Risk assessment
Hazard identification, risk estimation and evaluation, definition of risk-reduction measures and traceability of technical decisions.
Safety Studio · Control Soft & Automation
Machinery Safety Engineering and CE documentation
Risk assessment, design and validation of safety functions for new, modernized or integrated industrial machinery.
Prepare before 2027
20 January 2027 is the key date for machinery safety
Regulation (EU) 2023/1230 on machinery becomes applicable from 20 January 2027. Early preparation reduces the risk of costly changes, commissioning delays and incomplete technical documentation.
Machinery Safety services
From hazard identification to demonstrated safety performance
Our approach brings mechanical, electrical and automation analysis into one documented engineering workflow.
Safety functions
Definition of emergency stops, interlocks, two-hand controls, light curtains and safe operating modes.
Safety engineering
Control architectures, safety relays and safety PLCs, sensors, actuators and integration of safety circuits into the machine electrical design.
PL calculation and SISTEMA
Determination of PLr, subsystem modelling, verification of MTTFd, DCavg and CCF, and documentation of the result in SISTEMA.
Validation and testing
Validation plans, functional tests, fault scenarios, measurable results and evidence for technical acceptance.
CE technical documentation
Preparation of the technical documentation required for conformity assessment: risk assessment, schematics, calculations, validation records and relevant instructions.
Safety Studio
Also available as a software package for machinery-safety engineering
Safety Studio supports structured management of machine data, hazards, safety functions, calculations, validation activities and resulting documents.
Project information remains structured and traceable so that each risk-reduction measure can be followed through verification and documentation.
- Machine inventory and limits of use
- Risk assessment and risk reduction
- Safety-function definition
- SISTEMA calculation and documentation
- Validation plans and results
- CE technical-file structure
TÜV NORD certified professional competence
Functional Safety Certified Engineer – Machinery
Machinery Safety projects are technically coordinated using individually certified professional competence in machinery functional safety.
Certificate A031_02428/23Frequently asked questions
Preparing a Machinery Safety project
When does Regulation (EU) 2023/1230 apply?
The Regulation becomes applicable from 20 January 2027.
What machinery can be assessed?
New machinery, modernized machines, robotic cells and equipment integrated into production lines.
What documentation is produced?
Risk assessment, safety-function definition, SISTEMA calculations and reports, validation plans and the technical documentation defined for the project.
TECHNICAL REFERENCE
Technical preparation for a machinery-safety project
Risk reduction should be linked to identified hazards, safety functions and evidence that the implemented measures perform as intended.
What should a machinery risk assessment contain?
The assessment defines machine limits, identifies hazards, estimates risk and documents the selected risk-reduction measures. The result must remain linked to the real machine configuration, operating modes and foreseeable interventions.
How are PLr, PL and SISTEMA used?
The required performance level is established for each safety function. The implemented architecture is then evaluated using component data, MTTFd, DCavg and CCF as applicable. SISTEMA supports calculation and documentation but does not replace engineering judgement or validation.
What does validation add after design?
Validation verifies that the safety function behaves as specified, including fault scenarios and reset or restart conditions. Records should identify the test, result, responsible person and any corrective action.
Technical reference