AUTOMATION CASE STUDY
Preventing a Critical
Automation Safety Failure
Before Production Startup
EL Engineering was engaged to independently review the automation and safety control architecture of a highly automated production line for a leading medical device manufacturer.
INDUSTRY
Medical Device Manufacturing
SERVICE
Automation & Safety
PROJECT FOCUS
Independent Safety Control Review
Client Context
A highly automated production environment
A leading medical device manufacturer was preparing to commission a highly automated production line supplied by a global OEM.
The project relied on complex automation software, integrated safety controls and distributed communications to manage production while ensuring personnel protection and operational reliability.
THE SYSTEM INCLUDED
Industrial Robotics
Multiple industrial robots operating within the production environment.
Safety-Controlled Access
Guard doors and access points integrated into the safety control architecture.
Nitrogen-Controlled Areas
Process areas where the integrity of the safety system was critical to personnel protection.
The Challenge
A critical weakness in the safety control architecture
EL Engineering identified concerns regarding how safety guard unlock requests were being processed within the safety control system architecture.
The guard door unlock request originated from the Standard Task of the Safety Controller rather than the dedicated Safety Task. This meant the safety-related door release function could potentially be manipulated, compromising the integrity of the safety system.
WHY IT MATTERED
01 - Incorrect source
The request originated from the Standard Task rather than the dedicated Safety Task.
02 - Potential vulnerability
The approach could potentially allow the safety-related door release function to be manipulated.
03 - High-risk environment
The production line incorporated industrial robots and nitrogen-controlled environments, making the integrity of the safety architecture critical to personnel protection and operational safety.
EL's Approach
Independent review of the safety control architecture
EL Engineering carried out an extensive review of the automation software, safety software and overall guard-locking control system architecture.
The review examined how the systems operated together, including their behaviour under abnormal conditions and the integration between automation and safety communications.
THE REVIEW INCLUDED
01 - Automation software analysis
02 - Safety controller software review
03 - Guard-locking functionality and limitations
04 - Validation under abnormal conditions
05 - Integrated automation and safety communications
06 - Verification against machine safety requirements
The Outcome
A critical vulnerability identified before production startup.
EL Engineering's detailed review triggered a wider investigation involving the safety relay and controller OEM, as well as the safety controller supplier.
The safety controller was extensively redesigned and recertified over an eight-month period.
PROJECT IMPACT
✓ Personnel safety protected
✓ Critical vulnerability identified before production startup
✓ Industry-level redesign triggered
✓ Critical control system redesigned and successfully re-certified
Independent expertise. Practical impact.
EL Engineering's independent review identified a critical automation safety vulnerability before production startup, helping protect personnel and prompting a wider redesign and re-certification of the control system.