Mastering ISO 13849 for Industrial Safety Systems Design
You're responsible for designing, validating, or certifying safety systems in industrial environments. One miscalculation, one overlooked parameter, one ambiguous architecture decision - and your entire project stalls, compliance fails, or worse, someone gets hurt. The pressure isn’t just technical. It’s professional. You need to deliver systems that meet exacting legal and safety requirements, satisfy auditors, and earn the trust of engineers, managers, and regulators. Yet the ISO 13849 standard is complex, layered, and often misunderstood, even by seasoned practitioners. That confusion leads to costly delays, redesigns, and risk exposure. But what if you could navigate ISO 13849 with absolute clarity, every time? What if you could confidently design, assess, and validate safety-related parts of control systems with precision, speed, and documented compliance? Introducing Mastering ISO 13849 for Industrial Safety Systems Design - a precision-engineered learning pathway that transforms uncertainty into mastery. This course equips you to go from confusion to compliance in under 30 days, producing validated safety system designs that meet global standards and pass third-party audits without rework. Take it from Marcus R., Principal Safety Engineer at a Tier 1 automotive automation integrator: “I led a safety architecture redesign for a high-risk assembly line. After completing this course, I applied the PL and SIL calculation framework directly to our documentation. My team cut review time by 60%, and we passed TÜV certification on the first submission - something we haven't done in three years.” No more guesswork. No more second-guessing. This is your blueprint for becoming the go-to expert in functional safety design. Here’s how this course is structured to help you get there.Course Format & Delivery Details Self-Paced, Immediate Online Access
You begin the moment you're ready. There are no fixed start dates, no time zone conflicts, and no scheduling hassles. Whether you’re an automation engineer between shifts or a compliance officer squeezing in study during lunch breaks, this course fits your rhythm. On-Demand Learning with Zero Time Commitments
The entire program is on-demand. You control the pace. You decide when and how much to study. Most learners complete the core modules in 20 to 30 hours, with many applying key techniques to live projects within the first week. - Lifetime access to all materials
- Ongoing future updates at no extra cost - the standard evolves, and so does your knowledge
- 24/7 global access from any device, including smartphones and tablets
- Mobile-friendly layout ensures seamless progress from the office, plant floor, or commute
Instructor Support and Technical Guidance
You’re not learning in isolation. Throughout the course, you’ll have direct access to instructor-led guidance via structured Q&A channels. Whether you're stuck on performance level calculations, architecture validation, or interpreting Annexes, expert clarification is built into the experience. You’ll receive context-specific feedback, practical examples, and real-world clarification designed to accelerate your understanding - not automated responses, but human expertise aligned with industrial engineering realities. Certificate of Completion from The Art of Service
Upon finishing the course, you’ll earn a Certificate of Completion issued by The Art of Service - an internationally recognised credential trusted by thousands of engineers, compliance officers, and manufacturing firms worldwide. This isn’t just a participation badge. It's proof you’ve mastered the calculation, design, and validation workflows required by ISO 13849, with documented proficiency in performance level determination, fault exclusion, common cause failure analysis, and safety system architecture. - Add the certification to your LinkedIn profile, CV, and project documentation
- Use it to demonstrate compliance competence during audits or client reviews
- Signal your expertise to employers and stakeholders as a certified practitioner in functional safety
Transparent, Simple Pricing - No Hidden Fees
You pay one straightforward fee. There are no recurring charges, no add-ons, and no surprise costs. The price covers full access, future updates, downloadable tools, assessments, and your certificate. We accept all major payment methods including Visa, Mastercard, and PayPal - processed securely with bank-level encryption. Zero-Risk Enrollment: Satisfied or Refunded
If you complete the first two modules and don’t feel you’re gaining clarity, actionable knowledge, or measurable progress in your ability to apply ISO 13849, simply request a full refund. No questions, no barriers. This is our promise: you either master the standard, or you don’t pay. Confirmation and Access Process
After enrollment, you’ll receive a confirmation email. Your secure access details will be delivered separately once your course materials are fully provisioned - ensuring a stable, error-free learning environment from day one. Will This Work for Me?
