Anonymous Manufacturer | Villa Rica, Georgia
Executive Summary
A manufacturer operating a continuous coating machine in Villa Rica, Georgia partnered with PowerSafe Automation to address a persistent machine safety challenge: protecting operators who routinely worked in close proximity to hazardous motion while monitoring and adjusting the coating process. The application required operators to stand near moving equipment for visual inspection and process control, making traditional guarding and presence-sensing devices impractical.
PowerSafe Automation engineered a safeguarding solution using industrial safety mats integrated with a dedicated safety controller. The system created a clearly defined, pressure-sensitive safe zone that immediately stopped hazardous motion when entered—delivering reliable risk reduction without interrupting the coating workflow.
Customer Background
- Industry: Industrial finishing and coating
- Location: Villa Rica
- Facility Type: Continuous-process production line
- Machine Type: Conveyor-fed coating system
- Primary Safety Objective: Protect operators positioned near moving hazards during normal operation
The customer requested anonymity due to internal safety policies but approved the project for anonymous case study publication.
The Machine Safety Challenge
Process Overview
The coating machine included:
- A powered conveyor transporting parts through the coating zone
- Moving mechanical components and pinch points
- Manual quality checks and process adjustments
- Operators standing near the machine for extended periods
Because operators needed to remain stationary near the hazard, solutions such as light curtains, scanners, or fixed guarding would either interfere with the process or cause frequent nuisance stops.
Identified Risks
PowerSafe Automation’s on-site engineering review identified several concerns:
- No physical or electronic separation between operators and moving components
- Operators stepping into hazard zones during adjustments
- Reliance on procedural controls and awareness
- Emergency stops being used reactively rather than preventively
The challenge was not just access—it was sustained proximity to hazardous motion.
Why Safety Mats Were the Right Safeguarding Method
Safety mats are ideal when:
- Operators must stand near hazardous motion
- Defined standing zones can be established
- Continuous monitoring of presence is required
- Hands-free operation is necessary
For this coating machine, safety mats provided direct, unambiguous confirmation of operator presence exactly where protection was required.
Engineering the Safeguarding Solution
Step 1: Operator Position & Workflow Analysis
PowerSafe Automation began with a practical, engineering-led analysis focused on:
- Where operators naturally stood during inspection
- How often adjustments were made
- Movement patterns during normal and upset conditions
- Areas where a safe stop was required
This ensured the safeguarding system aligned with actual operator behavior, not idealized layouts.
Step 2: Safety Mat Layout & Zoning
Based on the analysis, safety mats were installed to:
- Define a clear operator-safe standing zone
- Cover the full length of hazardous access areas
- Eliminate gaps where unsafe positioning could occur
- Maintain comfortable working space without crowding
The mats were sized and positioned to ensure consistent detection regardless of operator stance or footwear.
Step 3: Safety Controller Integration
The safety mats were connected to a safety-rated controller, providing:
- Continuous monitoring of mat status
- Redundant, fail-safe safety channels
- Immediate stop of hazardous motion when stepped on
- Controlled restart only after the mat was cleared and reset
The controller also allowed for future expansion if additional mats or safety devices were required.
Installation & Commissioning
Mechanical Installation
- Mats secured to the floor with beveled edges to reduce trip risk
- Placement verified against machine hazard zones
- Durable mat construction selected for coating environment exposure
- Clear visual definition of protected areas
Electrical & Controls Integration
- Safety mat outputs wired directly to the safety controller
- Controller integrated into the machine’s safety stop circuit
- Reset devices positioned outside the protected zone
- Functional testing performed under real operating conditions
Installation was completed with minimal impact to production schedules.
Operator Experience & Acceptance
Designed for Real-World Use
From an operator perspective, the system was straightforward and intuitive:
- Stand on the mat = machine in safe state
- Step off the mat = machine eligible to run
- No need for hand interaction or wearable devices
- Clear understanding of protected vs non-protected areas
The mats reinforced safe positioning without slowing the process.
Training & Change Management
PowerSafe Automation conducted on-site training covering:
- Why safety mats were selected over other technologies
- How the mats interact with machine motion
- Proper restart procedures
- What conditions would prevent the machine from running
This training helped operators trust the system and use it correctly from day one.
Results & Measurable Outcomes
Safety Improvements
- Eliminated uncontrolled proximity to moving hazards
- Prevented machine operation while operators were in danger zones
- Reduced reliance on emergency stops
Productivity & Process Benefits
- No disruption to coating workflow
- Maintained inspection and adjustment efficiency
- Clear operator positioning reduced hesitation
- No increase in cycle time
Maintenance & Reliability
- Simple, durable safeguarding solution
- Minimal maintenance requirements
- Easy troubleshooting via safety controller diagnostics
Risk Reduction & Inspection Readiness
This project emphasized engineered risk reduction by:
- Physically linking operator presence to machine state
- Eliminating ambiguity about safe positioning
- Using monitored, fail-safe safety control logic
- Creating clearly defined safety zones
The result was a solution that inspectors and operators could easily understand and verify.
Why Safety Mats with a Safety Controller Worked
Key Advantages
- Direct detection of operator presence
- Ideal for stationary or semi-stationary workstations
- Hands-free, intuitive safeguarding
- Scalable safety architecture
For coating and finishing processes, safety mats often provide the most practical and reliable protection.
Scalability & Future Use
Following the success of this project, the customer now has a repeatable safeguarding strategy that can be applied to:
- Additional coating lines
- Inspection stations
- Packaging and finishing areas
- Other continuous-process equipment
The safety controller allows future expansion without redesigning the system.
Key Takeaways
- Safety mats excel where operators must stand near hazards
- Presence-based safeguarding removes ambiguity
- Engineering-led layout design improves effectiveness
- Simple systems often deliver the best real-world results
Conclusion
This anonymous manufacturer in Villa Rica, Georgia successfully reduced risk on a coating machine by implementing safety mats integrated with a safety controller.
By aligning safeguarding technology with real operator behavior and process needs, PowerSafe Automation delivered a solution that improved safety, preserved productivity, and created a scalable foundation for future machine safety upgrades.
