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FUNCTIONAL SAFETY

IO Engineering supports Functional Safety application to BS EN ISO 12100 and BS EN ISO 13849-1, helping clients identify hazards, define risk reduction measures, and specify safety-related control functions with clear performance targets (PLr). We produce structured, traceable documentation—risk assessment outputs, safety function definitions, and SISTEMA-ready validation as per BS EN ISO 13849-2, supporting efficient design decisions, smoother commissioning, and robust technical file preparation.

We guide you through the whole process from early stages of Hazards identification, risk reduction measures, to specification of safety-related control functions with clear performance targets (PLr), ensuring your system meets the safety levels mandated by most OEMs and other end clients

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Customized to fit your unique project needs, our Functional Safety expertise guarantees strict compliance with Global Standards.

OVERVIEW

  • Identify hazards and define risk reduction measures (ISO 12100)

  • Define and design safety-related control functions to required PLr (BS EN ISO 13849-1)

  • Produce traceable, auditable safety documentation that supports CE/UKCA technical files

  • Procedures and conditions for validating the defined safety functions (BS EN ISO 13849-2)

WHAT WE COVER

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  • New machine design, retrofits, line modifications

  • Risk assessment and Safety concept

  • Safety functions specification (what triggers, what happens, safe state)

  • PLr determination and architecture selection (Category)

  • SRP/CS design support (safety PLC/relays, interlocks, STO/SS1, light curtains, scanners, etc.)

  • Documentation structured for commissioning and handover

STANDARDS & COMPLIANCE

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  • BS EN ISO 12100 – Hazard identification, Risk assessment, and Risk reduction

  • BS EN ISO 13849-1 – Safety functions, PLr, Category, DCavg, MTTFd, CCF

  • BS EN ISO 13849-2 – Validation of such Safety functions

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We stay updated with evolving standards to provide guidance on the latest national and international standards applicable to your industry.

OUR METHODOLOGY

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⦁    Hazard identification & limits of machinery (intended use, misuse, life cycle)
⦁    Risk estimation & evaluation (severity, frequency/exposure, avoidance)
⦁    Risk reduction strategy (inherent design, safeguarding, SRP/CS)
⦁    Safety functions definition (trigger, response, safe state, reset, manual intervention)
⦁    PLr determination (required performance level for each function)
⦁    Architecture selection (Category and diagnostic approach)
⦁    Design evidence & calculations (MTTFd/DCavg/CCF; SISTEMA-ready model)

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DELIVERABLES (WHAT CLIENTS RECEIVE)

⦁    Risk Assessment aligned to ISO 12100 (hazards, measures, residual risk)
⦁    Safety Requirements / Safety Function Specification (SRS/SFS)
⦁    PLr table per safety function and analysis
⦁    Safety architecture proposal (Category, diagnostics approach, key components)
⦁    SISTEMA-ready structure (or completed model if you offer it as part of this service)
⦁    Traceability matrix (hazard → measure → safety function → evidence)

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INPUTS WE TYPICALLY NEED FROM THE CLIENT

  • Machine description, cycle overview, layouts

  • Existing schematics / EPLAN project (if any)

  • List of safeguarding devices and safety components (if selected)

  • Intended operating modes (Auto/Manual/Teach/Maintenance)

  • Production context (who interacts, how often, foreseeable misuse)

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TAILORED HARDWARE CONTROLS DESIGN ENGINEERING

We prioritize Functional Safety in our designs and offer a specialized assessment service for both new and existing control systems. Aligned with international standards like BS EN ISO 12100, BS EN ISO 13849-1, and BS EN ISO 13849-2. Our approach provides a systematic methodology for Risk Assessments and guidance on designing and integrating Safety-Related Parts of the Control Systems (SRP/CS)


MANUFACTURER TOOLS & ENGINEERING CALCULATIONS

 

We maintain a close collaboration with our customers' chosen manufacturers, enhancing precision.

To ensure accurate selection, compliance, and build-ready documentation, we use industry-recognised manufacturer configurators and proven electrical calculation methods to size, verify, and standardise control system hardware.

 

Manufacturer selection & configuration tools

  • Siemens TIA Selection Tool (TIA-ST): PLC/HMI/SCALANCE hardware, network component selection and configuration support

  • Siemens SIMARIS (Design/Curves): power distribution sizing, protective devices and coordination support

  • Rockwell Automation (Allen-Bradley) Product Selection / I/O Configuration tools: I/O module selection and configuration support

  • WAGO Configurator Tools: I/O systems, terminal blocks, power supplies, and accessories selection

  • Weidmüller Configurator Tools: terminal strips, marking, accessories, and panel interface component selection

OUR CUSTOMERS' PREFERRED MANUFACTURERS

© 2026 by IO Engineering Limited

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