You might be thinking: “I’m not a safety specialist - is this for me?” Or: “I’ve read the standard before and still didn’t feel confident.” This works even if: you’re a controls engineer new to safety validation, a project lead overseeing compliance, or a technical manager reviewing risk assessments. No prior deep expertise in functional safety is required. The content builds from foundational principles to advanced application through structured, role-specific examples. Hear from others in your position: - Lena K., Senior Automation Engineer: “I used to outsource all our safety validations. Now I lead them. This course gave me the exact workflow templates and calculation logic I needed to take ownership.”
- Diego T., Maintenance Supervisor: “I’m not an engineer by title, but my team relies on safety systems daily. This course finally made PL and MTTFd make sense - I can now question vendor claims and validate designs myself.”
We eliminate risk at every level - through lifetime access, expert support, a respected certification, and a full refund guarantee. You’re investing in certainty, not uncertainty.
Module 1: Foundations of Industrial Machine Safety and ISO 13849 - Introduction to functional safety in industrial machinery
- Evolution of safety standards: from EN 954-1 to ISO 13849-1
- Scope and applicability of ISO 13849 in modern control systems
- Understanding safety-related parts of control systems (SRP/CS)
- Legal and regulatory drivers: Machinery Directive, OSHA, IEC alignment
- Distinction between ISO 13849 and IEC 62061 (SIL vs PL)
- Key stakeholders in safety system design and validation
- Role of the designer, integrator, and certifier in risk reduction
- Overview of risk assessment and its link to safety functions
- Fundamental safety concepts: fail-safe, redundancy, diversity
Module 2: Understanding the ISO 13849-1 Framework and Structure - Breakdown of ISO 13849-1 sections: clauses 1 to 8
- Purpose and use of Annexes A through Z
- Difference between normative and informative content
- Understanding defined terms: performance level, MTTFd, DC, CCF
- Interpreting safety function definitions in real-world contexts
- How to read and apply the normative references correctly
- Integration of ISO 13849 with ISO 12100 and risk assessment
- Using clause 5 for safety requirement specification
- Understanding the validation lifecycle and documentation trail
- Common misinterpretations and how to avoid them
Module 3: Risk Assessment and Determining Required Performance Level (PLr) - Linking risk graph methodology to PLr assignment
- Parameters S1, S2, F1, F2, P1, P2 - definitions and scoring
- Interactive examples of risk graph application
- Documenting PLr justification for audits
- Handling high-risk scenarios: trapped personnel, energy release
- Using alternative methods for PLr determination
- Conservative vs optimised PLr selection strategies
- Collaborating with cross-functional teams on risk assessment
- Integrating risk assessment into project initiation
- Reviewing legacy systems for PLr compliance gaps
Module 4: Safety System Architecture and Design Principles - Understanding Categories B, 1, 2, 3, 4 - definitions and applications
- Functional differences between Category types
- Selecting architecture based on required PLr
- Architectural constraints and their role in PL achievement
- Use of dual channel, redundant, and diverse designs
- Designing for diagnostic coverage and fault detection
- Avoiding common design pitfalls in Category 3 and 4 systems
- Integrating emergency stops, guards, and safeguarding devices
- Role of separation and independence in safety circuits
- Best practices for layout, signal flow, and component selection
Module 5: Reliability Parameters – MTTFd, DC, and CCF - Mean Time to Dangerous Failure (MTTFd): definition and importance
- Three-band method: low, medium, high (based on B10d and manufacturer data)
- Calculating MTTFd from B10d and test cycles
- Using manufacturer MTTFd data vs internal calculations
- Diagnostic Coverage (DC): levels and measurement
- Methods for determining DC: component testing, FMEA, design analysis
- Common Cause Failure (CCF) - why it matters
- The 20-point checklist for CCF resistance (Annex F)
- Scoring and documentation of CCF measures
- Impact of environmental, installation, and operational factors on reliability
Module 6: Performance Level (PL) Calculation and Validation - Step-by-step PL calculation workflow
- Combining architecture, MTTFd, DC, and CCF to determine achieved PL
- Using the PL chart (Figure 5 of ISO 13849-1)
- Calculation tools: spreadsheets, templates, and digital assistants
- Handling multiple safety functions in one system
- Dealing with mixed architectures across subsystems
- Validation of calculated PL against required PLr
- When to redesign: identifying gaps between PL and PLr
- Documentation of calculation methodology for audit readiness
