Safety Validation for Machinery Safety

The fifth step to machinery safety: Safety validation

April 12, 2023


In a machine’s lifecycle, the topic of validation plays a major role in safety – for both manufacturers and operators alike. Therefore, workplace directives and standards, such as ISO 13849IEC 62061 and IEC 61508, require you, as manufacturers and operators of machinery, to validate your safety systems. To do this, it is essential to be well informed about the machine lifecycle as well as the implementation of the required protective measures.

Following a safety inspection, the question arises as to whether all safety-related risks have been considered and solved with the right measures. Validation is the only way of finding out whether the necessary risk reduction measures have been correctly implemented and whether the machinery therefore demonstrably complies with the relevant standards and regulations!

Customized validation – the right level to suit every requirement

What depth of validation is necessary and useful?

Pilz offers a range of services matched specifically to you, to validate your machinery efficiently using a structured method in the categories of machinery safety, risk minimization, functional safety and other legal requirements. Accordingly, as a machine manufacturer or operator, you can choose between three levels of validation service, precisely tailored to the project and requirements.

Validation methodLevel 1Level 2Level 3
Machinery safety♦♦♦♦♦
Risk reduction ♦♦♦
Functional safety♦♦♦♦♦
Other legal regulations  
Depth of testing: ♦ Basic, ♦♦ Detailed, ♦♦♦ Comprehensive
Case examplesLevel 1Level 2Level 3
CE marking, conformity assessment procedure  ♦♦♦
Complex installation that requires detailed testing  ♦♦♦
Pilz conducts the testing as a neutral body ♦♦ 
Minor changes to previously validated machinery ♦♦ 
Validation against similar machinery ♦♦ 
Moving existing machinery to a new location  
Re-inspection of previously validated machinery  
Depth of testing: ♦ Basic, ♦♦ Detailed, ♦♦♦ Comprehensive
Level 1Level 2Level 3
·Basic machinery safety inspection 
·Evaluation of the measures implemented
·Random function test
·Inspection of the PLr assignment
·Assessment of the applied PL principles 
·Detailed machinery safety inspection 
·Evaluation of the measures implemented
·Evaluation of the 5 main risks
·Safety functions test
·Check that the safety functions and components are correctly installed
·Inspection of the specified PL implementation (PL ≥ PLr)  
·Inspection of machinery safety legislation
·Inspection of compliance with the product standard
·Evaluation of the measures implemented
·Inspection of implementation of risk reduction
·Safety functions test
·Check that the safety functions and components are correctly installed
·Fault simulation
·Inspection of the specified PL implementation (PL ≥ PLr)
·Evaluation of the achieved PL (PL ≥ PLr) 
Inspection of:
·Safety requirements specification
·Safety-related software
·Electrical safety
·EMC/RA requirements
·Noise emission
·Pressure vessel requirements

Your benefits at a glance

  • Customised validation thanks to three different validation levels
  • Customised validation intensity and level of detail according to your individual requirements and needs
  • Cost-efficient validation methods and expertise from Pilz
  • Guarantee of compliance with standards that require independent safety validation, and specifications
  • Safety and protection due to a safe working environment

More Information

Safety validation for machinery safety

Related Product

Identification and Access Management – I.A.M. from PILZ

How do you master the subjects of employee protection, liability protection, productivity and data protection? How do you increase your quality and simultaneously prevent tampering on your machines? How do you protect your data and employees in equal measure?

With “Identification and Access Management”, I.A.M. for short, Pilz is offering a wide-ranging package of products and software, as well as tailor-made solutions for your daily access management challenges. They will help you organise your machine access and employee permissions. From simple authentication to complex access management, from functionally safe operating mode selection to electronic maintenance safeguarding. And also, of course, when protecting your valuable data from unauthorised access and from hacker attacks on your plant. With Pilz you’ll find the right solution and get safety and security in one system.

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