FSE
INDUSTRY
Machine safety in industrial environments is a major issue for all companies using automated or semi-automated equipment. It aims to protect operators, improve the reliability of installations, and ensure regulatory compliance, while maintaining a high level of industrial performance.
Why is machine safety essential?
Every year, machines are responsible for a large number of workplace accidents, sometimes serious. These incidents can lead to physical injuries, prolonged production downtime, significant financial losses, a deterioration of the social climate, and legal liability for the employer.
Implementing a rigorous machine safety approach makes it possible to significantly reduce these risks. It helps protect employees’ health, improve equipment reliability, legally secure the company, and sustainably optimize industrial performance.
The regulatory framework for machine safety
Machine safety is governed by a set of European and French regulatory and standardization texts. European Directive 2006/42/EC, known as the “Machinery Directive,” defines the essential health and safety requirements applicable to machines placed on the market. The Labor Code, for its part, requires employers to provide workers with compliant and safe equipment.
These requirements are complemented by harmonized standards, in particular EN ISO 12100 for risk assessment, EN ISO 13849 and EN 62061 for the design of safety-related control systems. Together, these texts define the obligations of manufacturers, integrators, and users in order to guarantee a high level of protection.
The main principles of machine safety
The safety approach is based on a hierarchical prevention logic. The primary objective is to eliminate hazards at the source through inherently safe design. When this elimination is not possible, collective protective measures must be implemented to prevent access to hazardous areas.
When these first two steps are not sufficient, appropriate protective devices must be integrated to reduce residual risks. Finally, user information and training complete this approach to ensure the safe and sustainable use of the equipment.
Risk assessment: the foundation of any safety approach
Risk assessment is the cornerstone of machine safety. It consists of identifying the hazards present on the machine, analyzing potential hazardous situations, estimating the severity of possible harm and the frequency of exposure, and then defining risk reduction measures.
This structured approach makes it possible to determine the required performance levels for safety functions, expressed as PL (Performance Level) or SIL (Safety Integrity Level). It ensures a consistent, effective design that complies with regulatory requirements.
Protective devices for industrial machines
Machine protection relies on a combination of mechanical and electrical devices. These solutions are selected and sized according to the risks identified during the risk assessment, operating conditions, and applicable standards.
Mechanical safeguards
Mechanical devices provide direct physical protection between the operator and the hazardous area. Protective screens help prevent exposure to projections, fragments, chips, or pressurized fluids, while maintaining good visibility of the process.
Partitions, guards, housings, and mesh enclosures are used to fully or partially isolate hazardous areas. They are commonly found around industrial robots, conveyors, presses, machine tools, and automated lines, and constitute effective collective protection.
Lockout and energy isolation procedures are designed to prevent any unintended restart during maintenance or adjustment operations. This approach applies to electrical, pneumatic, hydraulic, and mechanical energy and ensures complete safety for personnel.
Locking and interlocking systems prevent a guard from being opened while dangerous movements are still present. They ensure that access to risk areas is only possible after the machine has come to a complete and safe stop.
Acoustic and anti-vibration enclosures reduce noise and vibration exposure, helping to improve working comfort, reduce physical strain, and limit occupational risks associated with noise.
Electrical safeguards
Electrical safety devices actively detect hazardous situations and trigger the immediate shutdown of the machine. Emergency stop buttons allow for rapid and deliberate power cut-off in the event of imminent danger.
Light curtains and optoelectronic devices detect human presence in hazardous areas and automatically stop the machine. They offer an excellent balance between a high level of safety and maintained productivity.
Laser scanners and safety mats protect access zones while preserving smooth production flows, particularly in highly automated environments.
Safety control circuits, incorporating safety PLCs and safety relays, manage the machine’s critical functions. Their redundant architecture and self-monitoring mechanisms ensure a very high level of reliability.
Best practices for sustainably improving machine safety
Sustainable improvement of machine safety involves regular audits, systematic updates of risk assessments, continuous training of operators and technicians, and rigorous maintenance of safety devices. It is also essential to document every machine modification to ensure traceability and long-term compliance.
Conclusion
Industrial machine safety is a major human, technical, regulatory, and economic challenge. It aims to protect operators, improve equipment reliability, and ensure compliance, while directly contributing to overall company performance.
Adopting a structured, evolving approach adapted to real-world conditions makes it possible to sustainably reduce risks, improve equipment availability, and strengthen industrial responsibility. Investing in machine safety means choosing a safer, more efficient, and more sustainable industry.
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