively.

Development of headlamp platform ECUs at well-known headlamp manufacturer

  • A worldwide leader and international manufacturer in LED and xenon headlamp technology asked for an experienced interim project manager within a new project. The challenge was to develop a completely new platform controller in Germany and manufacture in Spain / Mexico. The mechanical headlamp development and production took place at the corresponding vehicle manufacturer in the USA.

    Gehrung & Partner was able to provide a very experienced interim project manager available at short notice. He led this project by about 1.5 years to a successful result for this challenge. The demanding schedule and quality targets were achieved despite the usual project difficulties. During the quotation phase submitted unrealistic development costs were not possible to keep, but could be made plausible by accurate cost monitoring actions so that they were also accepted by the company management and the customer. The part costs were slightly below the offer.

    The new innovative Headlamps build in the customer's vehicle was shown, as one of the little news, to the public at the Detroit Motor Show in 2016 and found appropriate attention.

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