- A structured approach to identifying risks, closing safety gaps, and achieving compliance across industrial environments.
What if your next site inspection were scheduled for tomorrow? Any system operators who feel nervous about this prospect should take a critical look at their internal processes. The good news is that, with the right approach, risks in industrial automation can be reliably identified and eliminated in good time before the next inspection date. Frank Bauder, Head of Safety Services at Leuze, explains how.
Seamless machine and system safety is the foundation of reliable and efficient operation in industrial automation. Regular risk assessments play a key role here by identifying weaknesses in the safe operation of machines. Experience shows that most problems arise long before an actual inspection – often due to negligence, time pressure, ignorance, or limited budgets. Leuze’s safety expertise and safety solutions help operators achieve safe and reliable operation. The support is divided into seven steps:
Step 1: Identify risks
Safety begins with transparency: All relevant risks must be identified, including at least mechanical and electrical risks, while taking the machine’s limits into account. Furthermore, the condition of any protective devices (e.g., safety sensors and controls) must be documented to detect any tampering or wear. A safety check from Leuze provides the necessary clarity by summarizing the results in a report.
Step 2: Assessing risks (EN ISO 12100)
The next step is to objectively assess the identified risks, classify them in accordance with standards, and derive risk-mitigating measures. The risk analysis thus forms the basis for all subsequent technical decisions and investments. The safety experts at Leuze prepare conclusive risk assessments, including the development of safety functions, recommended risk-mitigating measures, and a description of remaining residual risks.
Many problems often arise long before the actual inspection – frequently due to negligence, time pressure, ignorance, or limited budgets
Step 3: Create a safety concept
The safety concept describes the implementation of all risk-mitigating measures. It is ideally suited for discussing and determining feasibility, practicality, and user-friendliness with all parties involved, thereby avoiding misunderstandings. Based on this jointly agreed safety concept, the safety specialists from Leuze develop the detailed implementation and plan the verification and validation. This is underpinned by comprehensive industry and application knowledge, enabling practical and sustainable implementation.
Weak points in the safe operation of machines and systems are not always obvious at first glance.
Step 4: Focus on safety solutions in the concept
Traditionally, implementation is planned and developed according to the concept. All activities, from the idea to the selection of components, implementation, and verification of effectiveness, must be carried out completely for each machine or application. Traditional safety concepts often reach their limits in complex applications, for example, with changing formats (changing pallet loads) at muting stations. In these cases, more sophisticated safety solutions are required that are precisely tailored to the task at hand. Leuze offers solutions that are specifically geared to the application requirements – covering the entire process from task analysis and safety architecture to comprehensive documentation.
Step 5: Implement and commission the safety solution
A detailed analysis of the given application’s system layout is crucial. Only on this basis can the appropriate safety components (e.g. safety sensors or switches) be selected for the application and the corresponding device parameters defined. Success is also ensured thanks to commissioning and training on site by safety experts and product specialists.
Leuze’s safety expertise and safety solutions help operators achieve safe and reliable operation.
Step 6: Prove effectiveness
During verification and validation (proof of concept), the correct design and effectiveness of all safety-related components and functions are proven through tests, measurements, and fully documented testing under real-world conditions.
Step 7: Document and inspect regularly
All necessary documents, such as the risk assessment, measurement reports, and CE declaration of conformity, are provided and form the new actual status. A consistent level of safety is guaranteed through recurring inspections of protective devices and regular risk assessments to ensure compliance with the ‘state of the art’. This ensures both operators’ safety and the machine’s availability for production throughout its entire service life.
Summary: Safety works
Seven steps and an experienced safety partner at your side: System operators who follow these guidelines can enjoy peace of mind, even if the next site inspection is scheduled for tomorrow.