- Peer review and internal validation protocols
Module 7: Fault Exclusion and Justification (Annex F) - Understanding fault exclusion concept and intent
- Conditions under which fault exclusion is permitted
- Proving that a fault is “reasonably excluded”
- Documentation requirements for fault exclusion claims
- Link between fault exclusion and reliability data
- Use of operational history and field performance data
- Design for fault prevention: sealing, protection, access control
- Environmental and use condition monitoring in exclusion
- Common mistakes in fault exclusion justification
- Audit challenges and how to defend your position
Module 8: Common Cause Failure (CCF) Analysis and Prevention - Root causes of CCF: design, environment, operation
- Systematic vs random CCF scenarios
- Designing for independence: electrical, spatial, functional
- Selecting diverse components to resist CCF
- Software diversity and its limitations
- Rating CCF measures using Annex F checklist
- Scoring each CCF prevention method: 0, 1, 2, or 3 points
- Aggregating CCF scores and verifying minimum thresholds
- Linking CCF to achieved performance level
- Using CCF analysis in retrofit and upgrade projects
Module 9: Application of ISO 13849-2 (Validation) - Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Introduction to functional safety in industrial machinery
- Evolution of safety standards: from EN 954-1 to ISO 13849-1
- Scope and applicability of ISO 13849 in modern control systems
- Understanding safety-related parts of control systems (SRP/CS)
- Legal and regulatory drivers: Machinery Directive, OSHA, IEC alignment
- Distinction between ISO 13849 and IEC 62061 (SIL vs PL)
- Key stakeholders in safety system design and validation
- Role of the designer, integrator, and certifier in risk reduction
- Overview of risk assessment and its link to safety functions
- Fundamental safety concepts: fail-safe, redundancy, diversity
Module 2: Understanding the ISO 13849-1 Framework and Structure - Breakdown of ISO 13849-1 sections: clauses 1 to 8
- Purpose and use of Annexes A through Z
- Difference between normative and informative content
- Understanding defined terms: performance level, MTTFd, DC, CCF
- Interpreting safety function definitions in real-world contexts
- How to read and apply the normative references correctly
- Integration of ISO 13849 with ISO 12100 and risk assessment
- Using clause 5 for safety requirement specification
- Understanding the validation lifecycle and documentation trail
- Common misinterpretations and how to avoid them
Module 3: Risk Assessment and Determining Required Performance Level (PLr) - Linking risk graph methodology to PLr assignment
- Parameters S1, S2, F1, F2, P1, P2 - definitions and scoring
- Interactive examples of risk graph application
- Documenting PLr justification for audits
- Handling high-risk scenarios: trapped personnel, energy release
- Using alternative methods for PLr determination
- Conservative vs optimised PLr selection strategies
- Collaborating with cross-functional teams on risk assessment
- Integrating risk assessment into project initiation
- Reviewing legacy systems for PLr compliance gaps
Module 4: Safety System Architecture and Design Principles - Understanding Categories B, 1, 2, 3, 4 - definitions and applications
- Functional differences between Category types
- Selecting architecture based on required PLr
- Architectural constraints and their role in PL achievement
- Use of dual channel, redundant, and diverse designs
- Designing for diagnostic coverage and fault detection
- Avoiding common design pitfalls in Category 3 and 4 systems
- Integrating emergency stops, guards, and safeguarding devices
- Role of separation and independence in safety circuits
- Best practices for layout, signal flow, and component selection
Module 5: Reliability Parameters – MTTFd, DC, and CCF - Mean Time to Dangerous Failure (MTTFd): definition and importance
- Three-band method: low, medium, high (based on B10d and manufacturer data)
- Calculating MTTFd from B10d and test cycles
- Using manufacturer MTTFd data vs internal calculations
- Diagnostic Coverage (DC): levels and measurement
- Methods for determining DC: component testing, FMEA, design analysis
- Common Cause Failure (CCF) - why it matters
- The 20-point checklist for CCF resistance (Annex F)
- Scoring and documentation of CCF measures
- Impact of environmental, installation, and operational factors on reliability
Module 6: Performance Level (PL) Calculation and Validation - Step-by-step PL calculation workflow
- Combining architecture, MTTFd, DC, and CCF to determine achieved PL
- Using the PL chart (Figure 5 of ISO 13849-1)
- Calculation tools: spreadsheets, templates, and digital assistants
- Handling multiple safety functions in one system
- Dealing with mixed architectures across subsystems
- Validation of calculated PL against required PLr
