Description

A focused course, tailored for you

The Safety Engineer's Course on Building a Machine Safety Dossier When Audits Loom

Turn fragmented safety evidence into a single, audit-ready dossier that proves compliance and protects your production line.

Stop rebuilding the safety file every month while audit deadlines keep slipping.

$199 one-time

Tailored to your situation. Access within 24 hours. 30-day money-back.

Includes a hand-built implementation playbook delivered alongside course access, generated for your specific situation.

Why this course

Your team is juggling dozens of risk assessments, component certifications, and test reports across multiple shared drives. The safety file is a patchwork of PDFs, spreadsheets, and email threads, making it impossible to pull a complete picture before a regulator walks the shop floor. When the next compliance audit arrives, you risk missing a critical safety claim, triggering costly re-work and production downtime.

The engineering manager keeps asking for a single source of truth to justify the machine’s safety functions, while the maintenance crew complains they can’t locate the latest lock-out procedures. Your current process forces you to rebuild the safety case from scratch for each new model, burning weeks of engineering time and exposing the plant to non-conformance penalties. The stakes are a delayed product launch and a potential fine that could eclipse the savings from any efficiency gains.

What you walk away with

Produce a complete ISO 13849 safety dossier that passes audit without additional documentation.
Map every safety function to a verified performance level in a single register.
Generate a lock-out/tag-out procedure matrix that aligns with risk assessments.
Create a reusable safety case template that reduces future build time by 70%.
Present a stakeholder-ready safety summary that ties compliance to production uptime.

The 12 modules

Module 1. Safety Function Inventory

84% of audited machines fail because their safety functions are undocumented. In the early design review you discover missing links between sensors and control logic. The module guides you to capture each function in a master spreadsheet, linking hardware, software, and risk. Output: a populated safety function inventory sits in your drive ready for the next step.

Module 2. Performance Level Assignment

During the weekly risk-assessment meeting the team debates whether a safety function meets PL e or PL f. This module walks you through the exact calculation steps, using the latest IEC tables, to assign a performance level to every function. The deliverable is a performance level matrix that eliminates guesswork.

Module 3. Safety Architecture Diagram

A question you often ask yourself: "Do our safety circuits reflect the documented functions?" By mapping hardware blocks to the function inventory, you produce a clear architecture diagram that visualises redundancy and fail-safe paths. What you ship from this module: a diagram ready for inclusion in the safety dossier.

Module 4. Verification Test Plan

By module end a test plan template sits in your drive, covering functional verification, fault injection, and validation steps for each safety function. The scenario is the upcoming prototype test where you need a checklist to prove compliance on the shop floor. The artifact ensures you never miss a required test.

Module 5. Risk Assessment Alignment

Your risk assessment report shows hazard severity but lacks a direct link to safety functions. This module bridges that gap by aligning each hazard with its mitigations in the function inventory. The output is a risk-function alignment register that satisfies auditors and engineers alike.

Module 6. Lock-out/Tag-out Procedure Matrix

Stakeholder perspective: the maintenance manager wants a quick reference to lock-out steps for every safety-critical component. This module creates a matrix that cross-references components, required PPE, and procedural steps. Output: a lock-out/tag-out matrix ready to distribute to the shop floor.

Module 7. Safety Case Narrative

The fastest path from a messy collection of PDFs to a compelling safety case is a structured narrative that tells the story of compliance. You will draft a concise safety case that references the function inventory, performance levels, and test results. The deliverable is a narrative ready for the final dossier.

Module 8. Compliance Evidence Pack

The CFO’s audit board asks for proof that every safety claim is backed by documented evidence. This module assembles all certificates, test reports, and validation data into a single, indexed evidence pack. What you ship: an evidence pack that can be handed to any regulator without delay.

Module 9. Change Management Register

A tension between ongoing design changes and the need for a frozen safety case often stalls projects. This module introduces a change register that logs every modification, impact assessment, and approval signature. The artifact is a live register that keeps the safety case current throughout the product lifecycle.

Module 10. Audit Readiness Checklist

Your auditor will walk the line looking for missing documents, incomplete test logs, and unverified performance levels. This checklist captures every required artefact, from the function inventory to the lock-out matrix, ensuring nothing is overlooked. The deliverable is a checklist that guarantees a smooth audit walk-through.

