Cybertrol understands that functional safety is not a one-size-fits-all approach. Every plant has unique needs, and ensuring the safety of personnel and equipment requires a collaborative effort between OEMs, system integrators, and plant operations teams. From machine operators to operations managers, our team is equipped to work with your entire organization to implement safety solutions that align with industry standards and best practices.
Functional safety is a critical component of modern industrial systems, ensuring protection of personnel and equipment while maintaining compliance with evolving standards. As automation environments increase in complexity, effective risk mitigation requires a structured, lifecycle-based approach. Cybertrol integrates functional safety directly into existing control and information systems, creating a unified architecture that supports compliance, reliability, and operational performance.
Cybertrol’s functional safety engineers (TÜV Rheinland) deliver end-to-end functional safety solutions, including risk assessment, safety requirements specification, system design, implementation, and validation. From machine-level safeguarding to plantwide safety programs, solutions are engineered to align with standards such as IEC 61508 and ISO 13849 while remaining scalable and maintainable within broader automation environments.
Ensuring the safety of your machinery is necessary for maintaining a safe and efficient work environment. Our machine safeguarding services help you comply with industry regulations and reduce the risk of incidents by implementing effective safety controls. We provide:
Risk assessment and safety requirement specification documentation
Safety-related controls and programming
SISTEMA reports for safety function design and validation
System verification and validation to ensure compliance and functionality
Continuous maintenance and modifications to safety system
A strong safety program requires thorough planning and execution. We assist with the development of verification and validation plans, ensuring that safety measures are tested and documented. Our strategic safety planning services include:
Verification plans to confirm compliance with safety standards
Validation plans to ensure systems function as intended
Validation testing assistance for thorough safety evaluation
Functional safety extends beyond individual machines—it requires a plantwide approach. We offer holistic solutions to assess, identify, and mitigate risks across your facility. Our services include:
Plantwide risk audits to evaluate safety gaps
Individual risk assessments tailored to specific machinery or processes
Team-based task risk assessments to engage operators in the safety process
Our expertise spans the entire safety lifecycle, from risk assessment to ongoing maintenance and compliance. We provide:
Risk Assessments – A process that begins with a risk analysis to identify hazards, followed by a hazard analysis to determine the severity of each hazard (from minor incidents like a papercut to serious injuries like losing a finger)
Mitigation Planning – Develop targeted strategies to reduce both the likelihood and impact of risks
Safety System Implementation – Design, install, commission, and verify custom safety solutions
Ongoing Support – Provide continuous maintenance and updates for long-term compliance and safety
Table 1: Injury Severity
Table 2: Risk Level Decision Matrix
Table 3: Hierarchy of Risk Reduction Measures
Table 4: Minimum Risk Reduction Measures as a Function of Risk Level
Table 5: Minimum Functional Safety Performance
Sample Risk Assessment Using RIA TR R15.306-2016 Methodology - Cybertrol Engineering
Conduct risk assessments and mitigation planning
Develop safety requirement specifications (SRS)
Perform circuit calculations and conformance analysis using SISTEMA
Design, program, and implement safety system mitigations
Develop and execute verification and validation protocols
Minneapolis - Main Office
6550 Wedgwood Rd N, Ste. 300
Maple Grove, MN 55311
763.559.8860
Marshfield Office
204b E Upham St
Marshfield, WI 54449
763.559.8860
Madison Office
4602 S Biltmore Ln, Ste. 119
Madison, WI 53718
763.559.8860
24/7/365 Support
1.800.554.5104
support@cybertrol.com
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