- When to redesign: identifying gaps between PL and PLr
- Documentation of calculation methodology for audit readiness
- Peer review and internal validation protocols
Module 7: Fault Exclusion and Justification (Annex F) - Understanding fault exclusion concept and intent
- Conditions under which fault exclusion is permitted
- Proving that a fault is “reasonably excluded”
- Documentation requirements for fault exclusion claims
- Link between fault exclusion and reliability data
- Use of operational history and field performance data
- Design for fault prevention: sealing, protection, access control
- Environmental and use condition monitoring in exclusion
- Common mistakes in fault exclusion justification
- Audit challenges and how to defend your position
Module 8: Common Cause Failure (CCF) Analysis and Prevention - Root causes of CCF: design, environment, operation
- Systematic vs random CCF scenarios
- Designing for independence: electrical, spatial, functional
- Selecting diverse components to resist CCF
- Software diversity and its limitations
- Rating CCF measures using Annex F checklist
- Scoring each CCF prevention method: 0, 1, 2, or 3 points
- Aggregating CCF scores and verifying minimum thresholds
- Linking CCF to achieved performance level
- Using CCF analysis in retrofit and upgrade projects
Module 9: Application of ISO 13849-2 (Validation) - Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Linking risk graph methodology to PLr assignment
- Parameters S1, S2, F1, F2, P1, P2 - definitions and scoring
- Interactive examples of risk graph application
- Documenting PLr justification for audits
- Handling high-risk scenarios: trapped personnel, energy release
- Using alternative methods for PLr determination
- Conservative vs optimised PLr selection strategies
- Collaborating with cross-functional teams on risk assessment
- Integrating risk assessment into project initiation
- Reviewing legacy systems for PLr compliance gaps
Module 4: Safety System Architecture and Design Principles - Understanding Categories B, 1, 2, 3, 4 - definitions and applications
- Functional differences between Category types
- Selecting architecture based on required PLr
- Architectural constraints and their role in PL achievement
- Use of dual channel, redundant, and diverse designs
- Designing for diagnostic coverage and fault detection
- Avoiding common design pitfalls in Category 3 and 4 systems
- Integrating emergency stops, guards, and safeguarding devices
- Role of separation and independence in safety circuits
- Best practices for layout, signal flow, and component selection
Module 5: Reliability Parameters – MTTFd, DC, and CCF - Mean Time to Dangerous Failure (MTTFd): definition and importance
- Three-band method: low, medium, high (based on B10d and manufacturer data)
- Calculating MTTFd from B10d and test cycles
- Using manufacturer MTTFd data vs internal calculations
- Diagnostic Coverage (DC): levels and measurement
- Methods for determining DC: component testing, FMEA, design analysis
- Common Cause Failure (CCF) - why it matters
- The 20-point checklist for CCF resistance (Annex F)
- Scoring and documentation of CCF measures
- Impact of environmental, installation, and operational factors on reliability
Module 6: Performance Level (PL) Calculation and Validation - Step-by-step PL calculation workflow
- Combining architecture, MTTFd, DC, and CCF to determine achieved PL
- Using the PL chart (Figure 5 of ISO 13849-1)
- Calculation tools: spreadsheets, templates, and digital assistants
- Handling multiple safety functions in one system
- Dealing with mixed architectures across subsystems
- Validation of calculated PL against required PLr
- When to redesign: identifying gaps between PL and PLr
- Documentation of calculation methodology for audit readiness
- Peer review and internal validation protocols
Module 7: Fault Exclusion and Justification (Annex F) - Understanding fault exclusion concept and intent
- Conditions under which fault exclusion is permitted
- Proving that a fault is “reasonably excluded”
- Documentation requirements for fault exclusion claims
- Link between fault exclusion and reliability data
- Use of operational history and field performance data
- Design for fault prevention: sealing, protection, access control
- Environmental and use condition monitoring in exclusion
- Common mistakes in fault exclusion justification
- Audit challenges and how to defend your position
Module 8: Common Cause Failure (CCF) Analysis and Prevention - Root causes of CCF: design, environment, operation
- Systematic vs random CCF scenarios
- Designing for independence: electrical, spatial, functional
- Selecting diverse components to resist CCF
- Software diversity and its limitations
- Rating CCF measures using Annex F checklist
- Scoring each CCF prevention method: 0, 1, 2, or 3 points
- Aggregating CCF scores and verifying minimum thresholds
- Linking CCF to achieved performance level
