Towards dynamic safety assurance for Industry 4.0

Abstract

Abstract The goal of Industry 4.0 is to be faster, more efficient and more customer-centric, by enhancing the automation and digitalisation of production systems. Frequently, the production in Industry 4.0 is categorised as safety-critical, for example, due to the interactions between autonomous machines and hazardous substances that can result in human injury or death, damage to machines, property or the environment. In order to demonstrate the acceptable safety of production operations, safety cases are constructed to provide comprehensive, logical and defensible justification of the safety of a production system for a given application in a predefined operating environment. However, the construction and maintenance of safety cases in alignment with Industry 4.0 are challenging tasks. For their construction, besides the modular, dynamic and reconfigurable nature of Industry 4.0, the architectural levels of the things, fog and cloud computing have to be considered. The safety cases constructed at system design and development phases might be invalidated during production operations, thus necessitating some means for dynamic safety assurance. Moreover, flexible manufacturing in Industry 4.0 also underlines the need for safety assurance in a dynamic manner during the operational phase. Currently published studies are not explicitly supporting the safety assurance of Industry 4.0, which is the focus of this paper with special emphasis on dynamic safety assurance. At first, the Hazard and Operability (HAZOP) and Fault Tree Analysis (FTA) techniques are used for the identification and mitigation/elimination of potential hazards. Next, based on the hazard analysis results, we derived the safety requirements and safety contracts. Subsequently, safety cases are constructed using the OpenCert platform and safety contracts are associated with them to enable necessary changes during runtime. Finally, we use a simulations based approach to identify and resolve the deviations between the system understanding reflected in the safety cases and the current system operation. The dynamic safety assurance is demonstrated using a use case scenario of materials transportation and data flow in the Industry 4.0 context.