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Something that always makes me pause when reviewing designs… Proof test coverage that somehow always ends up being 100% effective. On paper it looks great. The numbers work nicely. The SIL calculation passes comfortably. But in the real world I always find myself thinking: Can we really detecting every dangerous failure with that test? In my experience, this is a major cause of rework. If the design progresses to the point where commissioning documents are written and then a FSA or design review reveals overly optimistic proof test coverage it’s a lot of work to correct. Anyone else experiencing this?

What is the best way to know the failure modes of components? Manufacturers usually don't provide failure modes and failure modes in databases as NPRD are usually very ambiguous.