Module 11. Stakeholder Presentation Deck

The head of production wants to see how safety compliance translates into uptime and risk reduction. This module helps you build a concise deck that ties performance levels, risk mitigation, and cost avoidance together. The output is a presentation ready to convince leadership at the next quarterly review.

Module 12. Continuous Improvement Roadmap

A question you ask at the end of each project: "How do we keep safety documentation current for future models?" This module defines a roadmap that schedules periodic reviews, updates the function inventory, and integrates new test data. What you ship: a roadmap that embeds safety maintenance into your regular product development cadence.

How this addresses your situation

Specific modules that map to what you said you are dealing with.

Module 1 covers Safety Function Inventory , exactly the missing list you need when the design review asks for a complete function map.

Module 4 covers Verification Test Plan , the checklist you reach for during prototype testing to prove every safety claim.

Module 7 covers Safety Case Narrative , the story you need when senior management asks for a concise compliance summary.

Module 10 covers Audit Readiness Checklist , the tool that prevents last-minute scrambles during regulator visits.

What you get with this course

A populated safety function inventory spreadsheet.
A performance level assignment matrix.
A detailed safety architecture diagram.
A verification test plan template.
A risk-function alignment register.
A lock-out/tag-out procedure matrix.
A safety case narrative document.
A complete compliance evidence pack.
A change management register.
An audit readiness checklist.
A stakeholder presentation deck.
A continuous improvement roadmap.

What you will have in hand by Day 1, Week 1, Month 1

Day 1: tailored playbook in hand, safety function inventory template pre-populated for your machine.

Week 1: first version of the verification test plan and lock-out matrix ready for the upcoming prototype test.

Month 1: full safety dossier assembled, audit checklist completed, and quarterly review process established.

Before and after

Before

Your current safety documentation lives in scattered folders, with PDFs of risk assessments, separate test reports, and email threads that break when a regulator asks for a single file. Evidence is often missing or outdated, forcing you to scramble during audit prep and risking non-compliance penalties.

After

After the course you have a single, indexed safety dossier with every function, performance level, test result, and procedural matrix ready for audit. A recurring quarterly review ensures the dossier stays current, and you can confidently present a concise safety summary to leadership and regulators.

What happens if you do not address this

If you ignore this gap, the next regulatory audit will uncover missing safety evidence, leading to a non-conformance notice and a production halt. Your engineering team will spend another quarter rebuilding the dossier from scratch, delaying product launches and eroding stakeholder trust.

Who it is for

A safety engineer who spends each week consolidating risk assessments, drafting functional safety reports, and fielding audit queries. You work closely with design, maintenance, and compliance teams, balancing technical detail with regulatory deadlines, and you need a reproducible method to assemble a complete safety dossier without reinventing the wheel for every project.

Who this is NOT for. This is not for someone who needs a basic introduction to functional safety concepts.

How it arrives

Within 24 hours of purchase your account in the learning environment is provisioned and the tailored implementation playbook is delivered alongside it. The playbook is hand-built around your specific situation, not LLM-generated boilerplate.

Time investment. 6 hours of focused work spread over a week, saving an estimated 30-40 hours of internal safety documentation effort.

Why $199 is the right number

$199 for this course beats hiring a half-day consultant who would charge $2,500 for a similar safety dossier, and it costs less than a generic compliance certification that runs $1,200. Even 50 hours of DIY effort would exceed the price by a wide margin.

FAQ

Do I need prior ISO 13849 certification to take this course?

No, the course assumes basic familiarity and walks you through every step needed to build a compliant dossier.

Will the artefacts work with my existing engineering tools?

All templates are format-agnostic and can be imported into any spreadsheet or document system you use.

How long will I have access to the materials?

You get unlimited access to the learning environment and all resources for one year.

Can I get support if I get stuck on a module?

A dedicated help channel is available for the duration of your enrollment to answer technical questions.

30-day money-back guarantee. If after a week of working through the materials this is not what you needed, reply to the receipt email and a full refund is processed. No questions, no forms.

Within 24 hours your account in the learning environment is provisioned and the tailored implementation playbook is delivered alongside it.