Pilz Certified Safety Integrator

Certified Safety Integration (CSI)
From Assessment to Validation

Independent Assessment. Engineered Implementation. Final Validation.

PowerSafe Automation participates in the Pilz Certified Safety Integrator program, bringing together risk assessment and validation with our onsite engineering, custom safeguarding, controls integration, fabrication, and installation capabilities.

The result is a structured approach that connects identified machine risks with practical engineered solutions and carries the project through installation and final validation.

Pilz Safety → PowerSafe Automation → Pilz Safety

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How the Process Works

1. Risk Assessment

Performed by Pilz

Pilz begins the process by evaluating the machine, identifying hazards, assessing risk, and documenting recommended risk-reduction measures.

Typical activities may include:

• Machine risk assessment

• Hazard identification

• Risk evaluation

• Safeguarding recommendations

• Safety-function requirements

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2. Onsite Design Review

Performed by PowerSafe Automation

PowerSafe takes the assessment into the field and evaluates how the recommended risk-reduction measures can practically be incorporated into the existing equipment and production environment.

This is where recommendations begin becoming an engineered solution.

Typical activities may include:

• Field measurements

• Existing equipment review

• Guarding layouts

• Safety-device applications

• Operator access considerations

• Maintenance considerations

• Electrical and controls review

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3. Engineering & Solution Development

Performed by PowerSafe Automation

PowerSafe develops the mechanical and electrical solution required to implement the identified risk-reduction measures.

Depending on the application, the solution may include:

• Custom machine guarding and/ or perimeter fencing

• Safety interlocked access

• Presence-sensing technologies such as:

  • Light curtains

  • Safety scanners

  • 3D safety radars

• Safety relays, safety controllers, and safety PLC integration

• Functional safety engineering

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4. Fabrication, Installation & Integration

Performed by PowerSafe Automation

PowerSafe manages the physical implementation of the engineered solution.

Our team can provide the mechanical, electrical, and controls resources required to take the project from design through installation and commissioning.

One implementation team for:

Design → Engineer → Fabricate → Install → Integrate → Commission

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5. Independent Validation

Performed by Pilz

Following implementation, Pilz returns to validate the completed safety solution against the defined safety requirements and assessment recommendations.

This creates separation between the team implementing the solution and the organization performing the final validation.

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A Defined Role for Each Partner

Project Stage	Pilz	PowerSafe
Risk Assessment	●
Risk-Reduction Requirements	●
Onsite Solution Design		●
Mechanical Engineering		●
Electrical / Controls Engineering		●
Fabrication		●
Safety Integration		●
Installation		●
Commissioning		●
Final Validation	●

Assess → Engineer → Implement → Validate

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Why This Structure Matters

Machine-safety projects can become fragmented when assessment, engineering, fabrication, controls, installation, and validation are treated as unrelated activities.

The Certified Safety Integrator structure creates a defined path from identifying risk to implementing and validating the resulting solution.

Pilz

Assessment + Validation

Provides the independent safety evaluation at the beginning and validation at the completion of the project.

PowerSafe Automation

Engineering + Implementation

Transforms the identified risk-reduction requirements into practical machine-safety solutions and manages their implementation.

Together, the process creates a clear handoff:

Identify the Risk → Define the Requirements → Engineer the Solution → Implement the Solution → Validate the Result

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