Connected safety systems are giving manufacturers real-time visibility into machine risks, behaviour and potential failures, according to Turck Australia and New Zealand managing director Geoff Thorp.
Thorp said machine safety is moving beyond physical barriers and emergency stops, with integrated safety networks helping manufacturers monitor operations and identify risks earlier.
“There’s been a significant shift in the approach to machine safety,” said Thorpe. “Today, manufacturers need integrated safety networks that improve visibility across operations and make predictive safety possible - without compromising efficiency.”
He pointed to Rapid Global’s Australian Workplace Safety Market Research report, which found that 34 per cent of warehousing managers and 41 per cent of manufacturing frontline workers agree their safety systems are modern and easy to use.
“The report warns that when systems are difficult to use, workers may bypass them or resort to unsafe workarounds,” Thorp said.
Technologies including IO-Link, In-Series Diagnostics (ISD) and human-machine interfaces (HMIs) are being integrated with safety components such as scanners, switches and sensors to provide greater insight into machine operations.
“These systems provide real-time visibility into machine stoppages, faults and operator interactions, helping teams identify risks earlier and respond proactively,” Thorp said.
TURCK, the local distributor of Banner Engineering solutions, supplies the Banner Engineering RSio Remote Safe I/O, which features six inputs for safety devices and configurable safety outputs. The device allows manufacturers to divide machines or production areas into independently monitored and controlled sections.
The RSio is also IP67-rated for out-of-cabinet installations, allowing diagnostics to be positioned closer to where they are required.
“In a complex material handling or manufacturing application, the RSio enables manufacturers to create independent safety zones, where different conveyor lines can be monitored and stopped independently,” Thorp said.
“With this intelligent device, there’s no need to shut down an entire line every time a hazard is detected as it isolates problems. The instant diagnostics help factory teams find and fix issues much faster, reducing downtime.”
Thorpe said manufacturers should consider safety technologies that can integrate with existing systems and scale as operations change.
Turck offers machine safety technologies, including light curtains, laser scanners, safety controllers, switches and energy control solutions, alongside industrial internet of things (IIoT) technologies.
“These are modular, flexible and user-friendly, designed for manufacturing systems of all sizes. No matter how complex your production or your warehouse system is, we’ve got a safety solution that will adapt to the requirements and evolve with your operations,” Thorp said.
“Connected, sensor-based safety systems provide manufacturers with real-time operational insight, helping teams identify hidden risks earlier while improving productivity, uptime and compliance,” he concluded.
