Control System Safety and ISO 13849 Management Assessment Tool (Publication Date: 2024/03)


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Discover Insights, Make Informed Decisions, and Stay Ahead of the Curve:

  • Have safety related parts of the control system been applied in a coherent way to the whole of an assembly of machinery?
  • Key Features:

    • Comprehensive set of 1513 prioritized Control System Safety requirements.
    • Extensive coverage of 115 Control System Safety topic scopes.
    • In-depth analysis of 115 Control System Safety step-by-step solutions, benefits, BHAGs.
    • Detailed examination of 115 Control System Safety case studies and use cases.

    • Digital download upon purchase.
    • Enjoy lifetime document updates included with your purchase.
    • Benefit from a fully editable and customizable Excel format.
    • Trusted and utilized by over 10,000 organizations.

    • Covering: Health And Safety Regulations, Respiratory Protection, Systems Review, Corrective Actions, Total Productive Maintenance, Risk Reduction, Emergency Stop System, Safety Certification, Circuit Design, Machine Control Systems, System Architecture, Safety Requirements, Testing Procedures, Guard Design, Human Factors, Emergency Procedures, Regulatory Compliance, Root Cause Analysis, Safety Training, Software Design, Record Keeping, Safety Checks, Operating Procedures, Reference Documentation, Environmental Safety, Crane Safety, Hazard Analysis, Failure Analysis, Chemical Handling Procedures, Occupational Health, Control System Engineering, Diagnostic Testing, Personal Protective Clothing, Industrial Hygiene, Personal Protective Equipment, Hazardous Energy Control, Control System Safety, Failure Mode And Effects Analysis, Safety Policies, Safety Manuals, Equipment modification, Emergency Release, Communications Protocol, Employee Rights, Programmable Systems, Risk Mitigation, Inspection Checklist, ISO 13849, Hardware Design, Safety Ratings, Testing Frequency, Hazard Identification, Training Programs, Confined Space Entry, Fault Tolerance, Monitoring System, Machine Modifications, Safe Speed, Process Hazard Analysis, Performance Level, Electrical Equipment Safety, Protective Equipment, Injury Prevention, Workplace Safety, Emergency Response Plan, Emergency First Aid, Safety Standards, Failure Investigation, Machine Guarding, Lockout Tagout Procedures, Policies And Procedures, Documentation Requirements, Programming Standards, Incremental Improvements, Failure Modes, Machinery Installation, Output Devices, Safe Direction, Warning Signs, Safety Functions, Fire Prevention And Response, Safety Culture, Safety Labels, Emergency Evacuation Plans, Risk Assessment, Safety Distance, Reliability Calculations, Job Hazard Analysis, Maintenance Schedules, Preventative Maintenance, Material Handling Safety, Emergency Response, Accident Investigation, Communication Network, Product Labeling, Ergonomic Design, Hazard Communication, Lockout Tagout, Interface Design, Safety Interlock, Risk Control Measures, Validation Process, Stop Category, Input Devices, Risk Management, Forklift Safety, Occupational Hazards, Diagnostic Coverage, Fail Safe Design, Maintenance Procedures, Control System, Interlocking Devices, Auditing Procedures, Fall Protection, Protective Measures

    Control System Safety Assessment Management Assessment Tool – Utilization, Solutions, Advantages, BHAG (Big Hairy Audacious Goal):

    Control System Safety

    Control system safety ensures that all safety measures are integrated and applied throughout the entire machinery system.

    1. Solutions: Implement a safety PLC with safe inputs, outputs, and communication protocols.

    Benefits: Ensures consistency and reliability of safety functions throughout the machinery assembly.

    2. Solutions: Use approved safety components that meet relevant safety standards.

    Benefits: Increases assurance of reliable operation and compliance with safety requirements.

    3. Solutions: Utilize safety-rated sensors and actuators to reduce risk of machine failures and errors.

    Benefits: Enhances detection of potentially hazardous situations and improves overall safety performance.

    4. Solutions: Apply proper wiring and connection techniques to minimize risk of failure or malfunction.

    Benefits: Reduces likelihood of unintended activation of safety systems and improves safety functionality.

    5. Solutions: Implement redundancy in critical safety components for increased reliability.

    Benefits: Provides a backup in case of component failure and ensures continuous safety functions.

    6. Solutions: Perform regular functional safety assessments and testing on the control system.

    Benefits: Identifies potential hazards or failures and allows for corrective actions to be taken before accidents occur.

    7. Solutions: Train and educate personnel on proper operation and maintenance of the control system.

    Benefits: Ensures proper use and helps prevent human error that could impact safety functions.

    8. Solutions: Include clear and concise safety instructions in control system documentation.

    Benefits: Facilitates proper operation and maintenance by operators and reduces risk of unsafe practices.

    9. Solutions: Establish emergency stop functions with easy accessibility and clear labeling.

    Benefits: Enables quick response to hazardous situations and helps prevent injury to personnel and damage to machinery.

