Safety Consulting – pragmatic, robust, audit-ready

I help operators, OEMs and integrators implement machine safety from concept to acceptance – with a focus on presses, robotics/AGV, BWS/AOPD, retrofit strategies and export crosswalks.

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For operators

Goal: legal certainty, effective measures, less downtime.

Focus areas

Embed risk assessments and safety routines into daily operations (per workplace/line)
Build a safety management cadence: roles, processes, inspection & interval plan
Periodic inspections: stop time/safety distance (EN ISO 13855), AOPD/guarding, documentation
Prioritised action plans with effort, deadlines and owners
Briefings & training for operators and maintenance

You receive

Audit-ready documents (risk assessment, inspection & validation plans, checklists)
A transparent roadmap (what, why, by when)
Quick wins to cut risk immediately

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For manufacturers or retrofitting specialists

Goal: safe, acceptance-ready machines – efficiently to conformity.

Risk analysis (ISO 12100)

Identify, evaluate (matrix/score) and prioritise risks – the basis for the safety concept.

Safety concepts

Inherently safe design (guarding/ergonomics)
Functional safety from sensor to actuator (EN ISO 13849 / IEC 62061)
Define and document acceptable residual risk

Implementing the safeguarding

Component selection (AOPD/light curtain, interlocks, E-stops, safe I/O/relays, safety control system)
Correct installation & integration (incl. EPLAN P8)
Safe software: architecture, parameters, diagnostics, testable states

Validation & acceptance

Validation plan & test protocols (AOPD function, modes of operation, release logic)
Evidence: PL/SIL calculations, EN ISO 13855 safety distances, EN 60204-1 checks
Acceptance documentation, including action tracking

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Productised consulting packages

Remote gap assessment (60 min + short report) – risks, standard gaps, quick wins, budget range
Export crosswalk (EU ↔ UK/USA/CA/GCC) – gap analysis, action plan, templates
Press retrofit concept – safety control system, BWS/AOPD, validation & acceptance plan
Document review – CE/DoC, risk assessment, P8, inspection reports → audit-ready

How I work

Short call – clarify scope & goals
Document review – drawings, photos/video, existing files
Workshop/remote session – decisions & standards pathway
Findings & action plan – priorities, owners, timeline
Optional support through to acceptance

About outputs (what you actually get)

A concrete action plan with priorities and timelines
Audit-ready evidence (PL/SIL, safety distances) and validation/inspection templates
Clear interface alignment with E&I, safety officers and partners to avoid rework

Notes on scope (clear expectations)

Risk assessments (GBU) are provided under German law; internationally I supply technical evidence (PL/SIL, EN safety distances, validation) and collaborate with local partners as needed.
Documentation available in EN/DE.

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