| 1 |
Define the application risk before selecting the robot |
ISO 10218-1 and ISO 10218-2 require a documented risk-reduction approach for the robot and the complete robot application.
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Compare the complete cell rather than the robot arm alone: robot, gripper, conveyor, packaging material, pallet, guarding, access points, and foreseeable misuse.
Risk assessment
Complete cell
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Application-specific risk assessment, layout drawing, hazard list, safeguarding concept, and list of residual risks.
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A robot marketed as “collaborative” is not automatically suitable for every packaging task. The final safety status depends on the integrated application.
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| 2 |
Choose the correct collaborative operating mode |
ISO/TS 15066 identifies four collaborative operation concepts: safety-rated monitored stop, hand guiding, speed and separation monitoring, and power and force limiting.
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Ask which mode is intended for each production step and whether the robot can safely transition between automatic and collaborative modes.
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Functional description, operating-mode diagram, safety circuit design, mode-selection logic, and validation records.
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Do not pay for collaborative functions that are not needed, and do not use power-and-force-limited operation when separation monitoring or guarding is more appropriate.
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| 3 |
Verify safety-rated control performance |
ISO 10218 links safety-related control functions to the applicable machinery-control safety requirements, including performance-level or SIL-based verification as determined by the risk assessment.
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Compare emergency stop, protective stop, gate monitoring, restart prevention, safe speed, safe position, and safe torque or force functions.
Confirm the required performance level or SIL for each safety function.
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Safety architecture, safety function list, calculated PL/SIL results, validation report, and safety-component certificates where applicable.
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A standard software alarm is not equivalent to a safety-rated function. Require clear separation between ordinary control functions and safety functions.
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| 4 |
Compare emergency-stop and protective-stop behavior |
ISO 10218 addresses protective measures, stopping functions, restart prevention, and safe access to hazardous areas.
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Record stop category, stopping time, stopping distance, restart conditions, and behavior after power recovery for every relevant operating mode.
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Stop-time and stop-distance test results under the maximum payload, maximum speed, worst-case reach, and representative tooling conditions.
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A short stopping distance can reduce the required protective separation distance, but the actual value must be measured and validated for the installed cell.
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| 5 |
Check speed and separation monitoring capability |
ISO/TS 15066 describes speed and separation monitoring as a collaborative method. ISO 10218 requires protective measures for hazardous movement and access.
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Compare safety-rated scanners, light curtains, pressure-sensitive devices, safe speed limits, monitored zones, protective separation distance, and reaction time.
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Sensor coverage map, minimum separation-distance calculation, reaction-time data, safety-zone configuration, and validation test results.
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The required separation distance depends on approach speed, robot speed, stopping performance, sensor resolution, and human reaction assumptions. It is not a universal fixed number.
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| 6 |
Validate power-and-force-limiting performance |
ISO/TS 15066 provides biomechanical guidance for contact conditions, including transient contact and quasi-static contact. ISO 10218 requires risk reduction for the complete system.
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Compare measured force, pressure, energy, speed, payload, tool mass, robot posture, contact location, and contact duration for the intended packaging process.
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Application-specific force and pressure measurements, test points, measurement equipment details, calibration records, and comparison with the applicable ISO/TS 15066 biomechanical data.
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Do not rely only on a robot’s catalog rating. Gripper edges, cartons, sharp tooling, payload inertia, and workpiece geometry can create additional contact hazards.
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| 7 |
Evaluate the end-of-arm tooling and packaging load |
ISO 10218 covers hazards arising from the robot system and tooling. The integrated gripper and workpiece must be included in the risk assessment.
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Compare payload, center-of-gravity limits, gripping force, vacuum loss response, tool mass, sharp edges, pinch points, dropped-load protection, and carton deformation.
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Tool drawings, payload and inertia calculations, gripping-force tests, loss-of-vacuum test, dropped-load assessment, and guarding or exclusion-zone requirements.
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The usable payload is the robot payload minus the gripper, adapters, sensors, cables, and product. Recalculate it for the maximum carton or case size.
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| 8 |
Review safeguarding for conveyors and access points |
ISO 10218-2 addresses integration of robot applications, including safeguarding, access control, protective devices, and interaction with other equipment.
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Compare fixed guards, interlocked doors, light curtains, area scanners, safe transfer openings, pallet access, conveyor interfaces, and bypass prevention.
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Cell layout, guard dimensions, interlock test records, protective-device response-time data, access-point assessment, and restart verification.
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Packaging lines often have hazards outside the robot reach envelope. Assess the conveyor, palletizer, case former, sealer, and adjacent machines as one system.
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| 9 |
Confirm functional safety during setup, teaching, and maintenance |
ISO 10218 includes requirements for operating modes, manual guidance or teaching, access, and maintenance-related risk reduction.
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Compare reduced-speed teaching, enabling device, three-position pendant switch, manual mode selection, restricted access, safe brake release, and stored-energy control.
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Teaching-mode procedure, maintenance lockout procedure, enabling-device test, reduced-speed verification, access authorization method, and training records.
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Many incidents occur during jam clearing, tool changes, and setup rather than normal automatic production. Include these tasks in the purchase specification.
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| 10 |
Require installation validation and global compliance documentation |
ISO 10218 applies to the robot and robot application; ISO/TS 15066 provides technical guidance for collaborative applications. Local legal requirements may also apply.
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Compare supplier documentation, declaration of conformity or incorporation where applicable, safety manuals, circuit diagrams, risk-assessment responsibility, software backups, and training support.
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Final validation report, safety-function test records, updated risk assessment, operating instructions, maintenance schedule, spare-parts list, and change-control procedure.
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The buyer or system integrator should obtain evidence for the installed configuration, not only a generic robot certificate. Revalidate the cell after major tooling, software, layout, or process changes.
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