    10. Solutions: Incorporate safety monitoring and diagnostic features to detect malfunctions or abnormal conditions.

    Benefits: Allows for proactive measures to be taken to prevent accidents or failures and improves overall safety performance.

    CONTROL QUESTION: Have safety related parts of the control system been applied in a coherent way to the whole of an assembly of machinery?

    Big Hairy Audacious Goal (BHAG) for 10 years from now:

    In 10 years, our goal is to have established a comprehensive and standardized approach to control system safety, ensuring that safety-related parts are seamlessly incorporated into the entire assembly of machinery.

    This will be achieved through the creation of a global standard for control system safety, which will be adopted by all industries and manufacturers. Our team will work tirelessly to develop this standard, taking into account the latest technological advancements and regulations.

    We aim to have all control systems designed and implemented in accordance with this standard, with an emphasis on risk assessment, hazard analysis, and continuous monitoring. This will not only ensure the safety of workers and the public, but also increase the efficiency and reliability of the machinery.

    Furthermore, we will educate and train engineers, technicians, and other stakeholders on the importance of integrating safety into control systems. This will create a culture of safety, where every individual understands their role and responsibility in maintaining a safe working environment.

    Lastly, we will partner with regulatory bodies and industry leaders to advocate for the adoption of our standard and encourage continuous improvements in control system safety.

    By achieving this BHAG, we will significantly reduce the number of accidents and fatalities related to control system failures, making the world a safer place for everyone.

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    Control System Safety Case Study/Use Case example – How to use:

    Client Situation:

    XYZ Manufacturing is a global leader in the production of heavy machinery used in the construction and mining industries. The company prides itself on its commitment to safety and has implemented various safety protocols and procedures throughout its manufacturing process. However, in recent years, there have been several incidents of workers getting injured due to malfunctions in the control system of the machinery. As a result, the company has received negative press and has faced legal action from affected employees. In order to address this issue and ensure the safety of its workers, XYZ Manufacturing has engaged our consulting firm to assess the coherence of safety-related parts of the control system across their entire assembly of machinery.

    Consulting Methodology:

    Our consulting team began by conducting a thorough review of the safety protocols and procedures currently in place at XYZ Manufacturing. This included an examination of their safety training programs, maintenance processes, and efficiency of safety checks during assembly. We also conducted interviews with key stakeholders, including managers, engineers, and workers, to gain an understanding of their perspectives on the current safety measures.

    Next, we conducted a detailed analysis of the control system across the assembly of machinery. This involved a thorough inspection of the hardware and software components, as well as a review of the safety functions and safety-related parts within each machinery. We also evaluated the effectiveness of the design, development, and implementation processes for these safety measures.


    Based on our analysis, our team provided XYZ Manufacturing with a comprehensive report outlining our findings and recommendations. Our report includes a detailed assessment of the coherence of safety-related parts of the control system across the assembly of machinery, along with specific areas of improvement and potential risks.

    Additionally, we provided XYZ Manufacturing with a roadmap for implementing our recommendations, which includes suggested timelines, resource allocation, and estimated costs for each action item. We also provided them with a list of reputable suppliers for safety components that align with industry standards and regulatory requirements.

    Implementation Challenges:

    One of the main challenges we encountered during this project was the lack of documentation of safety measures and processes. This made it difficult to accurately evaluate the coherence of safety-related parts of the control system. To overcome this, our team worked closely with XYZ Manufacturing to gather as much information as possible through interviews and observations.

    Another challenge was the resistance from some employees towards implementing new safety measures. This was primarily due to their perception of these measures as time-consuming and hindering efficiency. To address this issue, we emphasized the importance of prioritizing safety and the potential consequences of not doing so, while also providing solutions that would minimize the impact on production processes.

    KPIs and Management Considerations:

    To measure the success of our recommendations, we have established the following key performance indicators (KPIs):

    – Percentage of workers who complete safety training and demonstrate understanding of the safety protocols
    – Number of reported incidents and injuries related to the control system
    – Rate of compliance with safety checks during assembly process
    – Time and cost savings achieved through implementation of safety recommendations

    We have also advised XYZ Manufacturing to establish a safety committee responsible for regularly reviewing and updating safety protocols and procedures. This will ensure that safety remains a priority and that any new safety-related parts of the control system are implemented in a coherent way across the assembly of machinery.


    In conclusion, our consulting firm has provided XYZ Manufacturing with a thorough assessment of the coherence of safety-related parts of the control system across their assembly of machinery. Through our analysis, we identified areas for improvement and provided actionable recommendations to enhance safety and mitigate risks. By implementing our recommendations and establishing a safety committee, we are confident that XYZ Manufacturing will see a significant improvement in their safety record and maintain their reputation as a leader in the industry.


    – Control Systems Safety – A Review of Global Best Practices by Patrick Petit, Pascal Leroux, and Emeric Bean, IEC Whitepaper, 2018.
    – Effective Management of Safety Related Systems by Bob Huber, Institute of Industrial and Systems Engineers, 2016.
    – Global Control Systems Market for Power Generation Industry 2018-2022 by Technavio, Business Wire, 2018.

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