Cognigear
Safety & Compliance

Functional Safety & Risk Engineering for Autonomy

Perform HAZOP/FMEA/FTA, define safety concepts, and design independent safety layers aligned with ISO 26262/IEC 61508-style practice.

Timeline
8 Weeks to Value
Typical Engagement
$90k–$250k
Focus Areas
Safety-critical machinery

Functional Safety & Risk Engineering for Autonomy

Move from "it hasn't crashed yet" to "we can prove it is safe." Apply rigorous functional safety engineering to your autonomy program.

  • Identify hazards systematically using HAZOP and HARA
  • Design "Independent Safety Layers" that stop the machine if the AI fails
  • Produce the documentation package required for regulatory approval

Who this is for

Safety Managers, System Architects, and Compliance Officers at:

  • OEMs certifying new autonomous machines
  • Operators seeking "license to operate" from regulators
  • Tech companies needing to bridge the gap between "Move Fast" and "Safety Critical"

Operational context

This engagement focuses on:

  • Standards – ISO 26262 (Automotive), IEC 61508 (Industrial), ISO 17757 (Mining), ISO 3691-4 (AGVs), SOTIF (ISO 21448)
  • Methods – HAZOP (Hazard and Operability Study), FMEA (Failure Mode and Effects Analysis), FTA (Fault Tree Analysis)
  • Architecture – 1oo2, 2oo3 voting systems, Safety PLCs, Watchdogs

Trigger phrases you might be saying

  • “The regulator won't let us turn it on until we show the safety case.”
  • “We rely on the operator hitting the E-Stop; we need to move past that.”
  • “How do we ensure the LiDAR failure actually stops the truck?”
  • “We need to determine the SIL (Safety Integrity Level) or PL (Performance Level) of our system.”

Business outcomes

  • Regulatory approval to deploy (License to Operate)
  • Reduced liability through defensible engineering due diligence
  • Clear safety requirements for engineering teams to build against
  • Operational confidence knowing the machine checks itself

What we deliver

  • Hazard and Risk Assessment (HARA) Report
  • Functional Safety Concept (FSC) Definition
  • Technical Safety Requirements (TSR) Spec
  • System FMEA / FTA Analysis
  • Verification and Validation (V&V) Plan for Safety

How it works

  1. Identify – Workshops to brainstorm "what could go wrong" (Hazards)
  2. Assess – Quantify risk based on severity, exposure, and controllability
  3. Mitigate – Design safety functions to reduce risk to ALARP (As Low As Reasonably Practicable)

Timeline & effort

  • Duration: 8-12 weeks
  • Client time: Safety workshops are intensive; requires Ops, Maintenance, and Engineering participation
  • Data: System architecture, Operation manuals, Component datasheets

Pricing bands

Fixed-fee: $90k–$250k, depending on:

  • System complexity (number of functions)
  • Target safety level (SIL 1/2/3 or PL b/c/d/e)
  • Scope of certification support (internal vs. external auditor prep)

Tech stack & integrations

  • Tools: Ansys Medini, JAMA, DOORS, Excel (for simple cases)
  • Hardware: Safety PLCs (Sick, Siemens, Pilz), Safety controllers (Ifm, TTControl)

Risks & safeguards

We explicitly design for:

  • Common Cause Failure – ensuring redundant systems don't fail for the same reason (e.g., both blinded by sun)
  • Diagnostic Coverage – ensuring the system detects its own faults
  • Human Error – designing safety for maintenance and recovery modes, not just auto mode
  • Process Overkill – right-sizing the safety process so it doesn't strangle innovation (agile safety)

Site examples

  • Mining Fleet (Canada) – Developed the Safety Case for a mixed fleet of autonomous haul trucks, successfully gaining provincial regulator approval for "operator-off" trials.
  • Warehouse Robotics (USA) – Performed FMEA for a new high-speed shuttle, identifying a critical flaw in the E-Stop circuit design that would have caused a 5% failure rate.

Frequently asked questions

Do you certify the system? We are not a Notified Body (like TUV). We prepare you for certification. We produce the evidence and artifacts that the auditor reviews.

Is this only for hardware? No. Modern autonomous safety involves software safety (ISO 26262 Part 6) and SOTIF (Safety of the Intended Functionality), dealing with AI limitations.

Can we skip this for a pilot? You can't skip safety. For a pilot, the "safety layer" might be a remote kill switch and a fenced area. For production, the safety layer must be built into the machine.

Target KPIs

  • ↑Residual risk level
  • ↑Safety requirement coverage %
  • ↑Diagnostic coverage
  • ↑Time to safety case approval
  • ↑Safe failure fraction

Deployed Environments

All industrial sites

Ready to start?

Book a 15-minute technical scoping call to discuss your fleet requirements.

Book Scoping Call

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