- Using CCF analysis in retrofit and upgrade projects
Module 9: Application of ISO 13849-2 (Validation) - Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Mean Time to Dangerous Failure (MTTFd): definition and importance
- Three-band method: low, medium, high (based on B10d and manufacturer data)
- Calculating MTTFd from B10d and test cycles
- Using manufacturer MTTFd data vs internal calculations
- Diagnostic Coverage (DC): levels and measurement
- Methods for determining DC: component testing, FMEA, design analysis
- Common Cause Failure (CCF) - why it matters
- The 20-point checklist for CCF resistance (Annex F)
- Scoring and documentation of CCF measures
- Impact of environmental, installation, and operational factors on reliability
Module 6: Performance Level (PL) Calculation and Validation - Step-by-step PL calculation workflow
- Combining architecture, MTTFd, DC, and CCF to determine achieved PL
- Using the PL chart (Figure 5 of ISO 13849-1)
- Calculation tools: spreadsheets, templates, and digital assistants
- Handling multiple safety functions in one system
- Dealing with mixed architectures across subsystems
- Validation of calculated PL against required PLr
- When to redesign: identifying gaps between PL and PLr
- Documentation of calculation methodology for audit readiness
- Peer review and internal validation protocols
Module 7: Fault Exclusion and Justification (Annex F) - Understanding fault exclusion concept and intent
- Conditions under which fault exclusion is permitted
- Proving that a fault is “reasonably excluded”
- Documentation requirements for fault exclusion claims
- Link between fault exclusion and reliability data
- Use of operational history and field performance data
- Design for fault prevention: sealing, protection, access control
- Environmental and use condition monitoring in exclusion
- Common mistakes in fault exclusion justification
- Audit challenges and how to defend your position
Module 8: Common Cause Failure (CCF) Analysis and Prevention - Root causes of CCF: design, environment, operation
- Systematic vs random CCF scenarios
- Designing for independence: electrical, spatial, functional
- Selecting diverse components to resist CCF
- Software diversity and its limitations
- Rating CCF measures using Annex F checklist
- Scoring each CCF prevention method: 0, 1, 2, or 3 points
- Aggregating CCF scores and verifying minimum thresholds
- Linking CCF to achieved performance level
- Using CCF analysis in retrofit and upgrade projects
Module 9: Application of ISO 13849-2 (Validation) - Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Understanding fault exclusion concept and intent
- Conditions under which fault exclusion is permitted
- Proving that a fault is “reasonably excluded”
- Documentation requirements for fault exclusion claims
- Link between fault exclusion and reliability data
- Use of operational history and field performance data
- Design for fault prevention: sealing, protection, access control
- Environmental and use condition monitoring in exclusion
- Common mistakes in fault exclusion justification
- Audit challenges and how to defend your position
Module 8: Common Cause Failure (CCF) Analysis and Prevention - Root causes of CCF: design, environment, operation
- Systematic vs random CCF scenarios
- Designing for independence: electrical, spatial, functional
- Selecting diverse components to resist CCF
- Software diversity and its limitations
- Rating CCF measures using Annex F checklist
- Scoring each CCF prevention method: 0, 1, 2, or 3 points
- Aggregating CCF scores and verifying minimum thresholds
- Linking CCF to achieved performance level
- Using CCF analysis in retrofit and upgrade projects
Module 9: Application of ISO 13849-2 (Validation) - Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Purpose and scope of ISO 13849-2
- Difference between design validation and operational testing
- Validation throughout the lifecycle: concept to decommissioning
- Required validation activities for Categories B to 4
- Test planning: coverage, sequence, and documentation
- Functional testing of safety-related control functions
- Destructive vs non-destructive test methods
- Inspection of wiring, connections, and installation
- Verification of diagnostic capabilities and self-tests
- Reporting validation results and obtaining stakeholder sign-off
Module 10: Software and Firmware in Safety Systems - Software safety requirements under ISO 13849
- Development lifecycle for safety-related software
- Requirements for coding standards and style
- Use of structured programming techniques
- Version control and change management
- Static and dynamic code analysis tools
- Testing: unit, integration, and system-level
- Documentation of software safety claims
- Handling software updates in operational environments
- Auditor expectations for software validation records
