I have the same issue. I'm using Takeshi Iwai's simpledrm kernels from https://download.opensuse.org/repositories/home:/tiwai:/simpledrm/standard/ on two different devices for a few months - no issues so far. That worked fine until a few days ago when the "systemd[1]: Failed to start Setup Virtual Console" error appeared but the boot continued just fine. The latest kernel build (5.18.9-6.1.ge00841d-x86_64) hangs (visually) after this error message on both devices. Previous builds 5.18.9-5.1.ge0e67dc1 and 5.18.8-6.1.g296483f and non-simpledrm 5.18.6-1.1 work fine. As far as I can tell, the boot process continues even with 5.18.9-6.1.ge00841d as journalctl continues after the vconsole error, mounts volumes, starts plymouth etc. Adding "nosimplefb" doesn't solve the issue - at least not with the simpledrm build.