We Assist you in Achieving Machine Safety Compliance


Compliance means that our Machines are Safe and that we have met our legal obligations under New Zealand law. Achieving this means your people are protected and that all obligations have been fulfilled.

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Our Machine Safety Services

The machine risk assessment is the foundation of the machine safety process. It systematically identifies hazards associated with a machine, estimates the level of risk, and evaluates whether risk reduction measures are required.


This process follows the principles defined in AS/NZS 4024.1201 and within the wider AS/NZS 4024 framework. The outcome is a documented understanding of the machine’s hazards, the level of risk they present, and recommended measures to reduce those risks to an acceptable level.


Risk assessments form the basis for all subsequent safety design decisions and ensure that risk reduction measures are targeted, justified, and compliant with recognised standards.


The Safety Requirements Specification translates the results of the risk assessment into clear technical safety requirements for the machine. It defines the required safety functions, performance levels, and how the safety system must behave to adequately reduce risk.


The SRS is aligned with functional safety standards such as:
– AS/NZS 4024.1503
– ISO 13849-2


Within the context of the AS/NZS 4024 series, the SRS acts as the bridge between hazard identification, risk estimation and evaluation, and the design of the safety system. It ensures safety functions are clearly defined before engineering work begins.

Once the safety requirements are defined, the safety system can be designed and implemented. This includes selecting and integrating safety devices such as emergency stops, interlocks, light curtains, safety PLCs, and guarding systems.


The design must meet the performance and reliability requirements defined in the SRS and comply with the AS/NZS 4024 standards series as well as the relevant ISO standards depending on the particular type of machine being worked on.

This stage ensures that risk reduction measures are implemented correctly and in accordance with recognised engineering practices

Validation confirms that the installed safety system performs as intended and meets the requirements defined in the SRS. This includes testing safety functions, verifying performance levels, and confirming that all risk reduction measures are effective.
Validation is required by functional safety standards namely ISO 13849-2 and IEC 62061.
Within the AS/NZS 4024 lifecycle, validation provides objective evidence that the machine safety system achieves the required level of risk reduction and complies with applicable standards.

We work with Production Managers, Plant Managers, Asset Managers, Owners, Plant Directors, and Plant Supervisors to answer their questions about the safety and compliance of their machines.

We can help you find out if your machine is compliant

  • By evaluating the machine’s overall safety design and logic
  • Identifying high-risk operator tasks in daily use
  • Checking that dangerous moving parts are properly guarded to relevant standards
  • Assessing safety-critical electrical components and their Performance Level ratings
  • Reviewing hydraulic and pneumatic systems for compliance with safety standards
  • Considering whether your imported machines meet New Zealand safety expectations
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The Machine Safety Solution

We design our safety solutions using the three-step method outlined in AS/NZS 4024.1201, alongside the Hierarchy of Control Measures from the Health and Safety at Work Regulations (2016). We take pride in delivering solutions that meet the key requirements outlined below.

Compliant Machines

Achieving a compliant machine is a requirement in any of our Machine Safety projects. We take this very seriously and follow the current industry standards and all required legal processes when working on any Machine Safety project.

Cost

One or multiple designs may be proposed, in the detailed design phase costs will be specified. This is so the client can procced in making the necessary decisions on how to adequately reduce risk following the process set out in the Health and Safety at Work Act 2015.

Successful Installation

We bring our teams knowledge, experience, and capabilities to any Machine Safety project we work on, giving us confidence in achieving a successful installation of any system we design.

Usability of Machines

Usability must not be compromised when implementing safety measures, as required by both clients and AS/NZS 4024.1201. We ensure this by understanding how operators use the machine through site visits and client documentation, and incorporating these insights into the design stage.

Minimised Downtime

Minimizing this downtime as much as possible is taken into consideration during the design phrase. For example, this may include decisions about the number of installation personnel used or whether to prebuild part of the design off site.

Timely Delivery

We prioritise timely delivery, coordinating closely with our clients and maintaining clear communication to ensure our Machine Safety solutions are completed on schedule with minimal disruption.

The Three Step Method for Risk Reduction

Below is an explanation of the three-step method we use to adequately reduce risk when working on a machine safety project. It can be found in the New Zealand Standard AS/NZS 4024.1201:2014.

1

Inherently Safe Design Measures

The first step is to eliminate hazards where possible or otherwise reduce risk by redesigning the machine – for example, automating manual tasks or lowering forces, pressures, or weights to limit exposure.

2

Safeguarding and/or Complementary Protective Measures

The second step involves designing safeguards when hazards cannot be fully eliminated or risks sufficiently reduced. These may include fixed or interlocking guards, light curtains, hold-to-run controls, and other measures, complemented by emergency stops and escape/rescue provisions..

3

Creating Information for Use

The third step addresses residual risks that remain after design, safeguarding, and protective measures, by providing guidance in operating procedures, safe work practices, and recommended personal protective equipment.

Pilz Safety System Integrators

Our machine safety engineers are CMSE®-certified engineers (TÜV NORD), recognised as expert machinery safety professionals. We are also official Pilz system integrators, combining certified expertise with trusted safety technology to deliver reliable, compliant solutions.

Find Out More

Reach out to the team to see if we can help your machines become compliant. Flick us a message or give us a call.

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