Module 11: Diagnostic Coverage (DC) in Practice - Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Quantifying diagnostics: low, medium, high, full
- Designing effective diagnostic tests
- Types of diagnostic tests: periodic, continuous, demand-based
- Measuring DC through failure mode simulation
- Use of self-test features in relays, PLCs, and safety modules
- Documenting DC assumptions with evidence
- Common overestimation errors in DC assignment
- Linking DC to architectural constraints
- DC in multi-channel and redundant systems
- Reporting DC in technical files and validation reports
Module 12: Real-World Design Case Studies - Case study 1: Robotic cell guarding with light curtains
- Case study 2: Hydraulic press with dual-circuit E-stop
- Case study 3: Conveyor interlocking using safety PLC
- Case study 4: Retrofit of legacy machine with modern SRP/CS
- Case study 5: Automated warehouse with movable guards
- Architecture selection and rationale for each case
- PLr assignment and risk assessment documentation
- MTTFd and DC calculations applied step-by-step
- Validation test plans and execution logs
- Lessons learned and design improvements over time
Module 13: Audits, Technical Files, and Certification Readiness - Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Preparing a complete safety validation technical file
- Mandatory documentation per ISO 13849 and Machinery Directive
- Structure of the technical file: index, versions, approvals
- Including risk assessment, safety requirements, and drawings
- Storing calculation sheets, test records, and validation reports
- Preparing for notified body audits and factory inspections
- Responding to non-conformities and observations
- Using the technical file for product liability defence
- Best practices for digital and physical file management
- Checklist for audit readiness and continuous compliance
Module 14: Integration with Safety Controllers and Devices - Specifying safety relays, contactors, and logic solvers
- Using safety PLCs: advantages and limitations
- Interfacing sensors: E-stops, door switches, light curtains
- Actuator integration: power removal, braking, isolators
- Understanding safe output states and forced contacts
- Wiring practices for safety circuits (1oo2, 2oo3)
- Material selection and protection against environmental stress
- Reviewing manufacturer data for MTTFd and DC claims
- Handling failure modes of common devices
- Validation of third-party components in your architecture
Module 15: Advanced Topics in Machine Safety - Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Handling complex subsystems with mixed technologies
- Combining pneumatic, mechanical, and electrical safety functions
- Use of safety buses and networks (e.g., PROFINET, EtherCAT)
- Safety parameter transmission and network diagnostics
- Functional safety in mobile and autonomous systems
- Safety considerations in collaborative robotics (cobots)
- Transition paths from older standards to ISO 13849
- Maintenance and decommissioning planning
- Human factors in safety system usability
- Training operators and maintenance staff on safety functions
Module 16: Tools, Templates, and Practical Resources - Downloadable PL calculation spreadsheet templates
- Risk assessment worksheet with built-in PLr logic
- CCF checklist formatted for audit submission
- Technical file structure template (DOCX and PDF)
- Validation test plan and report templates
- Architecture selection guide (decision tree)
- MTTFd estimation tables from common component types
- DC assignment matrix for common diagnostics
- Checklist for fault exclusion justification
- Component data request form for suppliers
Module 17: Certification, Recognition, and Career Advancement - Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources
Module 18: Final Assessment, Mastery Defence, and Next Steps - Comprehensive assessment covering all 17 modules
- Scenario-based questions simulating real safety challenges
- Calculating PL for complex multi-function systems
- Justifying fault exclusions and CCF scores
- Evaluating architecture compliance against PLr
- Documenting validation evidence for audit trails
- Review process and feedback mechanism
- Reattempt policy and mastery reinforcement
- Action plan for applying skills to your next project
- Next steps: certification submission, peer review, advancement
- Overview of the Certificate of Completion from The Art of Service
- How the certification enhances your professional credibility
- Adding certification to LinkedIn and employment portfolios
- Leveraging your expertise in job interviews and promotions
- Using the certification to lead internal safety initiatives
- Positioning yourself as a safety systems subject matter expert
- Continuing education pathways in functional safety
- Connecting with other certified practitioners
- Staying updated on future revisions to ISO 13849
- Access to exclusive updates and practitioner resources