Two families of fault
Random hardware faults occur unpredictably during the operating life of
a hardware element — a transistor degrades, a solder joint cracks, a cosmic ray flips a
bit. They cannot be designed out, only detected and controlled, and they are quantified
with failure rates and metrics.
Systematic faults are built in: a requirement was ambiguous, an interface
was misunderstood, a timing analysis was wrong, a compiler option was unsafe. They exist
in every copy of the product from the moment of manufacture, and the only defence is
process rigour — which is why so much of the standard is about how you work rather than
what you build.
ASIL: how much rigour, and why
Every hazardous event is classified along three axes — severity of the
potential harm, exposure to the operational situation, and
controllability by the driver or other road users. The combination yields
ASIL A through D, or QM where no ASIL applies.
The ASIL then drives everything downstream: which methods are recommended or highly
recommended, what hardware architectural metrics you must reach, how independent your
confirmation measures must be, and whether an independent safety assessment is required
at all. It is the single most consequential judgement in the whole lifecycle.
The automated driving twist. Controllability was written for a driver
who is watching the road. Above SAE Level 3 that assumption evaporates, and
controllability arguments that were routine in ADAS quietly stop holding. We see more
invalid ASIL classifications from stale controllability rationales than from any other
single cause.
From safety goals to a safety case
The lifecycle moves from item definition and HARA to safety goals, then to a
functional safety concept that says what must happen to keep each goal
intact, then to a technical safety concept that allocates it to hardware
and software with fault tolerant time intervals and safe states. Hardware development
adds quantitative evidence — FMEDA, SPFM, LFM, PMHF — and software development adds
architecture, unit design, and verification against the ASIL-appropriate method table.
Around all of it sits safety management: the safety plan, the development interface
agreement with each supplier, tool qualification, and the confirmation measures —
reviews, audit and assessment — that make the argument independent rather than
self-declared. The output is the safety case: the reasoned argument,
supported by the work products, that the item is acceptably safe.