Safety Consulting and Engineering

CE MARKING Series Image
  • Certification project management
  • Determination and application of the relevant directives and standards
  • Hazard analysis and Risk Assessment
  • Creation of a Safety Concept and generation of related Safety Design
  • Evaluation of compliance and recommendations in relation with EHSR
  • Conducting required checks, tests, and measurements
  • Compiling the legally required documents including the technical construction file
  • Document archiving and management
  • Pilz will manage the activities and processes generating the necessary compliance strategies, safety designs and documents.
    Machinery manufactured in the EU, imported from non EU countries or substantially modified is subject to the CE Marking process, when put into service in the European market.
    The CE mark declares that your machines meet the essential requirements of all relevant EU directives. Products that carry the CE mark may be imported and sold without restrictions from national regulations. That's why the CE mark is also referred to as the "Passport to Europe." Assemblies of machines, such as robot cells and production lines, also fall under this obligation.
    The CE Marking process and the interpretation of this directive, along with other CE directives and standards requires a high level of knowledge and expertise.
    Pilz can act as your authorized representative and take responsibility for the conformance procedures for CE Marking. Pilz will manage the compliance and safety of individual machines and production lines (complex assemblies) in an ever-changing environment. Pilz will help you plan for and achieve compliance with the new machinery directive 2006/42/EC.
  • Inspections to establish the operational safety of ESPE
  • Inspection of other safety-related devices such as safety gate interlocks and Emergency-Stop units
  • We will discuss any safety-relevant concerns with you and offer solutions based on best industry practice.
  • Once the tests have been passed, the Pilz inspection badge is applied to the equipment
  • An inspection report is added to the documentation of the machinery.
  • Let Pilz conduct inspections to establish the operational safety of ESPE used to protect against mechanical hazards on production plants
    Due to the sensitive nature of Electro Sensitive Protective Equipment (ESPE), it is particularly important that devices such as light curtains are properly assembled, installed and inspected. Additionally in many jurisdictions there is a legal requirement for regular inspections of safety related equipment to detect possible safety issues arising from machine modifications, bypassing of safety systems or changes to work procedures.
    Pilz engineers will conduct inspections to establish the operational safety of ESPE used to protect against mechanical hazards on production plants. Other safety-related devices such as safety gate interlocks and Emergency-Stop units can also be included in the inspections. We will discuss any safety-relevant concerns with you and offer solutions based on best industry practice. Once the tests have been passed, the Pilz inspection badge is applied to the equipment and an inspection report is added to the documentation of the machinery.
    Pilz competence and objectivity are assured through our certification as an inspection body by DATech, under the terms of EN ISO / IEC 17020. Higher plant availability and greater safety for your staff is achieved.
  • Guidance on regulatory requirements when entering new markets
  • Coordination of compliance assessment and test activities
  • Determination and application of the relevant standards and regulations
  • Liaison with local regulatory bodies
  • Pilz will conduct the required assessment procedures and engineer the necessary compliance strategies to enable conformance with the appropriate ISO, IEC, ANSI and/or other standards.
    Users and exporters of machines are faced with complex compliance and regulatory issues when putting machinery into service or moving machinery from one country to another. A machine fully compliant with standards and regulations in one country may not conform to national rules in another. Ensuring freedom of movement with cost effective and timely compliance is critical to the success of manufacturing business. Access to the knowledge and resources of a competent compliance partner is therefore essential.
    In partnership with your compliance and engineering teams, Pilz will conduct the required assessment procedures and engineer the necessary compliance strategies to enable conformance with the appropriate ISO, IEC, ANSI and/or other standards. We will interpret the regulations applying in the target jurisdiction to establish which Occupational Safety and Health regulations apply such as those arising from OSHA in the USA, and European workplace safety directives and more.
    • Reduced approval costs through local conformance analysis by Pilz experts.
    • Reduced risk of market entry or production start up delays.
    • Our certification guarantees our competency to carry out the activities with a high level of reliability and necessary quality.
  • An analysis of the primary hazards on individual machines
  • Evaluation of the existing risk reduction measures
  • Judgement on compliance of machines with applicable regulations
  • A review of the viability of upgrading the safety of the machine
  • Prioritized recommendations on approach to improve current status
  • Let the Pilz experts analyze the workflow on the machines involving operating, and maintenance personnel to identify the main safety concern
    In manufacturing plants new machinery is often operated side by side with old machinery. New products also result in modification of machinery. It is a challenge for the plant, and health and safety managers to prioritize the management of risk and implement safety improvement plans and strategies.
    The Pilz Plant Assessment service includes on-site examination with subsequent evaluations and presentation of the results.
    Pilz adapted a structured Risk Assessment methodology to use in the Plant Assessment service. With this approach we rapidly gain sufficient data and information to make judgements on the important compliance and safety factors impacting your plant. Each machine is assessed using a multi attribute rating system so as to establish a suitable estimate of safety requirements and priorities that should be provided for each machine.
    Drawing from the experience of projects with machine builders and machine users all around the world, Pilz's expertise and comprehensive report on the safety status of the machinery will provide you with information on which you can prioritize effective investments, thereby optimizing profitability. The information provided can be used to plan machinery improvement programs or integrate such programs with other management initiatives.
