Machine safety by the numbers

According to Eurostat Accidents at work statistics, the European Union recorded 2.97 million non-fatal workplace accidents and 3,286 fatal incidents in 2022—with more than a quarter of fatal injuries linked to machinery or handling equipment.

These stark figures underline why safety cannot be an afterthought. When a machine operates without proper safeguards, the consequences can be immediate and severe: equipment damage, costly downtime, injury, or even legal repercussions. On the other hand, designing safety into systems from the start transforms machinery into assets that deliver reliability, efficiency, and trust.

Why machine safety matters more than ever

The role of machine safety has evolved dramatically over the past decade. Once viewed mainly as a compliance requirement, it is now a business-critical priority.

Several factors are driving this shift:

• Automation and digitalisation – Modern machines are faster, more powerful, and interconnected. While this unlocks productivity, it also introduces risks. A poorly safeguarded or unsecured machine can expose operators to accidents or even be exploited in a cyberattack.

• Stricter regulations – The new EU Machinery Regulation (2023/1230), applicable from January 2027, strengthens obligations for machine builders. It explicitly addresses digital risks such as embedded software, AI, and cybersecurity, making safety and security inseparable.

• High cost of accidents – Beyond the human toll, a single incident can lead to medical claims, fines, downtime, and reputational damage. In the EU, accidents cost businesses billions each year in lost working days alone.

In short, machine safety is no longer optional. Companies that embed safety and security into their design processes are better positioned to protect people, safeguard productivity, and remain competitive in an increasingly demanding market.

Regulatory landscape explained

Machine safety rests on a foundation of regulations and standards designed to protect operators and ensure compliance across markets.

EU Machinery Regulation (2023/1230)

In Europe, the EU Machinery Regulation (2023/1230) is the cornerstone. Replacing the long-standing Machinery Directive, it harmonises rules across EU member states and introduces new requirements for digital technologies. Its goal: ensure machines are safe not only mechanically but also in terms of software and cybersecurity.

Machine Safety Standards Flow

To apply this regulation in practice, international standards give engineers clear methods for assessing and implementing safety. Three of the most important are:

ISO 12100 → Risk Assessment

• General principles for identifying hazards and reducing risks.
• Foundation for all subsequent safety measures.

ISO 13849 → Performance Level (PL)

• Focuses on safety-related parts of control systems.
• Determines how reliably a system performs safety functions.

IEC 62061 → Safety Integrity Level (SIL)

• Applies to electrical, electronic, and programmable systems.
• Defines the probability of safety function failures.

Together, these standards provide a structured path: assess risks (ISO 12100), design reliable controls (ISO 13849), and validate them against SIL requirements (IEC 62061).

Compliance: A Non-Negotiable

For manufacturers and machine builders, compliance is non-negotiable. Failure to meet requirements risks market access, costly redesigns, and most importantly, preventable harm to people.

Designing for safety: principles and methodology

Effective machine safety is not about bolting on protective devices at the end. It’s about embedding safety principles into every stage of design and operation.

The combined approach can be broken into four key stages:

1. Risk reduction at source

• The safest machine is one where hazards are eliminated during design.
• Example: A packaging machine designed with enclosed cutting blades eliminates the hazard before guards are even considered.

2. Functional safety

• Safety-related control systems must always perform their function—even in case of faults.
• Example: A conveyor line equipped with light curtains must reliably stop if someone enters the hazardous zone, regardless of system errors.

3. Redundancy and reliability

• Critical systems often include backups to reduce failure risk.
• Example: Robotic welding cells may use dual-channel emergency stops. If one fails, the other still ensures shutdown.

4. Validation and continuous improvement

• Safety isn’t proven until it’s tested. Tools like SISTEMA validate performance levels (PL) or safety integrity levels (SIL).
• Example: A press brake control system can be analysed and verified before being certified safe for use.

By treating safety as a lifecycle process—from design to validation and maintenance—businesses ensure compliance, reduce downtime, and build greater trust with operators.

Building a risk assessment framework

At the heart of machine safety lies the risk assessment framework. It gives structure to identifying hazards, prioritising risks, and selecting appropriate safeguards.

A typical process follows three steps:

Identify hazards

• Look for mechanical, electrical, thermal, and human-interaction risks.
• Example: In a bottling plant, hazards might include pinch points on conveyors or exposed high-voltage parts.

Assess and prioritise risks

• Estimate severity of harm and likelihood of occurrence.
• Example: A fast-rotating blade is far higher risk than a slow conveyor and requires stronger controls.

Define risk-reduction measures

• Apply the “hierarchy of controls”: eliminate hazards where possible, then guard, interlock, or control them with reliable safety systems.
• Example: A robotic arm may combine light curtains, barriers, and motion-control safety functions.

Documenting this process is essential. It provides proof of compliance with ISO 12100, supports audits, and ensures that decisions are based on structured analysis, not assumptions.

Safety isn’t optional—it’s smart engineering

Let’s be honest: if you’re building machines and not thinking about safety, you’re doing it wrong. Safety isn’t a box to tick it’s integral to performance, reliability, and reputation. Accidents cost time, money, and trust. But smart safety design prevents all that. It’s not just about avoiding injuries—it’s about keeping machines running, teams confident, and customers loyal.

Here’s what good safety delivers:

• Fewer unplanned stops, thanks to robust interlocks and protective systems.
• Longer machine lifespans, because safe machines are better maintained and less stressed.
• Engaged operators, who know their environment is built with care.
• Credibility with customers, who expect responsibility as standard.

Take a packaging line with modern safety interlocks: it doesn’t just protect people—it boosts OEE by reducing downtime. Safety isn’t a cost centre. It’s a performance multiplier.

Machine safety is more than a compliance requirement—it’s a responsibility and an opportunity. By aligning with regulations, applying proven engineering principles, and following a structured design methodology, businesses can protect people while safeguarding productivity. A robust risk assessment framework ensures hazards are identified and reduced, while continuous improvement keeps systems effective for the long term.