When Should You Upgrade Your Machine Safety Systems?

Keeping your production machines safe is critical to safeguarding your workers, minimising downtime, and staying compliant with Australian Work Health and Safety (WHS) laws. 

Under the Occupational Health and Safety Act 2004, businesses or persons conducting a business must proactively manage risks associated with plant and machinery. This includes implementing and maintaining appropriate safety controls to ensure employees can operate the machines securely.

Relying on outdated or insufficient safety measures can lead to serious injuries, costly production halts, and legal exposure. In this blog, we’ll discuss the triggers for upgrading industrial machine safety solutions and provide guidance on how to strengthen protections in their facilities. 

What Are Machine Safety Systems?

Machine safety systems are the controls within a machine designed to prevent harm and reduce operational risk. Typical components in machine safety are emergency stop devices, interlock systems, safety relays, machine guarding, light curtains, safety mats, and presence-sensing devices.

These systems detect hazardous conditions and stop or isolate machinery before any injury occurs. While many of these systems are mandatory, and most machines come with these safety systems, having them properly updated and maintained is necessary to ensure they perform reliably.

Key Indicators It’s Time to Upgrade

Outdated or Unsupported Equipment

Legacy safety systems may no longer meet current safety standards or manufacturer recommendations. Old machineries also carry a high risk of poor vendor support and difficulty sourcing replacement parts. 

If minor incidents or near misses frequently occur, or if a recent safety audit identifies hazards associated with aging controls, it indicates that the existing safeguards may be insufficient. Consider regularly reviewing the support lifecycle of the machine’s safety devices and acting when parts become scarce to avoid costly downtime. 

Changes to Machinery or Production Flow

The introduction of new machines and workflows may render previous machine risk assessments obsolete, resulting in outdated safety systems. For example, adding automation or robotic cells may require different sensing zones or updated light curtains.

Any alteration that affects the site floor, such as repositioning equipment, adding conveyor lines, or even implementing faster cycle times, requires reviewing and likely upgrading safety measures to maintain proper protection. 

Safety Incidents, Near Misses or WHS Notices

If there is a rise in incident reports or near-miss signals, it’s a clear indication that current safeguards may be malfunctioning. Ignoring these warning signs can lead to repeated risk events, increased injury severity, and even fines by regulators. 

Non-Compliance with Current Standards

Failed internal audits or third-party inspections are another clear sign that existing systems do not meet the latest safety standards. If audits identify gaps, such as insufficient performance levels (PLs) or outdated validation documentation, it is time to plan an upgrade to align with current standards and avoid potential penalties.  

Poor Integration With Modern Systems

Older safety systems that lack integration with PLCs, SCADA, or Industrial IoT (IIoT) platforms miss opportunities for real-time monitoring, diagnostics, and predictive maintenance. Modern integrated safety solutions can provide alerts before failures, trend analysis of safety device performance, and insights to prevent downtime.

If the machine’s safety controls operate in isolation, it may be prudent to upgrade for better safety and decision-making.  

Benefits of Upgrading Your Safety Systems 

Upgrading one’s machine safety solutions brings multiple advantages in operations, productivity, and the bottom line:

When to Schedule a Safety Audit 

Scheduling audits at key points ensures that your business risks are identified and addressed before they lead to incidents or downtime. Here are several critical times to schedule a machine safety audit: 

What’s Involved in a Safety System Upgrade

Upgrading a safety system follows a structured process, from hazard identification to long-term maintenance. Here’s a step-by-step: 

Why Work With a Trusted Safety Partner

Partnering with local machine safety experts ensures timely support and leverages the knowledge of contractors who have deep industry experience.  Aus-Tech brings over 40 years of industry experience in manufacturing safety and automation. Our team of trusted industrial electrical contractors specialises in customised machine safety solutions, and we leverage our strong purchasing power from long-term supplier relationships to access the highest-quality products. 

Conclusion 

Machine safety is a critical part of manufacturing, and it must be taken seriously to ensure that downtime is minimised and staff safety is upheld. By partnering with a trusted provider like Aus-Tech, you gain expertise, quality components, and tailored solutions that increase worker protection and productivity. Contact our team to learn more about our machine safety solutions.