  • Full safety requirements list
  • Hazards evaluation and analysis
  • Standards & directives research
  • Production and evaluation of documentation
  • Pilz takes responsibility by working with you to perform the risk assessment
    Risk assessments in accordance with ISO 14121-1:2007. Each assessment identifies the hazards present, estimates and evaluates the risks, and determines and outlines the measures that may be applied to reduce the risks to acceptable levels.
    Usually it only takes a few factors to coincide for an accident to happen. The obvious question then is: could this situation have been anticipated and could appropriate measures have been taken in advance?
    Using the "Risk assessment" tool, systematic errors can be detected and avoided right at the development and design phase. In accordance with the European Machinery Directive, it is a legal requirement to produce a risk assessment.
    In addition to mechanical hazards this must also include (among others) thermal and electrical hazards throughout all of the machinery's lifecycle, for example during operation, maintenance and cleaning.
    Your benefits at a glance
    • Higher level of safety: risks are recognized at an early stage
    • Cost benefit: expensive modifications can be avoided
    • Time benefit: future projects can be implemented more efficiently
    • Objectivity: independent inspection of safety-related aspects
  • Use of fixed & movable guards
  • Implementation of line & machine stopping system
  • Means for safe removal of electrical & pressurized fluid power
  • Detection of workers in hazardous areas
  • On completion of a Risk Assessment Pilz will conduct a review of the machine system, identify areas of improvement and suggest concepts required to achieve compliance and safety.
    This review will facilitate compliance with relevant standards identified as applicable by the Pilz safety experts.
    Intelligent solutions will be created to ensure safety can be achieved without sacrificing overall plant and machinery effectiveness.
    Early consideration of best industry practice and innovative engineering measures will reduce risks and operating costs, while addressing compliance with legal and regulatory requirements. Pilz has the practical engineering experience of integrating safety with other disciplines, which assures compliance and safety while minimizing complexity and costs.
  • Requirements specification
  • Allocation of safety measures
  • Determination of integrity & performance levels
  • Detailed mechanical, electrical, electronic, software & control system design
  • Component selection
  • Consideration of design reviews and safety validation
  • Pilz takes responsibility by working with you to perform safety design services:
    Optimum results are achieved when a structured process is used at design stage to interpret the requirements, generate detailed designs and plan the following stages of System Implementation and system validation.
    Pilz can offer complete turnkey safety services and can manage all aspects of machinery safety including hardware design, software specifications, installation, training, and complete process line upgrades. Pilz LEANsafe technology ensures both lean AND safe methods are used.
    This structured approach will save you time and money while ensuring safety is achieved with compliance to relevant standards. When choosing us as your safety design partner you can trust on our reputation, the accreditation of our design systems to internationally recognized standards including IEC 61508.
  • Assessment of existing design versus safety requirements
  • Evaluation of the components selected
  • Check of sensor and actuator installation and wiring configuration
  • Test of safety-related software and hardware functions
  • Carry out a function test and fault simulation
  • Production of test report detailing validation results
  • Pilz engineers will conduct a structured method for inspecting the safety critical elements of your plant and machinery, thereby verifying the suitability of the safety measures implemented.
    When installing, retrofitting, modifying or upgrading machinery, you must be confident that work equipment is operating in full conformance with the required safety, regulatory and government standards throughout the production life.
    A structured systematic approach is critical for accurate and effective validation. Through validation planning at the design stage the steps, inspection measures and resources required for validation are detailed. The required functions and performance levels are verified.
    Safety Validation processes are implemented by competent personnel in a manner that is objective and systematic. Pilz has the practical engineering experience of assessing and integrating safety and their accreditation by internationally recognized bodies, assures compliance of your risk mitigation measures and the overall safety of your plant.
  • Project planning & controlling
  • Selection & procurement of the required components of actuators, sensors & control devices
  • Construction & erection of required mechanical structures
  • Construction & testing of required electrical panels
  • Electrical & control system installation
  • Programming of control & visualization systems
  • System commissioning
  • Selection of suppliers & contractors where applicable
  • Training of machine operators & maintenance personnel
  • Let the experienced Pilz project managers deal with the scheduling complexities within the constraints of installing and commissioning systems in busy industrial environments.
    Safety systems are critical elements in capital projects relating to automation and machinery. When integrating individual machines into a production line or upgrading existing machines, the time available for the implementation of safety measures and the integration of control systems is usually limited.
    Concentrating on your competencies, you are looking for a service partner offering customized consulting and engineering services covering the entire machinery life cycle.
    As a certified safety expert, Pilz customers expect and are provided with safety, quality and reliability through all processes and methods. When managing the implementation of safety systems in plant and machinery you can be secure in the excellence and consistency of their work.
    Pilz teams have managed the retrofit of safety systems on machinery in manufacturing plants across many industry sectors including automotive, aluminum and steel production, food and drink, paper converting, consumer goods and medical devices.
    Operating to tight timeframes and budgets, Pilz will incorporate mechanical, electrical, pneumatic, and hydraulic upgrades within the constraints of existing plants.
    Pilz will install the "Line Safety Systems" arising from the increased use of automation and robotics on high-speed production.
    The assurance of quality and reliability combined with hands-on engineering experience are essential prerequisites for the success of your implementation.
    With the knowledge gained from the Risk Assessment and Safety Design processes, Pilz can deploy experienced engineers to execute rapid implementation of the selected measures.
    The implementation will be carried out in accordance with regulations and standards with minimum cost and down time.
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