Safety management

SafetymanagementA modern safety management system that systematically identifies, analyses and monitors technical risks and continuously checks its efficacy is very important for companies in this day and age. Another term that is very popular alongside safety management is “technical risk management.” IQZ offers its support in the following fields of safety management. Further information can be found in the sub-headings:

  • Machine safety acc. to EC 2006/42, ISO 12100,
  • Functional safety acc. to IEC 61508 and derivatives for specific sectors (e.g. ISO 26262, ISO 13849, IEC 62061, ISO 61511, EN 5012x,
  • Hazard & risk assessment for systems requiring approval

Numerous methods are used by IQZ staff during safety management to systematically identify and, wherever possible, effectively avoid technical risks: FMEA, FMECA, FBA QRA

>  Follow this link to our one-pager on the topic of machine safety & functional safety

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Machine safety

Machine safety

The safety of machinery, incomplete machines or even a set of machines, etc. is becoming increasingly important these days so as to minimise health risks for the staff as well as environmental damage.

The higher statutory requirements on safety can mean much more work during the development and operation of machinery for both manufacturers and operators of machines or sub-systems.

At the same time, a high level of safety can also lead to a competitive advantage, helping to set a company apart from and ahead of its rivals and to reduce potential recourse claims. Moreover, increased safety often also means an increased availability and reliability of the machinery and plants.

In order to help you answer safety-related questions along the product life-cycle of your new and existing machines we can offer assistance on the following topics that is based on your technical documents and expertise with specific machines.

  • CE certification / EC Declaration of Conformity pursuant to the Machinery Directive 2006/42/EC
  • Risk assessment pursuant to the Machinery Directive 2006/42/EC and DIN EN ISO 12100
  • Assessment of safety-related control systems / functions acc. to DIN EN ISO 13849
  • Preparation of the operating instructions

We also offer a “Machine safety” workshop to train your employees in the field of machine safety. This teaches the basics for legally compliant work in the field of machine safety with the applicable guidelines, laws and standards. The three-day workshop consists of a total of six modules that can also be taught individually on request, either on your premises or in our training rooms.

  • Legal foundations
    Relevant legal requirements on machines
  • Concept “Development of new machines”
    From the idea to CE certification
  • Concept “Old and existing machines“
    Requirements on existing machines and their conversion
  • Risk assessment acc. to DIN EN ISO 12100 and the Machinery Directive 2006/42/EC
    Risk identification, assessment and reduction process
  • Functional safety acc. to DIN EN ISO 13849
    Identification and assessment of the performance level of safety-relevant control systems / functions
  • Preparation of operating instructions
    Documentation of the machine-related and safety-relevant documents

Please feel free to contact us if you have any questions or would like more information.


Figure: Machine safety

Functional safety

Functional safety is regarded as that part of the overall safety of a technical system that depends on the correct and perfect functioning of the safety-related system.

The field of functional safety generally covers the requirements of a component or system to perform its safety-related task correctly in accordance with the risk to be covered. This also has to take place in the event of internal errors or failures – or a correspondingly defined safe status has to be assumed. The complex of functional safety has become increasingly important in all technical fields over the past years and decades.

A basic safety standard exists for the field of functional safety, IEC 61508 (also published as DIN EN 61508), which deals with the functional safety of safety-related electrical, electronic and programmable electronic systems. Its origins lie in plant engineering and in the process industry.

The term “safety-related” hereby applies for every programmed system in which an error (on its own or in combination with other errors) can lead to personal injury or death, to devastating damage to the environment or the destruction of material assets.

The introduction of IEC 61508 marked the establishment of an interdisciplinary guideline for all safety-related systems.
One of the primary goals of the application-independent safety standard was to enable sector-specific norms to be derived from this so that the most important determining factors of the relevant field of use could be taken fully into account and their particular requirements catered for.

In certain fields of application, “practical” derivations of IEC 61508 have already been developed over the past few years. The following figure presents an overview of important derivatives.

Übersicht einiger branchenspezifischer Derivate der IEC 61508

Figure: IEC 61508

ISO 26262 is an application-specific derivative of IEC 61508 that formulates an internationally agreed safety standard suitable for the automotive industry. Just like the basic safety standard, it uses a so-called safety life cycle as a framework to systematically record those activities needed to guarantee the functional safety of safety-related E/E-systems.
The safety life cycle according to ISO 26262 is shown in the following figure:

Sicherheitslebenszyklus nach ISO 26262

Figure: Safety life cycle according to ISO 26262

A key phase in the safety life cycle is the performance of a risk assessment, or a hazard analysis and risk assessment (G+R), that systematically records the potential risks originating from the system in question in all operating modes. These have to be determined for all reasonably foreseeable circumstances, including failure conditions and misuse. So-called safety integrity levels (SIL (SIL 1 to SIL 4) in IEC 61508, ASIL (ASIL A to ASIL D) in ISO 26262) as used to classify safety functions with respect to their safety integrity. These can be determined using the risk charts by a combination of various risk parameters, for example.

The derivates of IEC 61508 place similar demands on the safety integrity so that they are to a large extent very similar to the meta-norm. Depending on the classification of the safety integrity, the relevant sector-specific body of standards make demands on the different phases of the safety life cycle that have to be observed and satisfied. For example, probabilistic values are specified in certain standards, some of which are listed in the following figure.


Figure: Safety integrity SIL overview

PFD hereby stands for “Probability of Failure on Demand”, PFHD for “Probability of Dangerous Failure per Hour” and THR for “Tolerable Hazard Rate”.

Depending on the standard, the normative requirements may include the performance of inductive and/or deductive safety analyses or compliance with probabilistic limit values for random hardware failures.

IQZ is your strong partner with its broad portfolio of methods and many years of experience with functional safety projects. Irrespective of whether you have to develop a functional safety process or implement special methods (e.g. FMEA/FMEDA/FTA/Markov), we will be happy to advise you.