Safety, security: differences and intersections
Although often mentioned together, safety and security focus on different—but connected—risks:
Machine Safety
Machine safety protects people, equipment, and the environment from harm. It covers risks from mechanical movement, electrical faults, or control system failures, and is guided by standards like ISO 13849 and IEC 61508.
Objectives:
• Protection against hazards posed by a machine or a system (protective measures, functional safety).
• Protection against hazards associated with the use of a machine or system.
Machine Security
Machine security protects systems and data from unauthorized access or manipulation. It covers risks such as hacking, malware, sabotage, or accidental misuse, and is guided by standards like IEC 62443.
Objectives:
• Confidentiality: No access to systems or data without authorisation.
• Integrity: Systems or data cannot be changed without authorisation.
• Availability: Authorised access to systems or data may not be obstructed.
Where they overlap
- A safety failure can open the door to a security issue (e.g., disabled safeguards).
- A security breach can quickly become a safety hazard (e.g., malicious changes to machine settings).
The key takeaway: engineers cannot treat these as separate checklists. Safety and security must be addressed together from the very start of machine design.
How regulation shapes safety and security
Legal requirements
In Europe, machine safety and security are not just best practices—they are legal requirements. For safety, standards such as ISO 13849-1:2023 and IEC 61508 set out how to design and validate safety-related control systems. On the security side, IEC 62443 defines how to protect industrial automation systems from cyber threats.
The challenge of dual compliance
The challenge for engineers is that these frameworks don’t exist in isolation. A machine that is compliant with ISO 13849 for safety may still fall short if it isn’t also protected against unauthorized access as outlined in IEC 62443. And with the new EU Machinery Regulation coming into force in 2027, the emphasis on digital safety and cybersecurity will only increase.
Building trust through integrated safety and security
Compliance should never be treated as a box-ticking exercise. These standards exist to reduce risk, protect operators, and safeguard the reputation of machine builders. More importantly, aligning safety and security from the outset ensures that a machine is not only legally compliant but also trusted by the people who use it.
Practical steps engineers can take
Integrating safety and security doesn’t need to be complicated. Here are five practical steps engineers can build into their workflow:
1. Run a risk assessment early: Identify hazards—mechanical, electrical, or digital—before design decisions lock in.
2. Design safety and security together: Treat them as two sides of the same coin, not separate checklists.
3. Use validated tools: Software like SISTEMA helps confirm that safety systems meet the right performance levels.
4. Plan for ongoing protection: Regular updates, patches, and operator training keep both safety and security measures effective.
5. Think lifecycle, not one-off: Compliance isn’t just about passing inspection on day one. Machines need to stay safe and secure for years to come.
Conclusion
Safety keeps people protected. Security keeps systems protected. Together, they create machines that are not only compliant, but also resilient and trustworthy. For engineers, the challenge is no longer choosing between safety or security—it’s understanding how to integrate both effectively.