Safety · Retrofit
Safety upgrade of an existing machine
Illustrative project for a productive machine that needs a safety upgrade after process changes or new use conditions.
Illustrative use case
01
Starting point
The machine remains operationally useful, but guarding, access, modes or interventions no longer match current operation.
02
What needs to improve
- Uncontrolled access to hazardous areas
- Legacy emergency-stop or interlock logic
- New maintenance or manual intervention modes
- Incomplete documentation after modifications
03
A solution to validate with the site
- Risk review focused on the modified scope
- Guarding and access redesign
- Safety functions and interlocking logic
- Functional verification and validation plan
- Documentation update and specialist support if required
Illustrative use case — architecture and results must be confirmed using real site data and representative products.
Technical scoping sheet
What must be confirmed before designing the solution.
These points are intentionally practical: they prepare a site visit, trial or pre-study.
01Trigger+
Machine still productive but access, modes or safety functions need upgrading.
02Architecture to validate+
Risk assessment + guarding + interlocks + safety PLC / relays + validation.
03Data to collect+
- Operating modes
- Access and energies
- Modification history
- Available schematics
04Acceptance criteria+
- Safety functions tested
- Coherent modes and reset
- Documentation updated
05Watch points+
- Scope changes
- Downtime
- Production / maintenance interaction
Key point
Prioritise risks before selecting components.
- Map operating and intervention modes
- Define safety functions before devices
- Agree validation responsibilities early
Pre-qualification