Proposed Solution

Polaris Automation was engaged to perform a comprehensive safety risk assessment and validation effort across all of the packaging system production areas. The scope of work included a detailed review of the initial assessment, verification of the original design, an updated full risk assessment, and a complete, documented validation of the entire system.

The assessment incorporated interviews with operators, maintenance personnel, engineers, and other staff who interact with the packaging system, as well as a thorough review of previously completed safety risk assessments, supporting documentation, intended usage, observation of the process to identify actual usage, and review of any previously identified injury data. Any newly identified hazards were documented, and mitigation strategies were developed to reduce risk to an acceptable level through the calculation of Hazard Rating Numbers (HRNs).

Safety verification services confirmed that existing hardware and software safety functions were properly designed and programmed for each area of the equipment. A complete report, using SISTEMA for design verification, was generated and reviewed with personnel at the site. Onsite safety validation followed, including systematic testing of all identified safety functions to validate both component level failure modes and machine safety programming. All work was performed in accordance with applicable federal, state, and local requirements, referencing relevant standards such as OSHA 1910 Subpart O, ISO 12100, ISO 138491, ISO 13849-2, and applicable ANSI standards.

Polaris Automation also conducted a comprehensive documentation review, including original risk assessments, safety schematics, workstation tasks, historical safety data, and Safety Data Sheets (SDS). Final deliverables included a completed risk assessment report, mitigation recommendations, SISTEMA file development, and the completed validation plan for every safety system on the equipment.

Outcome