Anonymous Manufacturer | Atlanta, GA
Executive Summary
A mid-sized manufacturer in Atlanta, Georgia partnered with PowerSafe Automation to improve operator safety and reduce risk exposure on a high-throughput production machine. The machine presented frequent access points, repetitive manual interaction, and a history of near-miss incidents. Traditional fixed guarding alone limited productivity and did not provide adequate flexibility for operators.
PowerSafe Automation implemented a machine safety solution using Keyence safety light curtains integrated with a dedicated safety relay. The solution balanced compliance, productivity, and real-world usability—resulting in safer operator interaction, reduced downtime, and a scalable safety architecture for future expansion.
Customer Background
- Industry: Discrete manufacturing
- Location: Atlanta
- Facility Type: Single-site production facility
- Workforce: 40–60 operators across multiple shifts
- Primary Challenge: Unsafe access to an automated machine during normal operation and setup
The customer requested anonymity due to internal safety policies but allowed their project to be documented for educational and industry-reference purposes.
The Safety Challenge
Machine Overview
The machine in question was a semi-automated production cell requiring frequent operator interaction for:
- Part loading and unloading
- Visual inspection during cycle pauses
- Minor adjustments between product runs
Operators needed regular access to the machine envelope, making traditional hard guarding impractical on all sides.
Identified Hazards
During an initial site walk and guarding assessment, the following risks were identified:
- Open access to hazardous motion during automatic cycles
- Inconsistent operator behavior during clearing and restart
- No presence-sensing safeguarding at access points
- Reliance on operator awareness rather than engineered controls
Although the machine had emergency stop devices, they were reactive, not preventive.
Why Safety Light Curtains Were the Right Solution
Safety light curtains are ideal when:
- Operators require frequent access
- Material flow must remain unobstructed
- Productivity cannot be sacrificed for safety
In this case, PowerSafe Automation selected Keyence safety light curtains due to their reliability, diagnostic capability, and ease of integration into existing control architectures.
Benefits of Light Curtains for This Application
- Non-contact safeguarding
- Immediate machine stop upon beam interruption
- No physical barriers restricting workflow
- Clear visual status indicators for operators and maintenance
System Design & Engineering Approach
Step 1: Engineering-Led Safety Assessment
Rather than a checklist-style audit, PowerSafe Automation conducted an engineering-led guarding assessment that focused on practical risk reduction. This included:
- Identifying operator access patterns
- Evaluating stopping distances
- Reviewing machine control architecture
- Determining appropriate safeguarding technology
Step 2: Safety Light Curtain Selection
Keyence light curtains were selected based on:
- Required protective height
- Resolution suitable for finger/hand detection
- Environmental conditions (dust, vibration, ambient light)
- Compatibility with safety relay logic
Step 3: Safety Relay Integration
A dedicated safety relay was installed to:
- Monitor the light curtain outputs
- Interface with machine stop circuitry
- Ensure fail-safe operation
- Enable controlled restart behavior
The relay provided redundancy and diagnostic clarity, ensuring the system met modern machine safety expectations.
Installation & Integration
Mechanical Installation
- Light curtains mounted on rigid aluminum framing
- Protective field aligned to cover the entire access opening
- Mounting height and distance verified using stopping-time calculations
Electrical & Controls Integration
- Safety relay wired into existing control panel
- Dual-channel safety circuits implemented
- Manual reset located outside the hazard zone
- Status indicators visible to operators
PowerSafe Automation worked closely with the customer’s maintenance team to minimize downtime during installation.
Operator Experience & Training
One of the most important success factors of the project was operator acceptance.
Operator-Focused Design
- Clear visual indicators on the light curtain
- Intuitive reset behavior
- No unnecessary nuisance trips
- Maintained production pace
Training Provided
- How the light curtain works
- What triggers a stop
- Safe restart procedures
- Why the system improves personal safety
This training helped eliminate unsafe workarounds and reinforced a safety-first culture.
Results & Measurable Outcomes
Safety Improvements
- Eliminated uncontrolled access to hazardous motion
- Reduced near-miss incidents
- Improved consistency in operator behavior
Productivity Gains
- Faster loading and unloading cycles
- Reduced downtime from guarding-related delays
- No impact on throughput
Maintenance & Reliability
- Minimal maintenance requirements
- Clear diagnostics for troubleshooting
- Reduced reliance on manual intervention
Compliance & Risk Reduction
While the project was not positioned as a paperwork-driven compliance exercise, the installed system aligned with widely recognized machine safety principles, including:
- Engineered risk reduction
- Redundant safety channels
- Fail-safe design philosophy
- Clear separation of safety and standard control functions
This approach helps manufacturers stay prepared for evolving OSHA inspection expectations without sacrificing operational efficiency.
Why Keyence + Safety Relay Worked So Well
Keyence Safety Light Curtains
- Fast response time
- High reliability
- Strong diagnostic feedback
- Compact, durable design
Safety Relay Architecture
- Clear safety logic
- Scalable for future expansion
- Simplified troubleshooting
- Supports layered safety strategies
Together, they created a solution that was both robust and operator-friendly.
Scalability & Future Expansion
The customer now has a standardized safety architecture that can be reused on:
- Similar machines
- Future automation projects
- New production lines
PowerSafe Automation documented the design approach, making it easy to replicate across the facility.
Lessons Learned
- Safety must match how operators actually work
- Presence-sensing devices outperform fixed guarding in high-interaction zones
- Engineering-led assessments lead to better outcomes than checklist audits
- Operator training is just as important as hardware selection
Conclusion
This Atlanta-based manufacturer successfully improved machine safety by implementing Keyence safety light curtains integrated with a safety relay, without compromising productivity or operator efficiency. The project demonstrates how modern machine guarding solutions—when engineered correctly—can enhance safety, streamline operations, and support long-term risk reduction goals. PowerSafe Automation’s turnkey approach ensured the solution was not only compliant and reliable, but also practical for real-world manufacturing environments.
